JP2020173320A - Image formation device - Google Patents

Abstract

To avoid delays in replacement parts even in an event of sudden mass use of replacement parts.SOLUTION: It assume that an average value per day of an amount of use after starting to use a toner container is a first value, a standard variation of the amount of use after starting to use is a second value, and an initial amount before starting to use the toner container is a third value. An output unit outputs replacement information after the elapse of a first period from starting to use the toner container when there is no mass use in which an amount of use is equal to or more than five times the first value per day after starting to use the toner container (NO in step S24), and outputs the replacement information after the elapse of a second period shorter than the first period from starting to use the toner container (step S25) when there are two or more times of mass use after starting to use the toner container (YES in step S24).SELECTED DRAWING: Figure 7

Description

The present invention relates to an image forming apparatus used in a printer, a copier, a facsimile or a multifunction device using an electrophotographic method or an electrostatic recording method.

Conventionally, as an image forming apparatus that forms an image on a recording medium such as paper and outputs it, an electrophotographic copying machine or printer, a facsimile or an inkjet printer, or a multifunction device that combines these with an image reading function has been known. Has been done. In these image forming apparatus, an image is formed and output while consuming consumables such as toner and ink. In addition, consumable parts such as photoconductors used in the image forming process cannot exhibit desired performance due to contamination by toner and ink and wear of the rubbing portion as they are used. Alternatively, recovery parts such as a toner recovery container for collecting waste toner cannot be used any more when the container is filled with waste toner by use. Parts such as consumables, consumable parts, and recovered parts that cannot be used due to the cumulative use associated with the image forming operation and need to be replaced are collectively referred to as replacement parts. Such replacement parts are provided with a predetermined part life.

When these replacement parts are used up or when the part life is reached, the image forming apparatus cannot output a normal image. Therefore, before the replacement parts are used up or the specified parts life is reached, spare replacement parts for replacement are delivered to the user, and the user temporarily stores the inventory and replenishes or replaces (hereinafter, hereinafter,). It is required to be able to replace it promptly when it becomes necessary. As a result, the image forming apparatus can be operated stably.

As a system for delivering spare replacement parts as described above, a consumables management system that determines the delivery timing of spare replacement parts based on the history of the user using the replacement parts is known (see Patent Document 1). ). In this consumables management system, for example, the remaining usable amount (hereinafter referred to as the remaining used amount) is predicted based on the usage history of the user's replacement parts. Then, based on the number of days until the remaining usage amount becomes 0 calculated from the slope of the remaining usage amount during a predetermined period and the number of days required for delivery of the replacement part, the timing of delivering the spare replacement part for replacement is determined. decide.

Japanese Unexamined Patent Publication No. 2017-37596

However, in the consumables management system described in Patent Document 1, a predetermined mathematical model is used to predict the future usage amount based on the user's past usage history of replacement parts. On the other hand, since the usage status of the replacement parts of the user is not always constant and changes every day, it is difficult to accurately predict the number of days until the remaining usage amount becomes zero. For example, if a large amount of usage that is many times larger than the predicted usage amount of a replacement part suddenly occurs, or if such a sudden mass usage is repeated, the predicted usage amount and the actual usage amount There is a risk that the error with will increase. This makes it difficult to predict the number of days until the remaining usage amount becomes 0, so there is a risk that the image forming apparatus cannot be used because the replacement parts cannot be delivered in time when the replacement parts need to be replaced. is there.

An object of the present invention is to provide an image forming apparatus capable of avoiding delayed delivery of replacement parts even if the replacement parts are suddenly used in large quantities.

The image forming apparatus of the present invention includes an image forming unit for forming an image and an output unit for outputting exchange information regarding replacement of replacement parts used in the operation of forming an image on a recording material. The first value is the average value of the usage amount of the replacement part after the start of use per predetermined period, the standard deviation of the usage amount after the start of use is the second value, and before the start of use of the replacement part. When the initial amount of the replacement part is the third value, if there is no large-scale use of the replacement part that is a predetermined multiple or more of the first value within the predetermined period after the start of use of the replacement part, the replacement part The replacement information is output after the first period has elapsed from the start of use, and if the replacement part has been used in large quantities more than a predetermined number of times after the start of use, the second period shorter than the first period from the start of use of the replacement part. It is characterized in that the exchange information is output after the lapse of time.

Further, in the image forming apparatus of the present invention, the remaining usable amount, which is the remaining usable amount of the image forming portion for forming an image and the replacement part used in the operation of forming an image on the recording material, is below the threshold value. It is provided with an output unit that outputs replacement information regarding replacement of the replacement part when the replacement part is replaced, and the average value of the usage amount of the replacement part after the start of use per predetermined period is the first value, and after the start of use. When the standard deviation of the amount used is the second value, if there is no large amount of use that is a predetermined multiple of the first value or more per predetermined period after the start of use of the replacement part, the above The threshold value is a first threshold value, and when the large amount of use is performed a predetermined number of times or more after the start of use of the replacement part, the threshold value is a second threshold value smaller than the first threshold value.

According to the present invention, even if there is a sudden mass use of replacement parts, it is possible to avoid delay in delivery of replacement parts.

It is sectional drawing which shows the outline of the image forming apparatus which concerns on 1st Embodiment. The cross-sectional view of the toner replenishing apparatus and the developing apparatus which concerns on 1st Embodiment. It is a block diagram which shows the control system of the image forming apparatus which concerns on 1st Embodiment. It is a top view which shows the operation panel of the image forming apparatus which concerns on 1st Embodiment. It is a flowchart which shows the processing procedure of the usage amount detection part of the control part of the image forming apparatus which concerns on 1st Embodiment. It is a flowchart which shows the processing procedure of the 1st determination part of the control part of the image forming apparatus which concerns on 1st Embodiment. It is a flowchart which shows the processing procedure of the 2nd determination part of the control part of the image forming apparatus which concerns on 1st Embodiment. It is a graph which shows the relationship between the number of working days and the amount of toner used per day in an Example which performed image formation using the image forming apparatus which concerns on 1st Embodiment, and a comparative example. It is a flowchart which shows the processing procedure of the 2nd determination part of the control part of the image forming apparatus which concerns on 2nd Embodiment. It is a flowchart which shows the processing procedure of the 2nd determination part of the control part of the image forming apparatus which concerns on 3rd Embodiment.

