JP2021184037A - Image forming apparatus and toner remaining amount determination method - Google Patents

Abstract

To provide an image forming apparatus that can accurately determine a remaining amount of toner.SOLUTION: An image forming apparatus 1 comprises: an electrifying device 15 that is applied with an electrifying bias to electrify a photoreceptor drum 14; an exposure device 13 that forms an electrostatic latent image on the photoreceptor drum 14; a developing device 16 that is applied with a developing bias to develop the electrostatic latent image into a toner image; a transfer roller 17 that is applied with a transfer bias to transfer the toner image on the surface of the photoreceptor drum 14 to a sheet; a density correction unit 40 that calculates a density correction value corresponding to the electrifying bias and the developing bias; a transfer correction unit 41 that calculates a transfer efficiency correction value corresponding to the transfer bias; a dot count unit 42 that calculates the number of dots in image data; a consumption amount calculation unit 43 that calculates a total consumption amount of toner, on the basis of the density correction value, the transfer efficiency correction value, and the number of dots; and a remaining amount determination unit 44 that determines a remaining amount of toner on the basis of, the total consumption amount.SELECTED DRAWING: Figure 2

Description

The present invention relates to an image forming apparatus for forming an image on a medium using toner and a method for determining the remaining amount of toner.

An image forming apparatus that forms an image using toner contained in a process cartridge is known (Patent Document 1). This image forming apparatus includes an acquisition means for acquiring the remaining amount of toner in the process cartridge, a predicting means for predicting the remaining amount of toner based on the image forming data, and a setting means for setting the predicted remaining amount of toner. Had. When the difference between the remaining amount of toner acquired by the acquiring means and the remaining amount of toner set by the setting means is smaller than a predetermined value, the control means of the image forming apparatus is the residual toner set by the setting means. The amount is updated by the remaining amount of toner acquired by the acquiring means, and when the difference is larger than a predetermined value, the remaining amount of toner set by the setting means is not updated.

Japanese Unexamined Patent Publication No. 2015-13453

However, in the above-mentioned image forming apparatus, the timing for updating the remaining amount of toner is changed according to a predetermined value, and the error of the remaining amount that increases while the toner is not updated is not sufficiently taken into consideration. Further, since the amount of toner consumed (image density) changes depending on the installation environment (temperature, humidity) of the image forming apparatus, only the remaining amount of toner is predicted based on the image forming data as in the above-mentioned image forming apparatus. Then, the remaining amount could not be predicted accurately. That is, the image forming apparatus described above could not accurately determine the remaining amount of toner.

In order to solve the above problems, the present invention provides an image forming apparatus capable of accurately determining the remaining amount of toner and a method for determining the remaining amount of toner.

The present invention is an image forming apparatus that forms an image on a medium using toner contained in a toner container, a charging apparatus that charges the photoconductor by applying a charging bias, and the charged photoconductor. And the static on the surface of the photoconductor using the toner supplied from the toner container by applying a development bias and an exposure device that forms an electrostatic latent image on the surface of the photoconductor. A developing device that develops an electron latent image into a toner image, a transfer device that transfers the toner image on the surface of the photoconductor to the medium by applying a transfer bias, and at least the charging bias and the developing bias. A density correction unit that calculates a density correction value corresponding to one of them, a transfer correction unit that calculates a transfer efficiency correction value corresponding to the transfer bias, and a dot count that calculates the number of dots of image data used to form the toner image. A unit, a consumption calculation unit that calculates the total consumption of the toner based on the density correction value, the transfer efficiency correction value, and the number of dots, and the toner container housed based on the total consumption. It is equipped with a remaining amount determination unit for determining the remaining amount of toner.

In this case, the density correction unit may use the product of the first density correction value corresponding to the charge bias and the second density correction value corresponding to the development bias as the density correction value.

In this case, the consumption amount calculation unit calculates the total consumption amount by integrating the unit consumption amount which is the consumption amount of the toner per the medium, and the remaining amount determination unit is housed in the toner container. The remaining amount may be calculated by subtracting the total consumption amount from the maximum capacity of the toner that can be accommodated.

