Waste Toner Density Detection via Torque Rupture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional image formation apparatuses face challenges in accurately detecting the amount of waste toner in the waste toner accommodation unit due to issues like uneven liquid levels and sensor soiling, which affects the precision of detection and leads to environmental concerns and inappropriate waste management.
Innovation Solution
The apparatus employs a waste toner accommodation unit with a rotation unit, segmentation unit, and determination unit that utilizes the density of waste toner to detect when a predetermined amount is reached, eliminating the need for liquid level detection and enabling appropriate waste processing and exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an optical sensor is used to detect the liquid level of waste toner, then the amount of waste toner can be detected, but the detection precision is affected by uneven liquid levels and sensor soiling
Solution Approach 1:
The invention changes the detection parameter from liquid level (height) to density (mass per volume). The density detection unit measures the density of waste toner in the accommodation chamber, which directly correlates to the amount of waste toner regardless of liquid level uniformity or sensor soiling. This parameter change resolves the detection precision and reliability issues inherent in optical liquid level sensing.
2Reliability
If the waste toner accommodation unit is designed with a margin capacity to handle detection inaccuracies, then detection reliability improves, but the device size increases
Solution Approach 1:
By switching from liquid level detection to density detection, the system achieves accurate waste toner amount measurement without requiring design margins. The density measurement directly reflects the actual amount of waste toner, allowing the accommodation unit to be optimally sized without excess capacity, thus reducing device volume while maintaining high reliability.
3Measurement precision
If a liquid level leveling mechanism is added to ensure uniform toner distribution, then detection accuracy improves, but the device complexity increases
Solution Approach 1:
The invention eliminates the need for liquid level leveling mechanisms by changing the detection approach to measure density rather than liquid level. Since density detection is insensitive to liquid level uniformity, complex mechanical leveling structures with agitation fins and rotation mechanisms are unnecessary, significantly reducing device complexity while maintaining detection accuracy.
4Object-affected harmful factors
If the waste toner accommodation unit is frequently exchanged to ensure proper waste management, then environmental impact is reduced, but productivity decreases
Solution Approach 1:
The density detection unit provides accurate real-time measurement of waste toner amount, enabling precise monitoring and optimization of waste toner accumulation. This allows the accommodation unit to be exchanged only when truly necessary, reducing unnecessary exchanges that would disrupt productivity while ensuring environmental compliance through accurate monitoring of actual waste toner levels.
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 allows for precise detection of waste toner levels without liquid level-related inaccuracies, facilitating timely exchange, reducing environmental impact, and enabling a miniaturized, simplified, and cost-effective image formation apparatus design.
Implementation Method 1
a rotation unit having first and second ends rotatably connected to two internal opposite surfaces, respectively, of the waste toner accommodation unit, the rotation unit transporting the waste toner from the first toward second ends as the rotation unit rotates
Implementation Method 2
the rotation unit transporting the waste toner from the first toward second ends as the rotation unit rotates
Implementation Method 3
a segmentation unit segmenting an interior of the waste toner accommodation unit into a first region covering a portion of the rotation unit and containing the rotation unit, and a second region excluding the first region, the segmentation unit having a plurality of holes in a direction along the rotation unit to allow the waste toner to communicate between the first and second regions
Implementation Method 4
a rotation stopping mechanism stopping the rotation unit from rotating when a load torque of the rotation unit attains a predetermined torque value
Implementation Method 5
an image formation apparatus utilizing density of waste toner in a waste toner accommodation unit
Implementation Method 6
a determination unit determining that the waste toner in the waste toner accommodation unit has reached a predetermined amount when the rotation unit stops rotating
Data Source
AI summary
An image formation apparatus has a waste toner accommodation unit including a toner transporting rotation member covered with a fixed pipe. As the member rotates, waste toner in the pipe is transported downstream. The toner transporting rotation member has an upstream portion with a recessed portion having a small diameter. As the toner transporting rotation member rotates, a detection plate located external to the waste toner accommodation unit repetitively moves and thus repetitively passes across a photo sensor. When the waste toner has reached the level of the pipe the waste toner is compressed in the pipe downstream and thus increases in density. This increases a load torque of the toner transporting rotation member and hence ruptures the recessed portion, and thus stops rotation. The photo sensor detects that the detection plate no longer passes across it, and thus detects a state full of toner.