<First Embodiment>
[Overall image forming apparatus]
Hereinafter, the first embodiment of the present invention will be described in detail with reference to FIGS. 1 to 8. In the present embodiment, a tandem type full-color printer is described as an example of the image forming apparatus. However, the present invention is not limited to the tandem type image forming apparatus, and may be an image forming apparatus of another type, and is not limited to being full color, and may be monochrome or monocolor.

As shown in FIG. 1, the image forming apparatus 1 includes an apparatus main body 10. The apparatus main body 10 includes an image reading unit 20, a sheet feeding unit 30, an image forming unit 40, a sheet conveying unit 50, and a control unit 70. The sheet S, which is a recording material, forms a toner image, and specific examples thereof include plain paper, resin sheets that are substitutes for plain paper, thick paper, and sheets for overhead projectors.

The image reading unit 20 includes a scanner unit provided on the upper part of the apparatus main body 10, and reads an image such as a document and converts it into image information which is an electric signal. The sheet feeding unit 30 is arranged in the lower part of the apparatus main body 10, includes a sheet cassette 31 for loading and accommodating the sheet S, and a feeding roller 32, and the accommodated sheet S is used in the image forming unit 40. Send.

The image forming unit 40 includes an image forming unit 80, a toner replenishing device 2, a laser scanner 43, an intermediate transfer unit 44, a secondary transfer unit 45, and a fixing device 46. The image forming unit 40 can form an image on the sheet S based on the image information. The toner replenishment device 2 includes a replenishment transport unit 41y, 41m, 41c, 41k, a toner container 42y, 42m, 42c, 42k, and a replenishment mechanism 47 (see FIG. 2). The toner containers 42y, 42m, 42c, 42k can accommodate the developer, and are arranged above the image forming units 80y, 80m, 80c, 80k via the replenishment transport units 41y, 41m, 41c, 41k. There is. In the present embodiment, the toner container 42 is given as an example of a replacement part used in association with the operation of forming an image on the sheet S. Details of the toner replenishing device 2 will be described later.

The image forming apparatus 1 of the present embodiment corresponds to full color, and the image forming units 80y, 80m, 80c, 80k are yellow (y), magenta (m), cyan (c), and black (k). ) Are provided separately with the same configuration for each of the four colors. The replenishment transport section 41y, 41m, 41c, 41k and the toner container 42y, 42m, 42c, 42k are similarly the same for each of the four colors of yellow (y), magenta (m), cyan (c), and black (k). It is provided separately in the configuration. Therefore, in FIG. 1, each configuration of the four colors is shown by adding a color identifier after the same reference numeral, but in FIG. 2 and the specification, it may be described only by a reference numeral without a color identifier. ..

The image forming unit 80 includes photosensitive drums 81y, 81m, 81c, 81k for forming a toner image, a charging roller 82, a developing device 83, and a cleaning blade 84. In the present embodiment, the image forming unit 80 is removable from the apparatus main body 10. The photosensitive drum 81 and the developing device 83 are also separately provided with the same configuration for each of the four colors of yellow (y), magenta (m), cyan (c), and black (k).

The photosensitive drum 81 is rotated by a drum motor (not shown), and carries an electrostatic image formed based on image information when forming an image and moves around. The charging roller 82 comes into contact with the surface of the photosensitive drum 81 to charge the surface. The developing device 83 has a developing sleeve 87 rotatably provided in the developing container, and develops an electrostatic latent image formed on the photosensitive drum 81 with toner. The developing device 83 contains a two-component developer that is a mixture of non-magnetic toner and a magnetic carrier, and toner is supplied from a toner container 42 filled with toner via a replenishment transport unit 41.

The developing device 83 is provided with a toner density sensor 85 (see FIG. 2). The toner concentration sensor 85 includes, for example, an inductance sensor, can detect the toner concentration inside the developing device 83, and transmits the detection result to the control unit 70. When the toner concentration detected by the toner concentration sensor 85 is lower than the target toner concentration, the control unit 70 drives a drive motor (not shown) to supply toner from the toner container 42 to the developing device 83.

The cleaning blade 84 is arranged in contact with the surface of the photosensitive drum 81, and cleans the developer remaining on the surface of the photosensitive drum 81 after the primary transfer. The laser scanner 43 exposes the surface of the photosensitive drum 81 charged by the charging roller 82 to form an electrostatic latent image on the surface of the photosensitive drum 81.

The intermediate transfer unit 44 includes a plurality of rollers such as a drive roller 44a, a driven roller (not shown), a primary transfer roller 44y, 44m, 44c, 44k, and an intermediate transfer belt 44b wound around these rollers. .. By applying a positive transfer bias to the intermediate transfer belt 44b by the primary transfer rollers 44y, 44m, 44c, 44k, the toner images having negative electrodes on the photosensitive drums 81y, 81m, 81c, 81k are formed on the intermediate transfer belt. Multiplex transfer is sequentially performed on 44b. The secondary transfer unit 45 includes a secondary transfer inner roller 45a and a secondary transfer outer roller 45b. By applying a positive secondary transfer bias to the secondary transfer outer roller 45b, the full-color image formed on the intermediate transfer belt 44b is transferred to the sheet S.

The fixing device 46 includes a fixing roller 46a and a pressure roller 46b, and a toner image transferred to the sheet S is transferred by sandwiching and transporting the sheet S between the fixing roller 46a and the pressure roller 46b. Is heated and pressurized to be fixed to the sheet S. The sheet transport unit 50 transports the sheet S fed from the sheet feed unit 30 from the image forming unit 40 to the discharge tray 10b via the discharge port 10a and loads the sheet S.