In this case, the toner container may be interchangeably attached to the image forming apparatus and may have a container-side storage unit for storing the total consumption amount and the maximum storage amount.

The present invention is a method for determining the remaining amount of toner in an image forming apparatus that forms an image on a medium using toner contained in a toner container, and comprises a charging step of charging a photoconductor by applying a charging bias and charging. An exposure step of exposing the photoconductor to form an electrostatic latent image on the surface of the photoconductor, and the toner supplied from the toner container by applying a development bias on the surface of the photoconductor. A development step of developing the electrostatic latent image into a toner image, a transfer step of transferring the toner image on the surface of the photoconductor to the medium by applying a transfer bias, and a charging bias and the development bias. A density correction step for calculating a density correction value corresponding to at least one of them, a transfer correction step for calculating a transfer efficiency correction value corresponding to the transfer bias, and a dot for calculating the number of dots of image data used for forming the toner image. It was housed in the toner container based on the counting step, the consumption calculation step of calculating the total consumption of the toner based on the density correction value, the transfer efficiency correction value and the number of dots, and the total consumption. A remaining amount determination step for determining the remaining amount of the toner is provided.

In this case, in the density correction step, the product of the first density correction value corresponding to the charge bias and the second density correction value corresponding to the development bias may be the density correction value.

In this case, in the consumption amount calculation step, the unit consumption amount, which is the consumption amount of the toner per the medium, is integrated to calculate the total consumption amount, and in the remaining amount determination step, the toner is stored in the toner container. The remaining amount may be calculated by subtracting the total consumption amount from the maximum capacity of the toner that can be accommodated.

According to the present invention, the remaining amount of toner can be accurately determined.

It is a schematic diagram (front view) which shows the image forming apparatus which concerns on one Embodiment of this invention. It is a block diagram which shows the image forming apparatus which concerns on one Embodiment of this invention. It is a flowchart which shows the image formation process which concerns on one Embodiment of this invention. It is explanatory drawing which shows the 1st table stored in the storage part of the image formation processing which concerns on one Embodiment of this invention. It is explanatory drawing which shows the 2nd table stored in the storage part of the image formation processing which concerns on one Embodiment of this invention. It is explanatory drawing which shows the 3rd table stored in the storage part of the image formation processing which concerns on one Embodiment of this invention. It is a flowchart which shows the toner remaining amount determination method which concerns on one Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. Fr, Rr, L, R, U, and D shown in each figure indicate front, back, left, right, top, and bottom. Although terms indicating directions and positions are used in the present specification, these terms are used for convenience of explanation and do not limit the technical scope of the present invention.

The image forming apparatus 1 according to the embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic view (front view) showing an image forming apparatus 1. FIG. 2 is a block diagram showing an image forming apparatus 1.

The image forming apparatus 1 is an electrophotographic printer, and forms an image on paper P using toner. As shown in FIG. 1, the image forming apparatus 1 includes an apparatus main body 2 that constitutes a substantially rectangular parallelepiped appearance. At the lower part of the apparatus main body 2, for example, a paper feed cassette 3 for accommodating a sheet of paper P (medium) is detachably provided. A paper output tray 4 is provided on the upper surface of the apparatus main body 2. The paper P as an example of the medium is not limited to paper, but may be a resin sheet or the like.

Further, the image forming apparatus 1 includes a paper feeding device 5, an image forming device 6, a fixing device 7, and a control device 8. The paper feeding device 5 is provided at the upstream end of the transport path 9A extending from the paper feed cassette 3 to the paper output tray 4, and feeds the paper P contained in the paper feed cassette 3 to the transport path 9A one by one. The image forming apparatus 6 is provided in the middle portion of the conveying path 9A, and forms a toner image on the conveyed paper P. The fixing device 7 is provided on the downstream side of the transport path 9A, and heat-fixes the toner image on the paper P. The control device 8 is provided inside the device main body 2 and controls the image forming device 1 in an integrated manner.

