Toner Conveyor Control via Development Unit Sensor
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Solution Overview
Problem
Existing image forming devices cannot determine if toner exists in the conveying path without a sensor, leading to uncertainty about the necessity of filling the developer conveyor with toner.
Innovation Solution
The image forming device includes a development unit, a conveyor, a toner sensor, an attachment/detachment detector, and a controller that determines the need for a filling operation based on a filling determination variable stored in the controller's storage when a cartridge is attached.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a toner sensor is installed in the conveyor to detect toner presence, then the ability to determine whether toner exists in the conveying path is improved, but the device complexity and cost increase
Solution Approach 1:
The patent uses the toner sensor installed in the development unit as an intermediary to indirectly detect toner presence in the conveyor. Instead of installing a sensor directly in the conveyor, the system uses the existing sensor in the development unit to infer conveyor status by monitoring toner flow into the development unit, thereby avoiding direct sensor installation in the conveyor path.
Solution Approach 2:
The system uses the existing toner sensor in the development unit for dual purposes: both for normal toner level detection in the development unit and for inferring conveyor status. This self-service approach allows the existing sensor to serve multiple functions, eliminating the need for additional conveyor-specific sensors.
2Productivity
If the conveyor is continuously filled with toner to ensure availability, then the productivity is improved, but the toner consumption and waste increase
Solution Approach 1:
The system implements feedback control by continuously monitoring toner presence in the conveyor using the toner sensor. Based on this feedback, the controller selectively activates the conveyor motor to fill the conveyor only when toner is detected as depleted, rather than continuous operation. This ensures image formation continuity while minimizing unnecessary toner consumption and waste.
Solution Approach 2:
The conveyor operation transitions from a static continuous operation mode to a dynamic on-demand mode. The conveyor motor is dynamically activated or deactivated based on real-time toner detection results, allowing the system to adapt toner supply to actual consumption rates and prevent both overfilling and depletion.
3Reliability
If the conveyor is emptied and refilled frequently to maintain toner freshness, then the toner quality is improved, but the loss of time and reduced productivity occur
Solution Approach 1:
The system performs preliminary toner filling of the conveyor during initial cartridge installation or after detected depletion, rather than requiring frequent manual interventions. The controller automatically manages toner transfer from the cartridge to the conveyor in advance, ensuring toner availability before it is needed for image formation, thus maintaining quality without operational interruptions.
Solution Approach 2:
The system maintains continuous toner supply to the development unit by keeping the conveyor operational and filled with toner. Rather than emptying and refilling the conveyor frequently, the system ensures continuous toner flow from the cartridge through the conveyor to the development unit, eliminating interruptions and maintaining both toner quality and productivity.
Data Source
AI summary
An image forming device forms an image using toner contained in an attached cartridge, and includes: a development unit that forms a toner image on a photoreceptor drum; a conveyor that receives the toner from the cartridge and conveys the toner to the development unit; a toner sensor that detects the amount of toner stored in the development unit; an attachment/detachment detector that detects attachment and detachment of the cartridge; and a controller including a storage, the controller determining whether to perform a filling operation to fill the conveyor with the toner based on a filling determination variable stored in the storage when attachment of the cartridge is detected.