Next, the image forming operation in the image forming apparatus 1 configured in this way will be described. When the image forming operation is started, the photosensitive drum 81 first rotates and the surface is charged by the charging roller 82. Then, the laser scanner 43 emits laser light to the photosensitive drum 81 based on the image information, and an electrostatic latent image is formed on the surface of the photosensitive drum 81. When toner adheres to this electrostatic latent image, it is developed, visualized as a toner image, and transferred to the intermediate transfer belt 44b.

On the other hand, the feeding roller 32 rotates in parallel with the operation of forming the toner image, and feeds while separating the uppermost sheet S of the sheet cassette 31. Then, the sheet S is transferred to the secondary transfer unit 45 via the transfer path in time with the toner image of the intermediate transfer belt 44b. Further, an image is transferred from the intermediate transfer belt 44b to the sheet S, and the sheet S is conveyed to the fixing device 46, where the unfixed toner image is heated and pressurized to be fixed on the surface of the sheet S, and the discharge port 10a. Is discharged from the discharge tray 10b and loaded on the discharge tray 10b.

[Toner replenishment device]
As shown in FIG. 2, the toner replenishment device 2 includes a toner container 42 for accommodating a replenishing developer, a replenishment mechanism 47, and a replenishment transport unit 41. The toner container 42 is detachably mounted corresponding to a plurality of hole-shaped mounting portions provided in the apparatus main body 10. The toner container 42 has a structure in which a spiral groove is dug in the inner wall of the cylindrical container, and the toner container 42 itself rotates to generate a carrying force of a developer in the longitudinal direction. A drive motor (not shown) is connected to each toner container 42, and the toner container 42 is rotated by driving the drive motor to discharge toner.

The downstream end of the toner container 42 in the developer transport direction is connected to the replenishment mechanism 47. The replenishment mechanism 47 has a pump unit 47a that discharges the developer from the discharge port 47b in which the developer is conveyed from the toner container 42. The pump unit 47a is formed in a bellows shape, and when it is rotationally driven, the volume changes to generate air pressure, and the developer conveyed from the toner container 42 is discharged from the discharge port 47b. The upper end of the replenishment transport unit 41 is connected to the discharge port 47b, and the lower end of the replenishment transport unit 41 is connected to the developer replenishment port 86 of the developing device 83. The developer discharged from the discharge port 47b by the pump unit 47a passes through the developer supply port 86 via the replenishment transport unit 41, and the rotation of the transport screw 89 causes the developer to enter the stirring chamber 88a of the developing container 88 of the developing device 83. Be replenished.

Such replenishment by the toner replenishment device 2 is performed by automatic toner replenishment control (ATR (Automatic Toner Replenisher) control). This ATR control controls the operation of the toner replenishing device 2 according to the density detection result of the patch image by the image ratio at the time of image formation, the toner density sensor 85, and the density sensor (not shown) that detects the density of the toner image. , The developer is replenished to the developing apparatus 83.

More specifically, at the time of image formation, the toner image is formed by consuming the toner contained in the developing device 83, so that the toner in the developing device 83 decreases every time the image drawing process is performed. .. The toner concentration sensor 85 provided in the developing device 83 detects whether or not a certain amount or more of toner is contained in the developing device 83. When the amount of toner in the developing device 83 falls below a certain amount, the replenishment mechanism 47 is activated to replenish the toner contained in the toner container 42 to the developing device 83. In the present embodiment, the toner concentration sensor 85 for detecting the toner concentration in the developing device 83 detects whether or not a certain amount or more of toner is contained, but the present invention is not limited to this, and other methods are used. A sensor may be provided. In this case, for example, the present invention is not limited to the inductance sensor, and for example, a powder level sensor using a piezoelectric vibrator may be used.

Since the toner consumed by the developing device 83 is finally supplied from the toner container 42, the toner in the toner container 42 disappears by continuing the image forming process. However, since the toner container 42 is configured to be detachable from the apparatus main body 10, it is possible to continue the image forming process by the image forming apparatus 1 by replacing it with a new toner bottle containing toner. is there.

The control unit 70 can be implemented by using one or more processors and a memory. Then, one or more processors execute the processing using the computer program or data stored in the memory, thereby executing or controlling each processing described later as what the control unit 70 performs. In the present embodiment, the control unit 70 is composed of a computer, for example, a CPU, a ROM that stores a program that controls each unit, a RAM that temporarily stores data, and an input / output circuit that inputs / outputs signals to and from the outside. It has. As shown in FIG. 3, the control unit 70 is connected to an image forming unit 40, a sheet conveying unit 50, an operation unit 11, a toner concentration sensor 85, an image reading unit 20, and the like via an input / output circuit, and signals with each unit. And control the operation. Further, the control unit 70 can be operated and set by the user by a command from a computer (not shown) connected to the device main body 10 or an operation of the operation unit 11.

An operation unit 11 is provided on the front upper portion of the apparatus main body 10. In addition to the operation buttons, the operation unit 11 is provided with an operation panel 11a including a touch panel capable of displaying the state of the image forming apparatus 1 and being touch-operable. The operation panel 11a is connected to the control unit 70, and the display content is controlled by the control unit 70, and information can be input from the outside. The control unit 70 constitutes an output unit that outputs exchange information regarding the exchange of the toner container 42. The exchange information here broadly includes displaying a wording prompting the replacement of the toner container 42 on the operation panel 11a, transmitting information requesting the replacement of the toner container 42 to the maintenance server 100, and the like.

The control unit 70 includes, for example, an image controller 71, a scanner controller 72, a usage amount detection unit 73, a replenishment controller 74, a timer 75, a prediction unit 76, a first determination unit 77, a display controller 78, and a second determination unit 79.

