Waste Toner Detection via Motor Current and Sensor Cleaning
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Solution Overview
Problem
Conventional image forming apparatuses lack accurate prediction of waste toner state and timely notification for replacement, leading to inefficient toner conveyance and incorrect detection of full load conditions due to environmental changes and sensor contamination.
Innovation Solution
An image forming apparatus equipped with a toner image carrier, transfer unit, cleaner, waste toner container with a screw, sensors to detect toner amount and motor driving force, and determination units to assess the toner state and notify users appropriately based on detected data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a light transmission sensor is used to detect waste toner amount, then the waste toner full load detection is simplified, but wrong detection occurs when the sensor is contaminated
Solution Approach 1:
The patent introduces a blowing unit that uses air flow as an intermediary to clean the light transmission sensor. The blowing unit directs air to the sensor surface to remove contaminated toner particles, thereby maintaining sensor detection accuracy without requiring complex replacement mechanisms
Solution Approach 2:
The system performs self-maintenance by automatically cleaning the sensor through the blowing unit. The sensor contamination problem is resolved by having the system clean itself during operation, eliminating the need for external intervention or complex manual maintenance procedures
2Quantity of substance
If the waste toner container capacity is increased to accommodate all waste toner from multiple photoreceptors, then the replacement frequency is reduced, but the notification timing becomes inaccurate due to unknown filling ratios
Solution Approach 1:
The patent implements preliminary notification before the waste toner container reaches full capacity. The notification unit alerts the user in advance based on predicted filling ratio, allowing timely replacement before actual full load occurs, preventing operational disruptions
Solution Approach 2:
The system continuously monitors waste toner amount using the light transmission sensor and provides feedback to the notification unit. This feedback mechanism enables dynamic adjustment of replacement timing based on actual accumulation rates, improving notification accuracy
3Quantity of substance
If the screw conveys waste toner uniformly to maximize filling ratio, then the container efficiency is improved, but rapid load application deteriorates conveyance efficiency when toner state changes
Solution Approach 1:
The patent makes the screw rotation speed dynamic rather than fixed. The rotation speed is adjusted based on detected waste toner amount and accumulation rate, allowing the system to adapt to changing toner states and maintain optimal conveyance efficiency throughout the filling process
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
The solution enables accurate prediction of waste toner filling ratio and timely notification for replacement, preventing incorrect detection and ensuring efficient toner conveyance and image forming operations.
Implementation Method 1
the waste toner container comprises a light transmission sensor. When the waste toner in the waste toner container is accumulated and light from the light transmission sensor is shielded, the output of the light transmission sensor changes.
Implementation Method 2
A screw is provided in the waste toner container. By conveying and uniformly leveling the waste toner using the screw, the waste toner container is configured to fill the toner as much as possible in the waste toner container.
Data Source
AI summary
An image forming apparatus includes a waste toner container for containing toner recovered from a photosensitive drum and an intermediate transfer belt. The waste toner container has a stirring screw for conveying the toner in the waste toner container. The stirring screw is driven by a waste toner motor. A CPU determines whether the waste toner container is in need of replacement depending on a rotation speed or driving current of the waste toner motor. If the waste toner container is in need of replacement, the CPU displays such on a display unit to provide a notification to a user.