Toner Estimation Using Motor Driving Time Correction

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Solution Overview

Problem

Existing image forming apparatuses face inaccuracies in estimating the remaining toner amount due to increased continuous rotation time of the toner supply motor, leading to deviations between actual and estimated toner levels, resulting in premature toner cartridge replacement and wasted toner.

Innovation Solution

The apparatus includes a processor that acquires driving information of the toner supply motor and uses a toner use amount correction table to estimate the remaining toner by calculating the amount used based on continuous driving time, thereby reducing estimation deviations and optimizing toner replacement timing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If the toner supply motor rotates continuously for a longer time to supply more toner, then the toner supply amount increases, but the deviation between actual and estimated remaining toner amount increases

Engineering Contradiction:

Improvetoner supply amountVSAvoidtoner remaining amount estimation accuracy

Core Design Contradiction:

Quantity of substanceVSMeasurement precision

Solution Approach 1:

The patent divides the continuous rotation time into discrete time bands (0-5s, 5-10s, 10-15s, etc.) and assigns different correction values to each band. This segmentation allows the system to account for non-linear toner consumption patterns at different rotation stages, improving estimation accuracy while maintaining continuous toner supply capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the estimation parameter from simple rotation time to rotation time combined with correction values that vary by time band. By introducing correction values that adjust the base estimation based on continuous rotation duration, the system accurately tracks toner consumption even during extended motor operation

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If the toner remaining amount is estimated without correction for continuous rotation time, then the estimation process is simple, but the estimation accuracy deteriorates

Engineering Contradiction:

Improveestimation process complexityVSAvoidtoner remaining amount estimation accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent pre-calculates and stores correction values for different rotation time bands before actual toner estimation is needed. These correction values are determined in advance based on empirical data about toner consumption patterns, allowing the estimation process to simply look up and apply the appropriate correction rather than performing complex real-time calculations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system automatically selects and applies the appropriate correction value based on the current rotation time band without requiring manual intervention. The correction mechanism serves itself by using the measured rotation time to determine which pre-established correction factor to apply, maintaining simplicity while improving accuracy

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10670987B1Image forming apparatus and estimation method that estimate a remaining amount of toner

Publication Date: 2020.06.02 TOSHIBA TEC KK

AI summary

According to one embodiment, an image forming apparatus includes a printer unit and a control unit. The printer unit forms an image on a sheet using a developer, and includes a predetermined driving member related to supply of the developer. The control unit acquires driving information regarding continuous driving of the driving member, acquires correction information regarding on correction of an amount of the developer used in accordance with the driving information, and estimates a remaining amount of the developer on the basis of the driving information and the correction information.