Toner Replenishment Control Using Image Data and Concentration Feedback
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Solution Overview
Problem
Existing image forming devices often fail to frequently correct toner replenishment amounts due to infrequent formation of toner patches, leading to inappropriate toner supply.
Innovation Solution
The image forming device incorporates a developing device, toner concentration detector, toner replenisher, required toner amount calculator, and multiple replenishment controllers to precisely calculate and control toner replenishment based on image data and toner concentration, ensuring the storage is replenished with the appropriate amount of toner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If toner patch is formed at predetermined timing only, then device operation is simple, but toner replenishment amount becomes inappropriate due to infrequent correction
Solution Approach 1:
The replenishment control is divided into two independent controllers: first replenishment controller that calculates required toner amount based on image data, and second replenishment controller that corrects based on actual toner concentration measurement. This segmentation allows each controller to specialize in one aspect, improving overall reliability without requiring a single complex controller
Solution Approach 2:
The second replenishment controller implements feedback control by measuring actual toner concentration with the concentration detector and comparing it with target concentration, then correcting the replenishment amount accordingly. This closed-loop feedback ensures accurate toner replenishment while the modular structure keeps device complexity manageable
2Measurement precision
If toner concentration detection is performed frequently, then toner replenishment accuracy is improved, but measurement and control complexity increases
Solution Approach 1:
The patent implements dynamic replenishment control where the replenishment amount is continuously adjusted based on real-time toner concentration measurements and image data analysis. The system adapts the measurement and replenishment frequency according to actual toner consumption patterns, achieving high precision without requiring constant fixed-frequency measurements
3Manufacturing precision
If dual replenishment controllers are implemented, then toner replenishment accuracy is improved, but device complexity increases
Solution Approach 1:
The patent extracts the correction function from the main replenishment control and implements it as a separate second replenishment controller. This extraction allows the first controller to focus on basic required amount calculation while the second controller handles the specialized correction based on concentration measurements, improving precision while keeping each controller's functionality simple and well-defined
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 approach ensures consistent and appropriate toner replenishment, maintaining optimal toner concentration for efficient image development.
Implementation Method 1
The toner concentration detector detects a concentration of the toner included in the developer in the storage of the developing device
Data Source
AI summary
According to an image forming device according to the disclosure, a required toner amount is calculated based on image data. A toner replenishment device replenishes a development device with toner of a first replenishment amount included in the required toner amount. Toner of the remaining second replenishment amount included in the required toner amount is replenished, based on a toner concentration detection value of a toner concentration sensor. When the image forming device stands continuously unused for a predetermined threshold time or longer, the toner of the second replenishment amount is not replenished during a time period from when an image forming process is started immediately after the unused time, until a specific time elapses.