Waste Toner Unit Torque Detection in Image Forming Assemblies
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Solution Overview
Problem
Existing image forming apparatuses face challenges in accurately detecting the exchange of waste toner collecting containers and transfer units, leading to potential errors in waste toner management and apparatus operation.
Innovation Solution
The apparatus incorporates a detecting mechanism with a rotatable member and urging member that changes states based on rotational load torque, outputting distinct detection signals to differentiate between new and used exchange units, ensuring accurate detection of waste toner collecting container fullness and transfer unit exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple full state detection method is used, then the device complexity is reduced, but the measurement precision of waste toner collection status deteriorates
Solution Approach 1:
The patent changes the detection parameter from simple presence/absence detection to rotational load torque measurement. By monitoring the torque required to rotate the stirring member, the system can distinguish between different states (empty, partial, full) of the waste toner collecting container, thereby improving measurement precision without significantly increasing device complexity
Solution Approach 2:
The patent replaces complex electronic sensors with a mechanical detection system. The detecting portion detects the rotational load torque through mechanical interaction with the stirring member, using the motor's rotational characteristics to infer waste toner collection status. This mechanical approach simplifies the overall system while maintaining detection accuracy
2Measurement precision
If rotational load detection is used for full state detection, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The patent makes the motor serving the stirring member also serve as the detection sensor. The same motor that stirs the waste toner is used to detect the full state by measuring its rotational load torque. This multi-functionality approach improves measurement precision while avoiding the need for separate detection hardware, thereby limiting the increase in device complexity
Solution Approach 2:
The system uses its own operational parameters (motor rotational load) for self-detection. The motor's torque consumption during operation serves as the detection signal, eliminating the need for external sensors. This self-service approach allows the system to monitor its own state without adding complex detection mechanisms
3Measurement precision
If the detecting portion is sensitive to rotational load changes, then the measurement precision is improved, but the reliability of detection signals deteriorates due to false detection
Solution Approach 1:
The patent performs preliminary detection during the startup phase of the motor before normal operation begins. By detecting the rotational load at this specific timing when the stirring member is stationary or moving minimally, the system can identify the initial torque characteristic that indicates full state without being affected by operational variations. This preliminary action approach improves reliability by detecting state before operational noise interferes
Solution Approach 2:
The patent uses periodic detection during motor operation cycles. The detecting portion monitors rotational load at specific periods or cycles of motor operation, allowing the system to distinguish between transient torque variations and sustained full state conditions. This periodic monitoring approach filters out false signals while maintaining detection sensitivity
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 enhances the accuracy of waste toner collection management and transfer unit exchange detection, reducing errors and ensuring continuous operation of the image forming apparatus.
Implementation Method 1
an urging member configured to urge the first rotatable member against the second rotatable member along a rotational axis direction of the first rotatable member
Implementation Method 2
the first rotatable member is movable to a first position and a second position different in position thereof relative to the second rotatable member with respect to the rotational axis direction of the first rotatable member in interrelation with a position of the second rotatable member relative to the first rotatable member with respect to a rotational direction of the first rotatable member depending on a magnitude of a rotational load torque of the rotatable member
Data Source
AI summary
An image forming apparatus includes a main assembly including an image forming portion, a driving source, and a detecting portion and includes an exchange unit including a rotatable member, a first rotatable member, a second rotatable member, and an urging member. The detecting portion changes in state depending on movement of the first rotatable member. A detection pattern of a detection signal outputted by the detecting portion is different between a case where the first rotatable member is in a first position and a rotational load torque of the rotatable member is less than a predetermined value, a case where the first rotatable member is in a second position and the rotational load torque is less than the predetermined value, and a case where the first rotatable member is in the second position and the rotational load torque is the predetermined value or more.