The image controller 71 transmits image pixel information to the scanner controller 72 and the usage amount detection unit 73. The scanner controller 72 generates a laser emission command according to the image pixel information transmitted from the image controller 71 to control the emission timing of the image reading unit 20. The replenishment controller 74 determines the operation timing of the toner container 42 based on the detection result of the toner concentration sensor 85. The replenishment controller 74 executes toner replenishment by the toner container 42 by rotationally driving the drive motor that drives the toner container 42 according to the determined operation timing. The replenishment controller 74 counts the number of times the toner container 42 is rotated as the number of times the toner is replenished, and transmits the counted number of times the toner is replenished to the usage amount detection unit 73.

The memory 42a is a memory provided in the toner container 42, and stores the remaining amount of toner, which is the remaining amount of toner contained in the toner container 42. When the toner container 42 is unused, the memory 42a stores the weight of the toner filled at the time of production as the remaining amount of toner. The remaining amount of toner stored in the memory 42a is managed by the usage amount detecting unit 73. The timer 75 acquires the date and time and transmits the date and time.

The prediction unit 76 calculates the number of remaining days D as the remaining usable period of the toner based on the amount of toner used per day and the remaining amount of toner transmitted from the usage amount detection unit 73. The first determination unit 77 determines whether or not to transmit the delivery request signal based on the number of remaining days D transmitted from the prediction unit 76. The second determination unit 79 determines whether or not to change the predetermined delivery threshold value of the remaining days D based on the daily toner usage amount transmitted from the usage amount detection unit 73.

The display controller 78 controls the display on the operation panel 11a of the operation unit 11 of the image forming apparatus 1, and displays according to the delivery request signal from the first determination unit 77. As shown in FIG. 4, on the display screen of the operation panel 11a, for each of the toners (toner Y, toner M, toner C, toner K) of the image forming apparatus 1, the remaining days D obtained for each toner, The necessity of delivery of each toner is listed. Whether or not the toner needs to be delivered is indicated as required when the display controller 78 receives a delivery request signal for the toner, and not required when the display controller 78 does not receive the toner.

A maintenance server 100 is connected to the first determination unit 77. The maintenance server 100 is a server device connected to the image forming device 1 via a wireless and / or wired network, and displays on the operation panel 11a according to a delivery request signal from the first determination unit 77. The displayed contents include, for example, the number of remaining usable days for each toner as shown in the operation panel 11a of FIG. 4, and the necessity of delivering the toner. By displaying the displayed contents on the operation panel 11a, the maintenance server 100 allows the operator of the maintenance server 100 to confirm the displayed contents and recognize the necessity of delivery arrangement for toner replacement. As a result, the replacement toner container 42 can be delivered to the installation location of the image forming apparatus 1 at an appropriate timing.

Next, the operation of the usage amount detection unit 73 will be described with reference to the flowchart shown in FIG. The process shown in FIG. 5 may be executed periodically periodically, for example, every second, or temporally, for example, the degree of image formation of a print unit such as one image or one page. It may be executed irregularly.

When the process is started, the usage amount detection unit 73 reads out the remaining amount of toner WT _-1 stored in the memory 42a (see FIG. 3) (step S1). The remaining toner amount WT _-1 is the remaining amount of toner stored in the memory 42a obtained in the processing of the flowchart of FIG. 5 last time (time (T-1) when the current time is T). The usage amount detection unit 73 acquires the image pixel information P from the image controller 71 (see FIG. 3) and the toner replenishment number N from the replenishment controller 74 (see FIG. 3) (step S2). The image pixel information P is the cumulative value of the number of pixels for which image formation and output have been performed so far, and the toner replenishment count N is the cumulative number of times the toner container 42 (see FIG. 3) has been rotated. The value.

The usage amount detection unit 73 calculates the increment ΔP of the image pixel information P and the increment ΔN of the toner replenishment count N (step S3). The increment ΔP of the image pixel information P is the result of subtracting the number of pixels indicated by the image pixel information P acquired in the previous step S2 from the number of pixels indicated by the image pixel information P acquired in the current step S2. The increment ΔN of the toner replenishment number N is the result of subtracting the toner replenishment number N acquired in the previous step S2 from the toner replenishment number N acquired in this step S2.

The usage amount detection unit 73 calculates the following formula using ΔP, ΔN, a representative value of the toner usage amount per pixel of the image, and a representative value of the toner usage amount per toner replenishment frequency (step S4). .. By this calculation, the usage amount detection unit 73 estimates and calculates the usage amount (estimated usage amount) Q of the toner estimated to be used at the current time T.
Q [mg] = (0.015 × ΔP + 180 × ΔN) / 2

In this formula, the representative value of the amount of toner used per pixel of the image is 0.015 [mg], and the representative value of the amount of toner used per number of toner replenishments is 180 [mg]. This formula uses the average of the toner usage estimation based on the output image and the toner usage estimation based on the toner supply amount from the toner bottle to determine the toner usage estimated to be used at the current time. It is a calculation formula for finding.

The usage amount detection unit 73 adds the estimated usage amount Q obtained in this step S4 to the cumulative toner usage amount _UT-1 obtained in step S5 of the previous time (time (T-1)). obtaining a cumulative toner usage _{U T} at the time T (step S5). That is, the usage amount detection unit 73 calculates _UT = _UT-1 + Q. When T = 1, 2, ..., U ₀ = 0. The usage amount detection unit 73 subtracts the estimated usage amount Q from the toner remaining amount WT _-1 read from the memory 42a in step S1 (WT _-1- Q), and obtains the result (WT _-1- Q) of the toner remaining amount WT at the current time _T. (Step S6). The amount detection unit 73, a remaining toner amount _{W T-1} stored in the memory 42a, is updated to the toner remaining amount _{W T} determined in step S6 (step S7).

The usage detection unit 73 acquires the current date by the timer 75 (see FIG. 3) of the control unit 70 (see FIG. 3), and the current date is processed according to the previous flowchart of FIG. It is determined whether or not it is after the day after the execution date (step S8). When the usage amount detection unit 73 determines that the current date is not the day after the date on which the process according to the flowchart of FIG. 5 was executed last time (NO in step S8), the usage detection unit 73 ends the process.

