Toner Amount Calculation Using Spatial Filters for Edge Effects
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Solution Overview
Problem
Existing image forming apparatuses face errors in toner consumption calculations due to the 'edge effect' when calculating toner consumption based on exposure signals generated after gradation correction, as the relationship between exposure intensities and toner density gradation levels becomes non-linear, leading to inaccuracies in toner consumption amounts.
Innovation Solution
An image forming apparatus and method that determine a base toner amount without considering the edge effect, apply a first spatial filter process based on the laser profile, and perform a second spatial filter process to calculate an edge emphasis amount, which is then limited to an uppermost value, ensuring accurate toner consumption calculations by summing the base toner amount and edge emphasis amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If toner consumption amount is calculated on the basis of exposure signal with gradation correction, then image quality is improved, but measurement precision of toner consumption amount deteriorates due to non-linear relationship between exposure intensity and toner density
Solution Approach 1:
The patent segments the toner consumption calculation into two independent parts: base toner amount calculation (using uncorrected image data) and edge effect calculation (using spatial filter processes). This segmentation allows each part to be optimized independently, with the base amount using simple linear relationships and edge effects handling the non-linearities separately, thereby resolving the contradiction between image quality and measurement precision.
Solution Approach 2:
The patent introduces an intermediary approach by using spatial filter processes (first and second spatial filter processes) as mediators between the exposure signal and toner consumption calculation. These spatial filters act as intermediaries that process the image data to extract edge effect information without directly using the non-linear corrected image data, thus enabling accurate toner measurement while maintaining image quality.
2Measurement precision
If edge effect is considered in toner consumption calculation, then measurement precision of toner consumption amount is improved, but device complexity increases due to multiple spatial filter processes
Solution Approach 1:
The patent applies preliminary action by performing spatial filter processes on the image data before the toner consumption calculation. The first spatial filter process is applied to the base toner amount, and the second spatial filter process is applied to extract edge effect information. By performing these actions in advance and systematically, the patent manages the complexity through structured preprocessing steps rather than complex real-time calculations during the main toner measurement process.
Data Source
AI summary
A base toner amount is determined without taking edge effect into account, and corresponds to a pixel value of image data for which gradation correction has not been performed. For the base toner amount, a first spatial filter process is performed corresponding to a laser profile of the exposure device. A second spatial filter process is performed for the base toner amount before or after the first spatial filter process and thereby an edge emphasis amount is determined corresponding to the edge effect. A limiter processing unit limits the edge emphasis amount to an uppermost value or less, and the uppermost value corresponds to the base toner amount after the first spatial filter process. A toner counter counts as a toner consumption amount a sum of the base toner amount after the first spatial filter process and the edge emphasis amount.