Toner Detection via Motor Rotation and Magnetic Permeability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately detecting the remaining toner level without a dedicated detection device, leading to insufficient time for toner replenishment, resulting in reduced operation rates and potential toner shortages.
Innovation Solution
An image forming apparatus using a two-component developer with a toner density control system, incorporating a toner supply amount calculation, toner consumption amount calculation, and toner density control to detect remaining toner levels based on accumulated motor rotations, image information, and magnetic permeability, allowing for precise detection from full to empty toner conditions without a special detection device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated remaining toner detection device is provided, then the detection precision is improved, but the device complexity and cost increase
Solution Approach 1:
The patent applies multi-functionality by enabling existing components (supply motor, ATC system, magnetic permeability sensor) to serve dual purposes: the supply motor both supplies toner and its rotation count detects remaining toner level, while the magnetic permeability sensor both controls toner density and indicates toner quantity. This eliminates the need for dedicated detection devices while maintaining detection precision.
Solution Approach 2:
The system uses itself for detection - the supply motor's own operation characteristics (rotation count, rotational time) are utilized to detect remaining toner levels, and the ATC system's own magnetic permeability measurements are used to infer toner quantity. This self-service approach avoids additional detection hardware while achieving accurate monitoring.
2Device complexity
If existing members are used to detect remaining toner level, then the device complexity is reduced, but the detection precision and reliability deteriorate
Solution Approach 1:
The patent implements feedback mechanisms where the supply motor's rotation count and rotational time are continuously monitored and fed back to calculate remaining toner levels. The ATC system's magnetic permeability measurements are also fed back to infer toner quantity. This feedback approach ensures accurate detection while using only existing components.
Solution Approach 2:
The system performs preliminary calculations of remaining toner levels based on supply motor rotation counts and rotational times before the toner actually runs out. This allows advance notification to users, preventing operation interruptions while maintaining simple device architecture.
3Device complexity
If ATC is used to detect remaining toner, then the device complexity is reduced, but the time for accurate detection is insufficient
Solution Approach 1:
The patent performs preliminary detection of remaining toner levels by accumulating supply motor rotation counts and rotational times before the toner actually depletes. This allows the system to notify users in advance with sufficient time for toner replenishment, preventing operation interruptions while keeping the system simple.
Solution Approach 2:
The system dynamically adjusts detection thresholds and notification timing based on accumulated motor operation data. By continuously monitoring and updating remaining toner level estimates in real-time, the system provides timely alerts while using only existing ATC components.
4Ease of operation
If the supply motor rotates for a predetermined time to supply toner, then the toner supply is controlled, but the detection of remaining toner becomes inaccurate when toner is nearly depleted
Solution Approach 1:
The patent dynamically adapts the detection method based on remaining toner levels. When toner is abundant, fixed rotation time supply control is used. When toner becomes scarce, the system switches to detecting actual rotation counts and measuring rotational times, which remain accurate even when toner is nearly depleted. This dynamic adaptation maintains both ease of operation and detection precision.
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
Enables exact detection of remaining toner levels, allowing timely user notification and preventing operation interruptions by chronologically tracking toner levels from full to empty, thus maintaining apparatus efficiency.
Implementation Method 1
a toner density control section for supplying the toner from a supply device to a developing device on the basis of magnetic permeability of the developer so as to cause toner density in the developing device to be constant
Data Source
AI summary
The image forming apparatus according to the present invention detects the amount of remaining toner by using (i) the result of calculation carried out by a toner supply amount calculation section based on an accumulated rotational time measurement section in a region where the amount of remaining toner is not less than a predetermined amount and toner supply is stabilized, (ii) the result of calculation carried out by a pixel count section in a region where the amount of remaining toner gets small and the amount of toner supply gets uneven, and (iii) the result of ATC carried out by a toner density control section. As a result, it is possible to exactly detect the amount of remaining toner without providing a special remaining toner detection device.