Toner Conveyance Abnormality Detection in Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses with electrophotographic systems rely on multiple sensors to detect toner conveyance abnormalities, which can lead to incorrect notifications and inefficiencies in toner supply, particularly due to the reliance on two sensors located at distant points.
Innovation Solution
An image forming apparatus with a toner container and an apparatus main body featuring a first and second conveyance unit, a sensor with a light emitting and receiving portion to detect toner levels, and a control unit that independently controls the conveyance units and executes an abnormality detection mode, acquiring values to determine if an abnormality exists based on predetermined conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two sensors are used to detect toner conveyance abnormalities, then detection coverage is improved, but device complexity increases and measurement precision decreases due to distant sensor locations
Solution Approach 1:
The patent extracts the detection function from a distant second sensor and relocates it to a first sensor positioned adjacent to the toner container outlet. This allows toner conveyance abnormalities to be detected at the source location, eliminating the need for a separate distant sensor while maintaining detection reliability.
Solution Approach 2:
The first sensor positioned near the outlet serves multiple functions: it detects both the presence of toner and conveyance abnormalities simultaneously. This multi-functional approach replaces the need for separate sensors, reducing device complexity while maintaining comprehensive monitoring capability.
2Reliability
If two sensors are used to detect toner conveyance abnormalities, then detection coverage is improved, but manufacturing cost and system complexity increase
Solution Approach 1:
The detection function is extracted from a distant location and consolidated at the toner container outlet, where a single first sensor can perform abnormality detection without requiring a second sensor at a different location, simplifying system assembly.
Solution Approach 2:
The patent merges the detection functions that would previously required two separate sensors into a single first sensor positioned at the outlet. This consolidation simplifies manufacturing and assembly while maintaining the ability to detect toner conveyance abnormalities effectively.
3Productivity
If independent control of first and second conveyance units is implemented, then toner supply efficiency is improved, but control system complexity increases
Solution Approach 1:
The conveyance system is segmented into a first conveyance unit (discharge mechanism) and a second conveyance unit (transport mechanism), each independently controllable. This segmentation allows optimized toner supply efficiency by controlling each unit separately based on specific operational requirements.
Solution Approach 2:
The control unit implements self-service control by automatically managing the independent operation of the first and second conveyance units based on sensor feedback and operational conditions, reducing the need for manual intervention while maintaining efficient toner supply.
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 solution allows for accurate detection of toner conveyance abnormalities and efficient notification, reducing downtime and improving toner supply management by using a single sensor system and independent control of conveyance units.
Implementation Method 1
a sensor including a light emitting portion configured to emit light toward an inside of the toner conveyance passage, and a light receiving portion configured to receive light emitted from the light emitting portion and passing through the inside of the toner conveyance passage
Data Source
AI summary
An image forming apparatus includes a toner container, a first conveyance unit, and an apparatus main body. The apparatus main body includes a photosensitive drum, a development roller, a second conveyance unit, a toner conveyance passage, light sensor, an acquisition unit, and a control unit configured to execute an abnormality detection mode. In an abnormality detection mode, the acquisition unit acquires a first acquired value after the driving of the second conveyance unit with the driving of the first conveyance unit stopped. When the first acquired value satisfies a first condition, the acquisition unit further acquires a second acquired value after the driving of the second conveyance unit with the driving of the first conveyance unit stopped. The apparatus main body further includes a notification unit to make notification of the abnormality when the second acquired value satisfies a second condition.