The amount detection unit 73, the current date, if it is determined that the day after the date of execution of the processing of the previous FIG. 5 (YES in step S8), and predicts a cumulative toner usage U _T 76 (See FIG. 3) and transmission to the second determination unit 79 (see FIG. 3) (step S9). That is, the amount detecting unit 73, a cumulative toner usage U _T, a toner use amount used (toner usage per day) at day 1 day including the current time T, the prediction unit 76 and the second determination unit Send to 79. The amount detection unit 73, the toner remaining amount _{W T,} transmitted to the prediction unit 76 initializes, to 0, a cumulative toner usage _{U T} (step S10).

Here, the prediction unit 76, by calculating the following formula 1 from the usage detection unit 73 every time to get the cumulative toner usage U _T, the cumulative toner usage amount obtained from the use amount detection unit 73 so far The average value of U _T U _AVE (cumulative average of toner usage per day) is calculated.

In Equation 1, i is the number of times the toner usage per day from the amount detecting unit 73 is notified, U _n represents the toner usage per day at the n-th notification. The prediction unit 76, by calculating the average value U _AVE cumulative toner usage, and remaining toner amount W _T received from the usage detection unit 73, the following equation using the current, the image forming apparatus 1 The number of remaining days D as the remaining usable period of the toner remaining in is calculated. Then, the prediction unit 76 transmits the obtained remaining days D to the first determination unit 77.
D _[Sun] = W _{T / U AVE}

Next, the operation of the first determination unit 77 (see FIG. 3) will be described with reference to the flowchart shown in FIG. The first determination unit 77 acquires the number of remaining days D transmitted from the prediction unit 76 (see FIG. 3) (step S11). The first determination unit 77 determines whether or not the number of remaining days D acquired in step S11 is equal to or less than the specified delivery threshold value (for example, 10 days) (step S12). When the first determination unit 77 determines that the number of remaining days D is not equal to or less than the delivery threshold value (NO in step S12), the first determination unit 77 ends the process.

When the first determination unit 77 determines that the number of remaining days D is equal to or less than the delivery threshold value (YES in step S12), it is determined that the toner container 42 will be used up soon. Therefore, the first determination unit 77 generates a delivery request signal for prompting a delivery request, which is an example of a preparation request for the replacement toner container 42 (step S13). Then, the first determination unit 77 transmits the generated delivery request signal to the display controller 78 (see FIG. 3) and also transmits the generated delivery request signal to the external maintenance server 100 (see FIG. 3) via the network. ..

Here, since the toner usage status by the user is not always constant and changes daily, it is difficult to accurately predict the number of remaining days. Therefore, it is conceivable to adopt the following statistical method and calculate the number of remaining days using the mean value and standard deviation, assuming that the usage status is normally distributed. That is, in addition to the average value _UAVE of the cumulative toner usage, the standard deviation σ of the cumulative toner usage acquired from the usage detection unit 73 within the specified period in the past is obtained as a feature amount (statistic) of the user's usage. .. The standard deviation σ is calculated by the following mathematical formula 2. Incidentally, i and U _n in equation 2 is defined as for formula 1.

Further, the remaining amount prediction error σ _L and the delayed delivery probability variable r are created in advance, stored in the memory, and read out as necessary. Remaining amount prediction error σ _L is the remaining amount prediction error obtained by an experiment conducted in advance, and the delayed delivery probability variable r is a variable that can arbitrarily set how much delayed delivery probability is allowed, and the larger r is, the more The probability of late delivery decreases while the probability of early delivery increases. Then, by performing the following calculation process, the number of remaining days D until the amount of toner becomes less than a predetermined amount is obtained. However, at this time, it is assumed that the characteristics of how to use the past specified period (i days) will continue for the next D days. here,
Toner usage after D days (center value): U _AVE x D
Standard deviation of toner usage after D days: √ (σ ² × D)
Prediction error of remaining amount after D days: σ _L
Delayed random variable: r
Toner remaining amount: W
Then, it becomes like the formula 3.

Solving Equation 3 for D yields Equation 4.

Regarding Equation 4, there are two solutions as D, and Equations 5 and 6 are defined as follows, with the larger solution as the longest remaining days D _max and the smaller solution as the shortest remaining days D _min .

Then, for consumables such as toner containers that cause the image forming apparatus 1 to stop due to disappearance, the setting on the side that minimizes the risk of stoppage by adopting the shortest D _min. Can be. However, user usage is not always normally distributed. For example, there may be a sudden usage situation such as when the usage is 5 times or more the average usage for only one day. In this way, a large amount of use is defined as a usage amount that is a predetermined multiple (for example, 5 times or more) of the first value (average usage amount) per predetermined period (for example, one day). The predetermined multiple is set to 5 times as an example here, but is not limited to this, and includes other multiples exceeding 1 time, for example, 1.2 times, 5.5 times, 7 times, and the like. Such sudden mass use may not be reflected in the average value or standard deviation when there is an average weight, for example, when used for more than 1000 days, and cannot be covered by the above method. There is. That is, when the toner container becomes almost empty and should be replaced in the remaining few days, if there is a sudden mass use, the toner container may become empty earlier than the predicted date and the image forming apparatus 1 may not be usable. is there. Therefore, in the present embodiment, measures are taken so that delayed delivery does not occur even in such a sudden usage situation, and the method will be described in detail below.

Next, the operation of the second determination unit 79 (see FIG. 3) will be described with reference to the flowchart shown in FIG. The second determination unit 79 performs processing according to the flowchart of FIG. 7 every time the usage amount detection unit 73 (see FIG. 3) outputs the cumulative toner usage amount U for a certain period, for example, one day. The second determination unit 79 acquires the cumulative toner usage U for a predetermined period transmitted from the usage detection unit 73 (step S21). The second determination unit 79 determines whether or not the cumulative toner usage amount U acquired in step S21 for a predetermined period is equal to or greater than the specified amount (count threshold value) (step S22). The specified amount is, for example, 5 times or more, preferably 7 times or more the average daily usage amount. In addition, although the specified amount is 5 times or more as an example here, it is not limited to this, and other multiples exceeding 1 time, for example, 1.2 times and 5.5 times, etc. are also included. In the present embodiment, for example, if the average daily usage amount is 10000 [mg], the specified amount is set within the range of 50,000 [mg] to 70,000 [mg].

