Image Forming Apparatus Toner Adhesion Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional image forming apparatuses require frequent interruptions for calibration, leading to reduced printing efficiency due to the need for manual determination of calibration necessity and the inability to maintain intended image quality under environmental changes despite process control.
Innovation Solution
An image forming apparatus with a dual control processor system that automatically performs process control and calibration processing, using an adhesion amount sensor to measure and correct toner adhesion, allowing for continuous printing without user intervention by outputting a calibration image during process control intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is performed at regular intervals to maintain image quality, then image quality consistency is improved, but printing efficiency deteriorates due to interruptions
Solution Approach 1:
The image forming apparatus performs self-calibration automatically without user intervention. The calibration processor determines calibration necessity based on printing volume and executes calibration autonomously, eliminating the need for manual user operations while maintaining image quality consistency.
Solution Approach 2:
The system performs calibration in advance during idle periods or intervals when printing is not occurring. By predicting calibration needs based on printing volume and executing calibration beforehand, the system prevents image quality degradation before it affects production, rather than reacting after quality issues arise.
2Reliability
If process control processing is performed continuously to maintain target adhesion amount, then adhesion control is improved, but image quality consistency deteriorates under environmental changes
Solution Approach 1:
The system uses adhesion amount sensors to continuously measure actual toner adhesion and feeds this information back to the control processor. The control processor compares measured adhesion amounts with target values and adjusts control parameters accordingly, creating a closed-loop feedback system that adapts to environmental changes while maintaining consistent image quality.
Solution Approach 2:
The system dynamically changes control parameters such as developing bias voltage based on measured adhesion amounts and environmental conditions. By adjusting these parameters in real-time, the system compensates for environmental variations and maintains both target adhesion amount and image quality consistency.
3Manufacturing precision
If user determines calibration necessity based on visual inspection, then image quality assessment is improved, but time consumption increases
Solution Approach 1:
The system replaces manual visual inspection with automated optical sensors and image processing. The adhesion amount sensors and calibration image analysis automatically assess image quality metrics, eliminating the need for user visual inspection while maintaining or improving assessment accuracy and significantly reducing time consumption.
Solution Approach 2:
The system introduces automated detection systems as intermediaries between the printing process and quality assessment. These sensors and processors act as mediators that continuously monitor print quality objectively, replacing subjective human judgment with precise automated measurement and eliminating time loss associated with manual inspection.
Data Source
AI summary
In an image forming apparatus, a storage portion stores a target adhesion amount of toner to adhere to an image bearing member at each of gradation levels as a target gradation level and a setting value of a control parameter used for control on the image forming portion at the target gradation level. A first control processor makes an adhesion amount sensor measure an actual adhesion amount corresponding to the setting value and thereafter compares a resultant measured value and the target adhesion amount and corrects the setting value if needed in association with at least one of the target gradation levels as a subject. A second control processor makes the image forming portion output a calibration image used for correcting the target adhesion amount using a period when the first control processor performs processing if there arises a need to correct the target adhesion amount associated with the subject.