Toner Consumption Tracking in Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses face inaccuracies in detecting the residual amount of toner due to changes in the amount of toner consumed when the bias applied to the developing roller and its rotation speed are altered, leading to errors in toner consumption calculations.
Innovation Solution
The apparatus operates in multiple image forming modes with different peripheral speed ratios between the developer bearing member and the image bearing member, allowing for accurate detection of toner consumption based on estimates of toner consumption per pixel, which are adjusted according to the specific mode, enabling precise tracking of toner usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the bias applied to the developing roller and the rotation speed of the developing roller are changed to adjust image tinge and density, then the image quality (tinge accuracy and tinge stability) is improved, but the accuracy of residual toner detection deteriorates due to changes in toner consumption amount
Solution Approach 1:
The patent applies parameter changes by storing different toner consumption amounts corresponding to different peripheral speed ratios in a storage medium. When the peripheral speed ratio changes, the system selects the appropriate pre-stored toner consumption value to maintain accurate residual toner detection while allowing image quality adjustment through speed ratio variation.
Solution Approach 2:
The system incorporates feedback by using the number of dots (image information) received by the image forming apparatus to calculate toner consumption. The calculated consumption is compared with actual consumption patterns, and the system adjusts its detection algorithms to account for variations caused by changing developing roller bias and rotation speed, thereby maintaining detection accuracy.
2Manufacturing precision
If the peripheral speed ratio between the developer bearing member and image bearing member is changed to optimize image formation, then the image density and tinge are improved, but the toner consumption estimation accuracy deteriorates
Solution Approach 1:
The patent stores multiple sets of parameters including different peripheral speed ratios and their corresponding toner consumption amounts in a storage medium. Based on the actual peripheral speed ratio used during image formation, the system retrieves the appropriate toner consumption value, ensuring accurate estimation regardless of the speed ratio chosen for optimizing image density.
Solution Approach 2:
The system dynamically adjusts its toner consumption calculation based on the actual operating conditions. By detecting the current peripheral speed ratio and selecting the corresponding pre-stored consumption value, the system maintains accurate toner consumption estimation while allowing flexible dynamic adjustment of developing roller parameters for optimal image density.
3Adaptability or versatility
If multiple image forming modes with different peripheral speed ratios are implemented to provide versatility, then the adaptability of the image forming apparatus is improved, but the complexity of toner consumption tracking increases
Solution Approach 1:
The patent manages multiple image forming modes by storing different toner consumption amounts corresponding to each mode's peripheral speed ratio in a storage medium. This allows the system to handle multiple modes with different parameters without increasing operational complexity, as the CPU simply retrieves the appropriate pre-stored consumption value based on the selected mode.
Solution Approach 2:
The system performs preliminary action by pre-calculating and storing the toner consumption amounts for each image forming mode before actual operation. This eliminates the need for complex real-time calculations during multi-mode operation, reducing the complexity of toner consumption tracking while maintaining full adaptability across different modes.
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 allows for accurate acquisition of toner consumption, ensuring appropriate timing for alerting users when toner is low and maintaining high image quality by accounting for varying toner usage patterns across different image forming modes.
Implementation Method 1
an image bearing member on which an electrostatic image is formed; and a developer bearing member that bears a developer to develop the electrostatic image formed on the image bearing member
Implementation Method 2
a developer bearing member that bears a developer to develop the electrostatic image formed on the image bearing member
Data Source
AI summary
Disclosed is an image forming apparatus that is capable of performing a first image forming mode that performs image formation at a first peripheral speed ratio representing a ratio of a peripheral speed of a developer bearing member to a peripheral speed of an image bearing member and a second image forming mode that performs the image formation at a second peripheral speed ratio different from the first peripheral speed ratio, and that detects an amount of a developer consumed in the image formation, based on an estimate of the amount of the developer consumed by one pixel and the number of pixels at a part at which the developer is consumed. The estimate of the amount of the developer consumed by the one pixel in the first image forming mode is different from that in the second image forming mode.