Toner Container State Detection Using Cam Outer Peripheral Shape
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional image forming apparatuses require multiple microswitches and signal lines to detect different toner container states, increasing costs and complexity.
Innovation Solution
An image forming apparatus with a motor, container detection sensor, and controller that distinguishes between toner container states by detecting the outer peripheral shape of a cam, using a single sensor to differentiate between states based on sensor signal levels during rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple microswitches are used to detect different toner container states, then detection accuracy is improved, but device complexity and cost increase
Solution Approach 1:
A single container detection sensor is designed to perform multiple detection functions by detecting different outer peripheral shapes of the cam. The sensor can distinguish between various toner filling amounts (first, second, and third amounts) and detect attachment state, replacing what would traditionally require multiple separate microswitches. This multi-functional approach reduces device complexity while maintaining detection accuracy.
Solution Approach 2:
The invention changes the physical parameter being detected from binary presence/absence (single microswitch) to multi-level outer peripheral shape characteristics. By detecting variations in the cam's outer peripheral shape at different angular positions, the single sensor can differentiate between multiple toner filling states, achieving high measurement precision without increasing device complexity.
2Measurement precision
If multiple microswitches and signal lines are used to detect different toner container states, then detection accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The container detection sensor serves multiple detection purposes with a single component, eliminating the need for multiple microswitches and their associated signal lines. This reduction in component count directly lowers manufacturing costs while maintaining the ability to accurately detect different toner container states through multi-functional operation.
Solution Approach 2:
Multiple detection functions that would traditionally require separate microswitches are merged into a single container detection sensor. The sensor combines the functionality of detecting attachment state and distinguishing between different toner filling amounts, reducing the total number of components and signal lines required, thereby reducing manufacturing cost.
3Device complexity
If a single sensor is used to detect multiple toner container states, then device complexity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The invention transitions from one-dimensional detection (single position microswitch detecting presence/absence) to two-dimensional detection by examining the cam's outer peripheral shape at multiple angular positions. This dimensional expansion allows a single sensor to capture sufficient information to distinguish between multiple toner filling states, maintaining high measurement precision while reducing device complexity.
Solution Approach 2:
The system utilizes the dynamic rotation of the cam to enable a single stationary sensor to detect multiple states. As the cam rotates, the sensor detects changes in the outer peripheral shape at different angular positions, dynamically capturing information about toner filling amount. This dynamic approach allows one sensor to perform what would statically require multiple sensors.
Data Source
AI summary
An image forming apparatus includes a motor, a container detection sensor, and a controller. When a toner container is attached, the motor generates a driving force for rotating a toner conveying member in the toner container. The container detection sensor is arranged at a position where the container detection sensor comes into contact with an outer periphery of a cam connected to the toner conveying member when the toner container is attached. The controller distinguishes between at least three attachment states of the toner container based on a sensor signal of the container detection sensor.