Toner Residual Estimation via Print Data Analysis
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Solution Overview
Problem
In image forming apparatuses, estimation errors at low toner residual amounts due to uneven toner distribution lead to redundant toner container orders when users detach and reattach containers to utilize remaining toner, causing multiple orders for a single container.
Innovation Solution
The apparatus employs a non-volatile memory device to store and manage toner residual amounts based on print data, identifying consumption and residual toner levels, and only initiates an order when the residual amount meets a predetermined threshold, independent of sensor outputs, preventing redundant orders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If toner residual amount is estimated from sensor output, then near empty status can be detected, but estimation error is large at low toner residual amount due to uneven toner distribution
Solution Approach 1:
The patent replaces the physical sensor-based measurement system with an information processing system that calculates toner residual amount based on print data. The controller identifies toner consumption amount from print data and calculates residual amount by subtracting consumption from initial amount, eliminating reliance on inaccurate physical sensors at low toner levels.
Solution Approach 2:
The patent creates an information model (data) that copies and represents the actual toner consumption state. Instead of directly measuring physical toner quantity with sensors, the system creates a digital representation of toner residual amount through calculation from print data, enabling more accurate tracking.
2Ease of operation
If users detach and reattach toner container to utilize remaining toner, then toner can be fully used, but near empty status is detected multiple times causing redundant orders
Solution Approach 1:
The patent implements a feedback mechanism where the controller monitors toner residual amount continuously based on print data and compares it with a threshold value. The system provides feedback about the current toner state and automatically manages ordering, preventing redundant orders even when users manipulate the container.
Solution Approach 2:
The patent performs preliminary calculation of toner residual amount based on print data before the actual near empty detection occurs. By proactively tracking consumption from print data, the system prepares accurate residual amount information in advance, enabling reliable order timing determination regardless of container manipulation.
Data Source
AI summary
A toner consumption amount identifying unit identifies a toner consumption amount of toner consumed in a printing process from the print data. A toner residual amount identifying unit identifies a toner residual amount in a toner container from the toner consumption amount. A toner residual amount data managing unit stores order-timing toner residual amount data into a non volatile memory device at a timing when an ordering process of the toner container succeeds, and deletes the order-timing toner residual amount data in the non volatile memory device if the value of the toner residual amount is larger than a value of the order-timing toner residual amount data. An order processing unit performs the ordering process if the order-timing toner residual amount data is not stored in the non volatile memory device and the value of the toner residual amount is either equal to or less than a predetermined value.