Toner Estimation Using Motor Drive Correction
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Solution Overview
Problem
Existing methods for estimating the remaining toner in toner cartridges, such as calculating based on toner supply motor rotation time, often result in inaccurate estimations as the remaining toner amount decreases, leading to deviations in the estimated values.
Innovation Solution
An image forming apparatus that includes a control unit which acquires driving information from a toner supply motor and correction information stored in a storage unit, allowing it to estimate the remaining toner amount by adjusting the count value based on a cumulative driving time and correction values from a count value correction table, ensuring accurate estimation even when the toner is nearly empty.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the remaining toner amount is calculated based on toner supply motor rotation time, then the estimation method is simple, but the estimation accuracy deteriorates as the remaining toner amount decreases
Solution Approach 1:
The patent changes the parameter used for estimation from simple rotation time to a corrected count value that accounts for the relationship between rotation time and remaining toner amount. By introducing correction values that adjust for the non-linear relationship between motor rotation and toner consumption at different toner levels, the system maintains estimation accuracy across the full range of toner quantities while keeping the overall method relatively simple.
2Measurement precision
If correction information is stored and used to adjust count values, then the remaining toner estimation accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing correction values in a correction table before actual toner estimation is needed. The correction information, which represents the relationship between rotation time and toner consumption at various toner levels, is prepared in advance and stored in memory. During operation, the system simply retrieves and applies the appropriate correction value based on current conditions, avoiding the need for complex real-time calculations while maintaining high estimation accuracy.
Data Source
AI summary
According to one embodiment, an image forming apparatus includes a printer unit that includes a driving member related to the supply of the developer, a storage unit that stores correction information regarding the correction of a supplied amount of the developer and a remaining amount of the developer, and a control unit. The control unit acquires driving information regarding the driving of the driving member. The control unit acquires the correction information in accordance with the remaining amount of the developer and estimates the remaining amount of developer based on the driving information and the correction information when the remaining amount of the developer stored in the storage unit satisfies a predetermined condition regarding the remaining amount, and estimates the remaining amount of the developer based on the driving information when the remaining amount of the developer stored in the storage unit does not satisfy the predetermined condition.