The transport path 9A is formed in a substantially S shape when viewed from the front. The transport path 9A is provided with a resist roller pair 10A that temporarily blocks the paper P to be transported and corrects the inclination (skew correction) of the paper P. Below the transport path 9A, an inverted transport path 9B for inverting the paper P and retransmitting it to the image forming apparatus 6 is provided. The inverted transport path 9B branches on the downstream side of the transport path 9A and extends downward, and the downstream end of the reverse transport path 9B joins the upstream side of the transport path 9A. The reverse transfer path 9B is provided with a plurality of transfer roller pairs 10B for conveying the paper P.

[Image drawing device]
The image forming apparatus 6 includes a toner container 11, a drum unit 12, and an exposure apparatus 13.

<Toner container>
The toner container 11 is a container for accommodating toner (developer). A container mounting portion (not shown) is provided on the upper left portion of the apparatus main body 2, and the toner container 11 is replaceably mounted on the container mounting portion. The toner may be a two-component developer in which a toner and a carrier are mixed, or a one-component developer composed of a magnetic toner.

As shown in FIG. 2, the toner container 11 is equipped with an integrated circuit board 20 for performing non-contact short-range wireless communication. The integrated circuit board 20 is configured by mounting the integrated circuit chip 21 and the antenna 24 on the board. The integrated circuit chip 21 has an arithmetic processor 22 that performs arithmetic processing, and a container-side storage unit 23 such as an EEPROM (Electrically Erasable Programmable Read Only Memory). The container-side storage unit 23 stores the total amount of toner consumed (A2) and the maximum amount of toner that can be stored in the toner container 11 (A1). The total consumption amount (A2) is the total amount of toner consumed, and its initial value is set to zero. The antenna 24 is electrically connected to the integrated circuit chip 21. The container mounting unit is equipped with a reading / writing unit 25 that performs short-range wireless communication facing the integrated circuit board 20 of the mounted toner container 11. The read / write unit 25 communicates with the integrated circuit board 20 in a non-contact manner via the antenna 24, and reads / writes data to / from the storage unit 23 on the container side.

<Drum unit>
As shown in FIG. 1, the drum unit 12 includes a photoconductor drum 14, a charging device 15, a developing device 16, and a transfer roller 17. The charging device 15, the developing device 16, and the transfer roller 17 are arranged around the photoconductor drum 14 in the order of the image forming process.

(Photoreceptor drum)
The photoconductor drum 14 is formed in a substantially cylindrical shape long in the front-rear direction (width direction), and is rotationally driven around an axis by a motor (not shown). A photosensitive layer (not shown) carrying an electrostatic latent image is formed on the surface layer of the photoconductor drum 14.

(Charging device)
The charging device 15 has a substantially cylindrical charging roller 15A extending along the photoconductor drum 14. The charging roller 15A is rotationally driven around an axis by a motor (not shown). The charging roller 15A is electrically connected to the charging power supply 15B (see FIG. 2). The charging power supply 15B applies, for example, a charging bias (V1), which is a direct current (DC) voltage, to the charging roller 15A. The charging roller 15A of the charging device 15 rotates around an axis while in contact with the photoconductor drum 14, and by applying a charging bias (V1), the photoconductor drum 14 (photosensitive layer) has a predetermined potential (for example, negative electrode property). ) Is charged.

(Developer)
The developing apparatus 16 has a pair of transport screws 16C and a developing roller 16A inside the housing 16D. The housing 16D is connected to the toner container 11 via a supply path (not shown) and houses the toner supplied from the toner container 11. Each transport screw 16C has a rotation shaft (not shown) extending along the photoconductor drum 14 and a spiral blade (not shown) fixed to the peripheral surface of the rotation shaft. The developing roller 16A is formed in a substantially cylindrical shape extending along the photoconductor drum 14. Each transport screw 16C and the developing roller 16A are rotationally driven around an axis by a motor (not shown). The pair of transport screws 16C circulate and transport the toner contained in the housing 16D while stirring.

