Toner Supply Ratio Calculation for Consistent Emptiness Detection
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Solution Overview
Problem
The determination of toner emptiness in image forming apparatuses based on toner density varies significantly with the printing ratio of image data, leading to inconsistent detection times from near emptiness to emptiness, which can cause unnecessary operation of the development unit under low toner density conditions.
Innovation Solution
An image forming apparatus that calculates a toner supply ratio based on the integrated value of a pixel count value of image data and the integrated value of the driving time of the toner supply motor, detecting toner emptiness when this ratio falls below a preset threshold, thereby stabilizing the number of prints until emptiness is confirmed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If toner emptiness is detected based on toner density, then the detection method is simple, but the number of prints from near emptiness to emptiness varies significantly with printing ratio
Solution Approach 1:
The patent changes the detection parameter from toner density alone to a comprehensive parameter combining pixel count value and motor driving time. This allows the system to account for different printing ratios and achieve consistent toner emptiness detection across various printing conditions, resolving the contradiction between simple detection and reliable consistent results.
2Reliability
If toner supply motor operates continuously to maintain toner density, then toner supply is ensured, but the development unit operates prolonged under low toner density conditions
Solution Approach 1:
The patent performs preliminary action by detecting toner near emptiness state before actual emptiness occurs. By using the comprehensive parameter (pixel count value and motor driving time), the system can predict toner depletion and trigger replacement warnings in advance, preventing prolonged operation under low toner density conditions while ensuring reliable toner supply.
3Ease of operation
If toner emptiness detection is based on fixed threshold, then the control logic is simple, but it cannot adapt to different printing ratios
Solution Approach 1:
The patent applies dynamics by making the detection threshold adaptive rather than fixed. The system dynamically adjusts the effective threshold based on the relationship between pixel count value and motor driving time, allowing it to adapt to different printing ratios while maintaining relatively simple control logic through the standardized parameter combination.
Data Source
AI summary
According to one embodiment, an image forming apparatus includes a photosensitive drum, an exposure unit, a development unit, a toner supply motor, and a processor. The exposure unit exposes the photosensitive drum based on image data. The development unit forms a toner image on the photosensitive drum with toner supplied from a toner cartridge. The toner supply motor supplies the toner to the development unit from the toner cartridge. The processor detects toner emptiness when a toner supply ratio calculated based on an integrated value of a pixel count value of the image data and an integrated value of a driving time of the toner supply motor is less than a preset threshold.