When the second determination unit 79 determines that the cumulative toner usage U in a predetermined period is equal to or greater than the specified amount (YES in step S22), the second determination unit 79 adds the number of times the threshold value is exceeded once (YES in step S22). Step S23). The number of times the threshold value is exceeded is set to 0 when the image forming apparatus 1 starts to be used. After that, the second determination unit 79 determines whether or not the number of times the threshold value is exceeded is equal to or greater than the specified determination threshold value (for example, twice) (step S24). Further, in step S22, even when the second determination unit 79 determines that the cumulative toner usage amount U in a predetermined period is not equal to or more than the specified amount (NO in step S22), the process of step S24 is executed. When the second determination unit 79 determines that the number of times the threshold value has been exceeded is not equal to or greater than the predetermined determination threshold value (NO in step S24), the second determination unit 79 ends the process.

When the second determination unit 79 determines that the number of times the threshold is exceeded is equal to or greater than the specified determination threshold (YES in step S24), the second determination unit 79 sets the specified delivery threshold (for example, 10 days) for the number of remaining days. Change (step S25). Here, the second determination unit 79 changes the delivery threshold value from 10 days ago to, for example, 40 days ago, and transmits the changed delivery threshold value signal to the maintenance server 100 via the network. That is, the second determination unit 79 detects that the user consumes a large amount of toner equal to or more than a predetermined amount per day, and if the tendency is repeated, the cumulative average of the amount of toner used per day. It is judged that there is a high possibility that a large amount of consumables will be consumed suddenly, which greatly exceeds. In such a case, the second determination unit 79 determines that the time when the toner is delivered to the installation location of the image forming apparatus 1 after the toner delivery request is likely to be delayed with respect to the timing when the toner is used up. The toner is delivered to the installation location of the image forming apparatus 1 as soon as possible. The delivery threshold value may be changed once and then left as it is, or may be reset by replacing the toner container 42.

Here, the number of days for changing the delivery threshold is 40 days before in the present embodiment, but the number of days is not limited to this. For example, it may be 20 days or 30 days before, or it may be set according to the degree of sudden mass use. That is, if the large amount of use is 10 times as large as the average value, it can be changed 40 days before, and if the large amount of use is about 5 times the average value, it can be changed to 20 days before. Alternatively, a gradient may be provided according to the number of times of mass use, such as 20 days before the number of times of mass use is once and 30 days before if it is twice.

[Example]
Using the image forming apparatus 1 described above, the timing of transmitting the delivery request signal was verified for the usage situation with sudden mass use. FIG. 8 is a transition graph of the amount of toner used by the user per day. The alternate long and short dash line in the figure represents the count threshold value [mg] used in step S22 of the flowchart of FIG. 7 above. In the case of the user in this simulation, there was a day when the toner of 70,000 [mg] or more was consumed about once every 400 days, and the timing when the amount of toner used per day exceeded the count threshold was three times by 1200 days. ..

In this embodiment, the delivery threshold is changed when the threshold is exceeded twice. On the other hand, in the comparative example, the delivery threshold was not changed. The timing at which the delivery request signal is output in the examples is indicated by a white triangle (950 days), and the timing at which the delivery request signal is output in the comparative example is indicated by a black triangle (1100 days). In this embodiment, since the delivery threshold is changed based on the occurrence of the second sudden mass use, the toner container is delivered before the occurrence of the third sudden mass use of toner. The image forming apparatus 1 did not stop. On the other hand, in the comparative example, the toner delivery was not in time for the third sudden occurrence of a large amount of toner, and the image forming apparatus 1 was stopped.

Here, the average value and standard deviation of the examples and the comparative examples are the same. In the comparative example, the number of remaining days was calculated using the average value and standard deviation, but for sudden large-scale use of about one day in 400 days, the average weight almost reflects the average value and standard deviation. It was not possible to accelerate the remaining days. On the other hand, in this example, it was confirmed that although the average value and standard deviation are the same as those in the comparative example, it is possible to cope with the delay in delivery even if there is a sudden usage situation.

That is, the average value of the usage amount of the toner container 42 (see FIG. 3) after the start of use per predetermined period (for example, one day) is the first value, and the standard deviation of the usage amount after the start of use is the second value. It is assumed that the initial amount of the toner container 42 before the start of use is the third value. In this case, after the start of use of the toner container 42, the control unit 70 uses the toner if there is no large-scale use that is a predetermined multiple (for example, 5 times) or more of the first value per predetermined period (1 day). The exchange information is output after the lapse of the first period (after the lapse of 1100 days) from the start of use of the container 42. Further, when the control unit 70 uses the toner container 42 a predetermined number of times or more (for example, twice or more) after the start of use of the toner container 42, the control unit 70 has a second period shorter than the first period (1100 days) from the start of use of the toner container 42. The exchange information is output after the lapse of time (after 950 days have passed).

Here, the remaining usable amount, which is the remaining usable amount of the toner container 42 used in the operation of forming an image on the sheet S, is defined. The residual amount used here means an amount of toner that can be used in the image forming process from now on with respect to the amount of toner remaining in the toner container 42. In this case, if the control unit 70 does not use the toner container 42 in a large amount that is a predetermined multiple (for example, 5 times) or more of the first value per predetermined period (for example, one day) after the start of use. When the remaining usage amount becomes equal to or less than the first threshold value, the replacement information of the toner container 42 is output. Further, when the toner container 42 has been used in large quantities for a predetermined number of times (for example, twice) or more after the start of use of the toner container 42, the control unit 70 uses the toner when the remaining usage amount becomes less than the first threshold value and becomes less than the second threshold value. The exchange information of the container 42 is output.