The developing roller 16A is arranged between the photoconductor drum 14 and the transport screw 16C. Further, the developing roller 16A is arranged with a predetermined gap with respect to the surface of the photoconductor drum 14. The developing roller 16A is electrically connected to the developing power supply 16B (see FIG. 2). The developing power supply 16B applies, for example, a developing bias (V2) in which an AC voltage and a DC voltage are superimposed to the developing roller 16A. The developing roller 16A of the developing apparatus 16 rotates around an axis and applies a developing bias (V2) to obtain an electrostatic latent image on the surface of the photoconductor drum 14 using the toner supplied from the toner container 11. Develop into a toner image.

(Transfer roller)
The transfer roller 17 as an example of the transfer device is formed in a substantially cylindrical shape extending along the photoconductor drum 14, and is rotationally driven around an axis by a motor (not shown). The transfer roller 17 contacts the underside of the photoconductor drum 14 to form a transfer nip. The transfer roller 17 is electrically connected to a transfer power source 17B (see FIG. 2). The transfer power supply 17B applies a transfer bias (V3) having a polarity (positive electrode property) opposite to the polarity (for example, negative electrode property) of the toner to the transfer roller 17. The transfer roller 17 rotates about an axis while in contact with the photoconductor drum 14, and a transfer bias (V3) is applied to transfer the toner image on the surface of the photoconductor drum 14 to the paper P.

<Exposure device>
The exposure apparatus 13 is provided above the photoconductor drum 14, and emits scanning light toward the surface (photosensitive layer) of the photoconductor drum 14. The exposure apparatus 13 exposes the charged photoconductor drum 14 to form an electrostatic latent image on the surface of the photoconductor drum 14.

[Fixing device]
The fixing device 7 includes a fixing belt 7A, a pressure roller 7B, and a heater 7C.

The fixing belt 7A is an endless belt, and is formed in a substantially cylindrical shape long in the front-rear direction (width direction). The pressure roller 7B is formed in a substantially cylindrical shape that is long in the front-rear direction. The pressure roller 7B is pressed against the fixing belt 7A to form a pressurized region between the pressing roller 7B and the fixing belt 7A. The fixing belt 7A and the pressure roller 7B are rotatably supported inside a housing (not shown), and are supported by the device main body 2 via the housing. The heater 7C is provided inside the fixing belt 7A and is in contact with the inner peripheral surface of the fixing belt 7A at a position corresponding to the pressurized region. The heater 7C generates heat when energized and heats the fixing belt 7A. The pressurized region refers to a region from the upstream position where the pressure is 0 Pa to the downstream position where the pressure becomes 0 Pa again via the position where the maximum pressure is reached.

<Control device>
As shown in FIG. 2, the control device 8 has an arithmetic processing unit 30, a storage unit 31, and an interface unit 32.

The arithmetic processing unit 30 is a processor that executes arithmetic processing according to a program stored in the storage unit 31. The storage unit 31 includes an auxiliary storage device such as a RAM (Random Access Memory), a ROM (Read Only Memory), and a semiconductor drive. The storage unit 31 stores (stores) programs and data used in the image forming apparatus 1. Controlled devices such as a paper feeding device 5, an image forming device 6, a fixing device 7, a reading / writing unit 25, and various power supplies 15B, 16B, and 17B are electrically connected to the interface unit 32. Further, an external terminal such as a personal computer is connected to the interface unit 32 via a network or the like (not shown). The arithmetic processing unit 30, the storage unit 31, and the interface unit 32 are electrically connected to each other.

The control device 8 and the controlled device are connected to a power source via various drive circuits (not shown). Further, the image forming apparatus 1 is provided with an operation panel 26 (touch panel) on which a user operates and information is displayed, and a speaker (not shown) that emits sound. The operation panel 26 and the like are also electrically connected to the interface unit 32 and controlled by the control device 8.

