Waste Toner Drive Phase Detection to Prevent Motor Overload
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Solution Overview
Problem
Existing image forming apparatuses lack effective methods to detect and prevent overloading of waste toner collecting containers, which can lead to motor breakdowns and toner overflow, using conventional torque detection methods.
Innovation Solution
A dual-rotatable member system is employed to detect changes in rotational load torque, restricting phase shifts based on torque changes, ensuring accurate detection of waste toner levels and preventing overloading by restricting phase return to a first phase when torque decreases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a torque detecting means is provided to detect rotational load torque of the waste toner conveying screw, then the waste toner container full state can be detected and motor breakdown can be prevented, but the device complexity increases due to additional detection mechanisms
Solution Approach 1:
A phase difference detecting mechanism is introduced as an intermediary between the driving motor and the waste toner conveying screw. This mechanism uses two rotatable members with different rotational speeds to indirectly detect torque changes through phase shifts, avoiding direct torque measurement while achieving reliable overload detection
Solution Approach 2:
The patent replaces complex mechanical torque detection mechanisms with a simplified phase difference detection system using optical or magnetic sensors. This substitution reduces mechanical complexity while maintaining reliable torque monitoring capability through non-contact sensing
2Measurement precision
If conventional torque detection methods are used, then the detection mechanism can be implemented, but accurate detection of waste toner levels is difficult due to torque fluctuation and false readings
Solution Approach 1:
The system performs preliminary detection of phase differences between the two rotatable members before making a full overload determination. This preliminary action allows the system to anticipate torque changes and distinguish between normal fluctuations and actual overload conditions, improving detection accuracy
Solution Approach 2:
The phase difference detection system continuously monitors the relative positions of the two rotatable members and provides feedback to the control mechanism. This feedback enables real-time adjustment and distinction between temporary torque variations and sustained overload conditions, eliminating false readings
3Measurement precision
If the phase difference detecting mechanism uses two rotatable members with different rotational speeds, then torque changes can be detected through phase shifts, but the device complexity increases due to additional rotatable members and synchronization requirements
Solution Approach 1:
The patent combines the torque detection function with the existing drive mechanism by making both rotatable members part of the normal power transmission path. The first rotatable member is driven directly by the motor, while the second is driven by the waste toner conveying screw, merging detection with existing operational components to minimize additional complexity
Solution Approach 2:
The two rotatable members serve multiple functions: they transmit driving force to the waste toner conveying screw while simultaneously enabling torque detection through their phase relationship. This multi-functionality reduces the need for separate detection mechanisms and minimizes overall system complexity
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 system effectively prevents waste toner container overloading, reducing the risk of motor failure and toner overflow by accurately monitoring and managing waste toner levels, thereby extending equipment lifespan and maintaining operational efficiency.
Implementation Method 1
a phase which is a position of the second rotatable member relative to the first rotatable member with respect to a rotational direction of the first rotatable member changes from a first phase toward a second phase different from the first phase
Data Source
AI summary
An image forming apparatus includes a driven member, a driving source, a first rotatable member, a second rotatable member, a detecting portion capable of detecting that the second rotatable member is in a second phase, and a restricting portion. The first rotatable member and the second rotatable member are rotated in a first phase when a rotational load torque of the driven member is a first torque and are rotated in the second phase when the rotational load torque of the driven member is a second torque. In a case where the phase changes from the first phase to the second phase, even when the rotational load torque of the driven member lowers from the second torque toward the first torque, the restricting portion restricts that the phase returns from the second phase to the first phase.