Waste Container Detection in Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses face issues in accurately determining when a waste container is full, leading to premature alerts or shutdowns due to uneven waste distribution, and the cleaning device's waste-recovering ability decreases over time, necessitating timely replacement.
Innovation Solution
An image forming apparatus equipped with two detecting units, a counting unit, and a determining unit that calculates an estimated waste amount based on toner image forming operations, determining the container is full only when both units detect waste and the count value exceeds a predetermined threshold, ensuring accurate timing for replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single detecting member is used to detect waste accumulation, then the device complexity is reduced, but the measurement precision of waste amount is insufficient leading to inaccurate full-container determination
Solution Approach 1:
The detection system is segmented into multiple detecting members (first and second detecting members) positioned at different locations within the container. Each detecting member independently monitors waste accumulation in its specific zone, allowing the system to achieve high measurement precision without requiring a single complex detection mechanism. This segmentation enables accurate determination of whether the container is truly full versus temporarily detecting waste in one area.
2Reliability
If the container is monitored continuously with high sensitivity, then the reliability of waste full detection is improved, but false detection occurs when waste is unevenly distributed causing unnecessary shutdowns
Solution Approach 1:
The system performs preliminary detection actions by monitoring waste accumulation trends over time using multiple detecting members before making a final determination. Rather than immediately shutting down when one sensor detects waste, the system accumulates detection data and compares it against predetermined thresholds, allowing it to distinguish between temporary local accumulation and true container fullness. This preliminary assessment prevents false detections and unnecessary shutdowns.
3Productivity
If the container capacity is maximized to reduce replacement frequency, then the productivity is improved, but the cleaning device effectiveness decreases over time requiring timely replacement
Solution Approach 1:
The system implements continuous feedback monitoring of waste accumulation levels and cleaning device performance. By tracking the amount and type of waste collected over time, the system can assess the declining effectiveness of the cleaning device and prompt timely replacement. This feedback mechanism allows the container to be maximized in capacity while maintaining awareness of the cleaning device's operational status, ensuring replacement occurs before complete failure.
Data Source
AI summary
An image forming apparatus includes: an image forming unit; a containing unit; two detecting units; a counting unit; and a determining unit. The image forming unit is configured to form a toner image. The containing unit is configured to contain waste that is generated when the image forming unit forms a toner image. The two detecting units that are configured to detect the waste accumulated in the containing unit. The counting unit starts, when at least one of the two detecting units detects waste, counting up a count value based on the toner image forming operation executed by the image forming unit. The determining unit determines that waste accumulated in the containing unit has reached a maximum amount if the count value of the counting unit is equal to or greater than a predetermined first threshold value and both of the two detecting units detects waste.