Toner Cartridge Remaining Life Estimation Using Weight Correction
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Solution Overview
Problem
Image forming apparatuses face inaccuracies in estimating toner usage, leading to incorrect remaining life information of toner cartridges, which can result in inefficient toner supply and potential toner depletion errors.
Innovation Solution
The apparatus calculates a correction factor based on the actual and estimated accumulative usage of toner, obtained by measuring the weight of the toner cartridge, to accurately determine the remaining life information and diagnose the operational state, thereby correcting toner usage and supply efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If toner usage is estimated based on image forming operations, then remaining life information can be provided continuously, but measurement precision deteriorates due to inaccuracies in estimation
Solution Approach 1:
The system implements feedback by measuring the actual weight of the toner cartridge at intervals and using this measurement to calculate a correction factor. This correction factor is then applied to adjust the estimated accumulative usage, creating a closed-loop system that continuously improves estimation accuracy based on actual observations.
Solution Approach 2:
The system changes the parameter of toner usage measurement from purely operational estimation to a hybrid approach that incorporates weight-based correction. By introducing the correction factor derived from weight measurements, the system transforms the estimation parameter to achieve higher precision while maintaining continuous monitoring capability.
2Measurement precision
If weight measurement is used to obtain correction factor, then toner usage accuracy improves, but device complexity increases due to additional measurement requirements
Solution Approach 1:
The system utilizes the inherent weight property of the toner cartridge itself to provide correction data. The toner cartridge serves its own measurement function by having its weight measured, eliminating the need for separate complex measurement systems. This self-service approach improves accuracy while minimizing additional device complexity.
Solution Approach 2:
The weight measurement acts as an intermediary that bridges the gap between operational estimation and actual toner consumption. By introducing this intermediate measurement parameter, the system can correct estimation errors without requiring direct complex monitoring of toner flow or application, thus improving accuracy with moderate complexity addition.
3Measurement precision
If correction factor is applied to estimate accumulative usage, then remaining life information accuracy improves, but loss of time occurs due to additional calculation steps
Solution Approach 1:
The system performs preliminary action by calculating and storing the correction factor in advance based on weight measurements. This pre-calculated correction factor is then readily available for applying to operational estimates, reducing the real-time computational burden. The time-consuming calculation is performed ahead of time when weight data is available, rather than during critical monitoring moments.
Data Source
AI summary
An operating method of an image forming apparatus including estimating an accumulative usage of toner in a toner cartridge, determining initial remaining life information of the toner cartridge and indicating a remaining amount of the toner based on the estimated accumulative usage of the toner, obtaining weight information indicating a first weight of the toner cartridge at a first time point at which the remaining amount of the toner is within a predetermined range, determining a correction factor indicating an error factor between the estimated accumulative usage of the toner and an actual accumulative usage of the toner, based on the obtained weight information and the estimated accumulative usage, and correcting an amount of toner to be used in an image forming operation to be performed after the first time point based on the correction factor, and determining adjusted remaining life information based on the correction factor.