Toner Sensor Detection for Uneven Accumulation in Image Forming Apparatus
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In image forming apparatuses, uneven toner accumulation in toner containers leads to increased load torque for the motor driving the stirring conveying screw, causing excessive current flow and false overload detection, which can result in inefficient toner supply and potential equipment damage.
Innovation Solution
The apparatus includes a toner state determination method using a toner sensor, RFID tag, and reader/writer to detect toner levels and voltage waveforms, determining uneven accumulation and triggering notifications to the user to address the overload issue by identifying the cause of the problem and guiding corrective actions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stirring conveying member rotates to convey toner, then toner supply to the developing unit is maintained, but when toner is unevenly condensed at one side of the container, the screw receives resistance from condensed toner resulting in increased load torque and excessive current flow
Solution Approach 1:
The system performs preliminary detection of toner distribution state using a toner sensor before the motor overload occurs. By detecting uneven toner accumulation in advance and notifying the user to shake the container, the system prevents the condensed toner from causing excessive resistance and motor overload, thereby maintaining reliable operation.
Solution Approach 2:
The system implements feedback by continuously monitoring toner distribution through the toner sensor and comparing it against predetermined thresholds. When uneven accumulation is detected, the system provides feedback to the user via notification, enabling corrective action (shaking the container) to restore proper toner distribution and prevent motor overload.
2Speed
If the motor drives the stirring conveying member at normal speed, then toner is conveyed efficiently, but when toner is unevenly accumulated, the load torque increases causing the driving current to exceed the boundary and trigger false overload detection
Solution Approach 1:
The system performs preliminary detection of toner distribution state using a toner sensor before the motor overload occurs. By detecting uneven toner accumulation in advance and notifying the user to shake the container, the system prevents the condensed toner from causing excessive resistance and motor overload, thereby maintaining reliable operation.
Solution Approach 2:
The toner sensor acts as an intermediary device that detects toner distribution state and provides early warning before motor overload occurs. This intermediary detection mechanism allows the system to distinguish between normal high-current operation during rapid toner supply and abnormal high-current operation caused by toner condensation, thereby reducing false overload detection.
3Stability of the object's composition
If toner is left in the container with one side facing downward for a long time, then the container remains stable, but the toner becomes unevenly condensed at one side increasing resistance to the stirring conveying screw
Solution Approach 1:
The system performs preliminary detection of toner distribution state using a toner sensor before the motor overload occurs. By detecting uneven toner accumulation in advance and notifying the user to shake the container, the system prevents the condensed toner from causing excessive resistance and motor overload, thereby maintaining reliable operation.
Solution Approach 2:
The system implements feedback by continuously monitoring toner distribution through the toner sensor and comparing it against predetermined thresholds. When uneven accumulation is detected, the system provides feedback to the user via notification, enabling corrective action (shaking the container) to restore proper toner distribution and prevent motor overload.
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 solution effectively identifies and addresses uneven toner accumulation, preventing motor overload and ensuring efficient toner supply by notifying users to shake the toner container, thereby maintaining apparatus performance and preventing damage.
Implementation Method 1
The toner sensor detects an amount of the toner at the one end of the accommodating container
Implementation Method 2
The reader/writer is provided at a body side position of the image forming apparatus, which faces the communication tag, and communicates with the communication tag
Data Source
AI summary
An image forming apparatus includes an accommodating container provided at one end thereof with a toner supply port, a stirring conveying member that conveys toner to the supply port, a rotational driving unit that rotationally drives the stirring conveying member, a current detection unit that detects a driving current, an overload detection section that detects that the stirring conveying member is in an overload state when the driving current is within a range of an excess current, an unevenness determination section that determines whether the toner has been unevenly accumulated at the one end or the other end of the accommodating container, and a cause determination section that determines that a cause of the overload is uneven distribution of the toner when the overload state of the stirring conveying member is detected and being determined that the toner has been unevenly accumulated at the one end or the other end.