Since the delivery request signal is a signal that is notified depending on how the image forming apparatus 1 is used, it is desirable that the delivery request signal be reset if the population of users who use the signal changes. For example, the second determination unit 79 can be reset by an input operation from the consumables management screen displayed on the operation panel 11a or by an operator's operation input on the maintenance server 100. The content and operation timing of this operation are not limited to specific examples.

As described above, according to the image forming apparatus 1 of the present embodiment, when the control unit 70 is used twice or more after the start of use of the toner container 42, the control unit 70 is used for the first period from the start of use of the toner container 42 ( The exchange information is output after the lapse of the second period (950 days) shorter than 1100 days). As a result, the delivery request signal can be notified sufficiently in advance for sudden consumption, so that it is possible to avoid a delay in delivery of consumables when a large number of sudden toner uses are repeated, and the image forming apparatus 1 can be used. Opportunities for outages can be reduced.

In the image forming apparatus 1 of the above-described embodiment, the case where the delivery threshold value is changed when the determination threshold value or more is used twice or more has been described, but the present invention is not limited to this. For example, if the determination threshold value or more is used more than once, the delivery threshold value may be changed. In this case, delay in toner delivery can be prevented more reliably. Alternatively, the history of toner usage per day acquired each time the date progresses is statistically processed, and the toner deviates from the significant distribution (the distribution created in advance as the distribution of normal toner usage). When the frequency of appearance of the usage amount is higher than the threshold value, the regular request signal may be output.

Further, in the present embodiment, the case where the toner container 42 is applied as an example of the replacement parts used in the operation of forming an image on the sheet S has been described, but the present invention is not limited to this. For example, it may be a drum unit, a developing unit, a fixing unit, a waste toner collection container, a cleaning web of the fixing device 46, or the like. That is, in the present embodiment, the usable amount of the replacement part is clearly defined, and the toner container 42 in which the device stops when the usable amount becomes 0, the recovered toner container for collecting the used toner, and the fixing member become dirty. It is particularly effective for fixing web members that collect toner.

<Second embodiment>
Next, a second embodiment of the present invention will be described in detail with reference to FIG. The present embodiment differs from the first embodiment in that the sudden large-scale use is not one-day use but continuous use for, for example, 10 days. That is, in the present embodiment, the second determination unit 79 changes the delivery request threshold value when the integrated toner consumption value for a certain period is equal to or greater than a predetermined value. In the present embodiment, the delivery request signal is notified at the timing when the remaining number of days D is 10 days or less. Therefore, if the integrated value of the toner consumption for 10 days exceeds 200,000 [mg], the control of changing the delivery request signal threshold value is adopted. However, since the other configurations are the same as those in the first embodiment, the same reference numerals are given and detailed description thereof will be omitted.

Next, the processing procedure of the second determination unit 79 in the present embodiment will be described with reference to the flowchart shown in FIG. The second determination unit 79 performs processing according to the following flowchart each time the usage amount detection unit 73 outputs the cumulative toner usage amount for a certain period, for example, one day. The second determination unit 79 acquires the toner consumption U1 to U10 for the past 10 days from the present (step S31), and integrates the acquired toner consumption data (step S32). The second determination unit 79 determines whether or not the integrated value of the calculated toner consumption for the past 10 days is equal to or greater than the threshold value (step S33). Here, the threshold value was set to 200,000 [mg], which is twice the integrated value for 10 days of the average value. The threshold value is, for example, twice or more, preferably three times or more, the integrated value for 10 days of the average value. Here, as an example, the integrated value is doubled, but the present invention is not limited to this, and other multiples exceeding 1 times, for example, 2.5 times or 3 times, etc. are also included. When the second determination unit 79 determines that the integrated value is not equal to or greater than the threshold value (NO in step S33), the second determination unit 79 ends the process.

When the second determination unit 79 determines that the integrated value is equal to or greater than the threshold value (YES in step S33), the second determination unit 79 changes the specified delivery threshold value (for example, 10 days) for the number of remaining days (step). S34). Here, the second determination unit 79 changes the delivery threshold value from 10 days ago to, for example, 40 days ago, and transmits the changed delivery threshold value signal to the maintenance server 100 via the network.

As described above, according to the image forming apparatus 1 of the present embodiment, the range of sudden mass use can be widened, so that the delivery request signal can be used for sudden consumption in more diverse usage situations. Can be notified in advance.

In the image forming apparatus 1 of the above-described embodiment, the range for integrating the toner consumption is limited to the past 10 days, but the present invention is not limited to this. For example, the range may be one week, or it may correspond to the visit cycle of the serviceman.

<Third embodiment>
Next, a third embodiment of the present invention will be described in detail with reference to FIG. The present embodiment is different from the first embodiment in that the delivery request threshold value is changed when the sudden mass use occurs a plurality of times and the interval between them is shorter than a predetermined interval. However, since the other configurations are the same as those in the first embodiment, the same reference numerals are given and detailed description thereof will be omitted.

The processing procedure of the second determination unit 79 in this embodiment will be described with reference to the flowchart shown in FIG. The second determination unit 79 performs processing according to the flowchart of FIG. 10 every time the usage amount detection unit 73 (see FIG. 3) outputs the cumulative toner usage amount U for a certain period, for example, one day. The second determination unit 79 acquires the cumulative toner usage U for a predetermined period transmitted from the usage detection unit 73 (step S41). The second determination unit 79 determines whether or not the cumulative toner usage amount U acquired in step S41 for a predetermined period is equal to or greater than the specified amount (count threshold value) (step S42). The specified amount is, for example, 5 times or more, preferably 7 times or more the average daily usage amount. Therefore, for example, if the average daily usage amount is 10000 [mg], the specified amount is set within the range of 50,000 [mg] to 70,000 [mg].

