Toner Amount Calculation for Image Forming Apparatus
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Solution Overview
Problem
Existing electrophotographic image forming apparatuses inaccurately calculate toner consumption due to the 'edge effect' caused by edge electric field variations, leading to overestimation of toner consumption, especially in thin line edges, due to the influence of spatial filter characteristics.
Innovation Solution
An image forming apparatus with a toner amount calculating unit that determines the distribution pattern of electrostatic latent images, calculates electric field variations, limits these variations to an uppermost value based on the target pixel's value, and adjusts electric field intensity to accurately determine toner consumption, using spatial filters in both primary and secondary scanning directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If spatial filter is used to estimate electric field variation based on inverse proportion to second power of distance, then electric field intensity distribution can be calculated, but electric field variation is overestimated in edge parts of thin lines leading to excessive toner consumption calculation
Solution Approach 1:
The patent changes the calculation parameters by introducing an upper limit value for electric field variation based on the pixel value in the electrostatic latent image distribution pattern. When the calculated electric field variation exceeds this upper limit, it is capped at the upper limit value, preventing overestimation in thin line edge regions while maintaining accuracy in other areas.
2Reliability
If electric field variation is calculated without limiting to uppermost value, then complete electric field intensity can be determined, but toner consumption amount becomes larger than actual consumption
Solution Approach 1:
The patent converts the harmful overestimation of electric field variation into a beneficial capping mechanism. By setting the upper limit value based on the pixel value, the excessive electric field variation calculations in thin line regions are converted into controlled values that reflect actual toner consumption more accurately, turning the overestimation problem into a solution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach accurately calculates toner consumption by limiting electric field variation levels, thereby reducing errors caused by spatial filter characteristics and ensuring precise toner usage measurement.
Implementation Method 1
an exposure device configured to irradiate the photoconductor with light on the basis of an exposure signal and thereby form an electrostatic latent image
Data Source
AI summary
An exposure device irradiates a photoconductor with light on the basis of an exposure signal and thereby forms an electrostatic latent image. A toner amount calculating unit (a) determines a distribution pattern of the electrostatic latent image on the basis of the exposure signal, (b) determines an electric field variation level of a target pixel, (c) determines an electric field intensity of the target pixel on the basis of a value of the target pixel in the distribution pattern and the electric field variation level, and (d) determines a toner consumption amount corresponding to the electric field intensity. Further, the toner amount calculating unit limits the electric field variation level to an uppermost value or less, the uppermost value corresponding to a value of the target pixel in the distribution pattern of the electrostatic latent image.