Toner Replenishment Control Using Sensor Timing for Near Empty Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for determining the near empty state of toner in image forming apparatuses require additional components like sub hoppers and sensors, increasing costs without providing a cost-effective solution for continuous operation.
Innovation Solution
An image forming apparatus with a developing device, toner supply system, sensor, timer, and controller that determines the near empty state based on the time required to replenish toner from a cartridge to a developing device, eliminating the need for a separate sensor or container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sub hopper with a toner sensor is provided to determine the near empty state, then the near empty state can be accurately detected, but the cost increases due to additional components
Solution Approach 1:
The existing toner sensor in the developing device is made to serve dual purposes: its original function for toner replenishment control and the new function for near empty state detection. The controller determines the near empty state by analyzing the output signal from this existing sensor, eliminating the need for a separate detection sensor.
Solution Approach 2:
The near empty state detection function is merged with the existing toner replenishment control system. The sub hopper and its sensor are integrated into the overall toner management system, where the same sensor output is utilized for both replenishment timing and near empty state determination, reducing component count.
2Reliability
If a sub hopper is provided between the developing device and toner cartridge, then the near empty state can be determined, but the device complexity and cost increase
Solution Approach 1:
The system performs preliminary detection of the near empty state by analyzing toner sensor output trends before the toner is completely depleted. The controller monitors the sensor output over time and determines the near empty state in advance, enabling proactive toner replacement while maintaining continuous operation.
Solution Approach 2:
The existing toner sensor and sub hopper system serves multiple functions including both toner replenishment control and near empty state detection. The system uses its own existing components rather than requiring entirely separate dedicated components for each function.
3Measurement precision
If a separate toner sensor is provided in the sub hopper, then the near empty state can be detected, but the cost increases
Solution Approach 1:
The existing toner sensor is designed to perform multiple functions: controlling toner replenishment based on sensor output signals and determining near empty states by analyzing the same sensor output. This multi-functional use eliminates the need for additional dedicated sensors, reducing manufacturing costs.
Solution Approach 2:
Instead of creating a separate physical sensor for near empty detection, the system uses the existing sensor's output signal to infer the near empty state. The controller analyzes the sensor output trends and determines the near empty condition through signal processing rather than physical duplication.
Data Source
AI summary
An image forming apparatus includes a developing device that forms a toner image on a sheet; a supply device provided with a cartridge for accommodating toner and supplying the toner in the cartridge to the developing device; a sensor that acquires a physical quantity relating to an amount of toner in the developing device; a timer that counts time; and a controller that drives the supply device until a condition that the acquired physical quantity indicates that the amount of toner is equal to or greater than a predetermined value is satisfied when a condition that the physical quantity indicates that the amount of toner becomes small is satisfied, counts time during which the supply device is being driven with the timer, and determines that the amount of toner in the cartridge becomes smaller than a predetermined amount if the counted time is longer than a predetermined threshold value.