When the second determination unit 79 determines that the cumulative toner usage U in a predetermined period is equal to or greater than the specified amount (YES in step S42), the timer 75 is activated to acquire the date and time (step S43). The second determination unit 79 adds the number of times the threshold value is exceeded once (step S44). The number of times the threshold value is exceeded is set to 0 when the image forming apparatus 1 starts to be used. The second determination unit 79 determines whether or not the threshold value has been exceeded for the second time (step S45). When the second determination unit 79 determines that the number of times the threshold value has been exceeded is not the second time (NO in step S45), the second determination unit 79 ends the process.

When the second determination unit 79 determines that the number of times the threshold value has been exceeded is the second time (YES in step S45), the second determination unit 79 clears the number of times the threshold value has been exceeded (step S46). The second determination unit 79 calculates the period for exceeding the threshold value from the difference between the date when the threshold value is exceeded for the first time and the date when the threshold value is exceeded for the second time (step S47). After that, the second determination unit 79 determines whether or not the threshold period is equal to or less than the determination threshold (step S48). Here, the determination threshold is applied to 100 days as a predetermined interval. However, it is of course not limited to 100 days. That is, in the embodiment of FIG. 8, when the interval of continuous mass use is equal to or less than a predetermined interval (100 days or less), the control unit 70 has elapsed a second period (950 days or less) from the start of use of the toner container 42. ), The toner container 42 is output. When the second determination unit 79 determines that the threshold period is not equal to or less than the determination threshold value (NO in step S48), the second determination unit 79 ends the process.

When the second determination unit 79 determines that the threshold period is equal to or less than the determination threshold value (YES in step S48), the toner is delivered to the installation location of the image forming apparatus 1 after the toner delivery request. Judge that there is a high possibility that it will be delayed with respect to the timing when it is used up. Therefore, the second determination unit 79 changes the specified delivery threshold value (for example, 10 days) of the remaining days to, for example, 40 days ago (step S49), and sends the changed delivery threshold value signal to the maintenance server 100 via the network. Send.

As described above, according to the image forming apparatus 1 of the present embodiment, the delivery threshold value is changed when sudden mass use occurs a plurality of times at short intervals. Therefore, it is possible to surely suppress the occurrence of delayed delivery in a situation where delayed delivery of toner is likely to occur.

<Other embodiments>
In each of the above-described embodiments, the number of days of the delivery threshold is changed according to the amount of toner consumed per unit period, and the toner is delivered in advance when the toner is used up. On the other hand, the usable toner amount (remaining amount) may be changed without changing the delivery threshold value. Specifically, a user whose daily toner consumption exceeds 70,000 [mg] changes the usable toner amount from 1000 [g] (first threshold value) to 900 [g] (second threshold value). By doing so, the toner delivery signal is output early, and the toner can be delivered before it is actually used up.

Further, in each of the above-described embodiments, a part or all of each embodiment may be used in an appropriate combination, or a part or all of each embodiment may be selectively used. Further, the various numerical values used in the above description are examples, and are not limited to the above numerical values.

Further, in each of the above-described embodiments, all the functional units of the control unit 70 may be implemented by hardware, or some of them may be implemented by software. When a part is implemented by software, for example, the software is stored in the memory in the control unit 70, and the processor of the control unit 70 executes the software to realize the function of the corresponding function unit. Can be done.

The present invention supplies a program that realizes one or more functions of the above-described embodiment to a system or device via a network or storage medium, and one or more processors in the computer of the system or device reads and executes the program. It can also be realized by the processing to be performed. It can also be realized by a circuit (for example, ASIC) that realizes one or more functions.

1 ... Image forming apparatus, 40 ... Image forming unit, 42, 42c, 42k, 42m, 42y ... Toner container (replacement part), 70 ... Control unit (output unit), S ... Sheet (recording material).

Claims (10)

It is provided with an image forming unit for forming an image and an output unit for outputting replacement information regarding replacement of replacement parts used in the operation of forming an image on a recording material.
In the output unit, the average value of the usage amount of the replacement part after the start of use per predetermined period is the first value, and the standard deviation of the usage amount after the start of use is the second value. When the initial amount before the start of use is the third value,
If, after the start of use of the replacement part, there is no mass use that is a predetermined multiple or more of the first value per predetermined period, the replacement information is provided after the first period has elapsed from the start of use of the replacement part. Output and
When the mass use is performed a predetermined number of times or more after the start of use of the replacement part, the replacement information is output after a second period shorter than the first period has elapsed from the start of use of the replacement part.
An image forming apparatus characterized in that. The predetermined number of times is one.
The image forming apparatus according to claim 1. The predetermined number of times is two times.
The image forming apparatus according to claim 1. The predetermined number of times is two times.
The output unit outputs the replacement information after the second period has elapsed from the start of use of the replacement part when the interval of continuous mass use is equal to or less than a predetermined interval.
The image forming apparatus according to claim 1. Regarding the replacement of the replacement part when the remaining usable amount, which is the remaining usable amount of the image forming portion for forming an image and the replacement part used in the operation of forming an image on the recording material, becomes equal to or less than the threshold value. Equipped with an output unit that outputs exchange information
When the average value of the usage amount of the replacement part after the start of use per predetermined period is the first value and the standard deviation of the usage amount after the start of use is the second value.
After the start of use of the replacement part, if there is no mass use that is a predetermined multiple or more of the first value per predetermined period, the threshold value is the first threshold value.
When the large amount of use is performed a predetermined number of times or more after the start of use of the replacement part, the threshold value is a second threshold value smaller than the first threshold value.
An image forming apparatus characterized in that. The predetermined number of times is one.
The image forming apparatus according to claim 5. The predetermined number of times is two times.
The image forming apparatus according to claim 5. The predetermined number of times is two, and when the interval of continuous mass use is equal to or less than the predetermined interval, the threshold value is the second threshold value.
The image forming apparatus according to claim 5. The predetermined period is one day, and the predetermined multiple is 5 to 7 times.
The image forming apparatus according to any one of claims 1 to 8, wherein the image forming apparatus is characterized in that. The predetermined period is 10 days, and the predetermined multiple is 2 to 3 times.
The image forming apparatus according to any one of claims 1 to 8, wherein the image forming apparatus is characterized in that.

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