Waste-Toner Container Fullness Detection Using Light Sensor
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Solution Overview
Problem
Existing image forming apparatuses face issues in accurately detecting the fullness of waste-toner containers due to vibrations causing the toner pile to collapse, leading to incorrect sensor readings and potential user misconceptions about apparatus malfunction, and require additional components to distinguish between full and empty states under varying light conditions.
Innovation Solution
An image forming apparatus with a translucent waste-toner container and a light sensor system that includes a light-emitting and light-receiving portion, a light-blocking member, and a control unit to detect container fullness and attachment status, maintaining the apparatus in a non-printable state until the container is replaced, using threshold voltages to differentiate between full and empty states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single light sensor is used to detect both bottle attachment and waste toner fullness, then production costs are reduced, but detection accuracy deteriorates because the situations where the bottle is not attached and where the bottle is full cannot be clearly distinguished
Solution Approach 1:
The detection function is segmented into two distinct detection modes: attachment detection mode and fullness detection mode. The control unit switches between these modes based on the operational state, allowing a single sensor to perform multiple functions at different times without confusion between detection targets
Solution Approach 2:
The light-blocking member is made movable between a retracted position (when bottle is attached) and a projected position (when bottle is removed). This dynamic positioning changes the light reception state, enabling the sensor to distinguish between attachment and fullness conditions through temporal variation in detection signals
2Measurement precision
If the waste toner container is made translucent to enable optical detection, then detection capability is improved, but the ability to clearly distinguish between full and empty states deteriorates when outside light enters during cover opening
Solution Approach 1:
The system performs attachment detection before fullness detection. By first confirming the bottle is properly attached through the light-blocking member position, the system establishes a prerequisite condition that prevents fullness detection from being performed under interfering light conditions
Solution Approach 2:
The light-blocking member serves as an intermediary element that mediates between the light source and light sensor. When projected, it blocks outside light from reaching the sensor, thereby eliminating light interference during detection operations
3Device complexity
If the light sensor detects waste toner fullness by blocking light, then detection simplicity is improved, but reliability deteriorates when the toner pile collapses due to vibration or weight changes
Solution Approach 1:
The light-blocking member is designed to move dynamically in response to bottle attachment status. When the bottle is removed, the member projects to block light; when attached, it retracts. This dynamic behavior provides a reliable, state-dependent signal that is independent of toner pile stability
Solution Approach 2:
The system uses the light-blocking member's position as a proxy indicator for bottle attachment status. Instead of directly measuring toner fullness (which is unreliable), the system detects the mechanical state of the blocking member, which reliably reflects whether the bottle is attached or removed
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
Ensures accurate detection of waste-toner container fullness and attachment, preventing user misconceptions about apparatus malfunction and reducing production costs by eliminating the need for additional switches, while maintaining the apparatus in a non-printable state until the container is replaced.
Implementation Method 1
a light sensor having a light-emitting portion and a light-receiving portion whose output voltage varies according to the amount of light received
Data Source
AI summary
An image forming apparatus includes a waste-toner container, a light sensor having a light-emitting portion and a light-receiving portion, a light-blocking member for covering the light sensor to detect the attachment of the waste-toner container, and a control unit. When the waste-toner container is determined to be full based on the output voltage of the light sensor, a printing operation is stopped or is not started until it is determined that the waste-toner container is removed and then attached, and that the waste-toner container is not full. A method for detecting the fullness of a waste-toner container includes the steps of detecting the fullness of the waste-toner container, prohibiting printing, detecting whether or not the waste-toner container is attached, and permitting printing.