[Image formation processing]
Here, the operation of the image forming apparatus 1 will be described with reference to FIGS. 1 and 3. FIG. 3 is a flowchart showing an image forming process. For example, the control device 8 executes the image forming process as follows based on the image data input from the external terminal.

The control device 8 executes the charging step S1, the exposure step S2, the developing step S3, the transfer step S4, and the fixing step S5.

In the charging step S1, the charging power source 15B applies a charging bias (V1) to the charging roller 15A, so that the charging device 15 (charging roller 15A) charges the surface (photosensitive layer) of the photoconductor drum 14 (for example, minus). To be charged). In the exposure step S2, the exposure apparatus 13 emits scanning light based on the input image data toward the photoconductor drum 14. When the exposure apparatus 13 exposes the charged photoconductor drum 14, an electrostatic latent image is formed on the surface of the photoconductor drum 14. Specifically, the exposed portion of the photosensitive layer of the photoconductor drum 14 has no negative charge, and an electrostatic latent image drawn by the negative charge is formed on the photoconductor drum 14.

In the developing step S3, the developing power supply 16B applies a developing bias (V2) to the developing roller 16A, so that the developing roller 16A develops an electrostatic latent image on the surface of the photoconductor drum 14 into a toner image with toner. Specifically, the toner in the housing 16D of the developing apparatus 16 forms a toner thin layer on the surface of the developing roller 16A, and the developing roller 16A rotates so that the toner thin layer faces the photoconductor drum 14 in a region facing the photoconductor drum 14. Will be transported to. The toner constituting the toner thin layer flies toward the photoconductor drum 14 due to the potential difference between the developing roller 16A and the photoconductor drum 14. The negatively charged toner repels the unexposed portion and adheres to the exposed portion (electrostatic latent image). In this way, the electrostatic latent image formed on the surface of the photoconductor drum 14 is developed into a toner image.

The paper feed device 5 separates the paper P in the paper feed cassette 3 one by one and feeds them to the transport path 9A. The paper P is conveyed along the transfer path 9A, skew-corrected by the resist roller pair 10A, and sent to the transfer nip.

In the transfer step S4, the transfer power source 17B applies a transfer bias (V3) to the transfer roller 17, so that the transfer roller 17 transfers the toner image on the surface of the photoconductor drum 14 to the paper P. Specifically, since the transfer roller 17 is positively charged by the transfer bias (V3), the toner image (negative electrode property) supported on the photoconductor drum 14 is attracted to the transfer roller 17 and is attracted to the paper P passing through the transfer nip. Transcribed.

In the fixing step S5, the fixing device 7 heat-fixes the toner (toner image) on the paper P passing through the pressure region formed between the fixing belt 7A and the pressure roller 7B. Specifically, the fixing belt 7A heated by the heater 7C heats the toner (toner image) on the paper P passing through the pressurized region while rotating around the axis. The pressurizing roller 7B pressurizes the toner on the paper P passing through the pressurizing area while rotating around the axis. The paper P on which the toner image is fixed on one surface is discharged to the paper ejection tray 4.

When printing (image formation) is performed on both sides of the paper P, the paper P that has passed through the fixing device 7 is switched back at the downstream end of the transport path 9A and sent to the reverse transport path 9B. The paper P is conveyed by the transfer roller pair 10B, returned from the reverse transfer path 9B to the transfer path 9A again, and skew-corrected by the resist roller pair 10A. Then, an image is formed on the other side of the paper P through the same steps as described above. The double-sided printed paper P is ejected to the output tray 4.

[Detection of remaining toner]
The electrophotographic image forming apparatus 1 has a mechanism for detecting the remaining amount of toner contained in the toner container 11. For example, the control device 8 determines the remaining amount of toner by using the image data used for forming the toner image and the data stored in the integrated circuit board 20 of the toner container 11. Specifically, the control device 8 obtains a unit consumption amount (UA), which is the amount of toner consumed per sheet of paper P, from the number of dots (DC) of the image data and the amount of toner consumed per dot, and this unit. The consumption amount (UA) is added (integrated) to the total consumption amount (A2) stored in the container side storage unit 23. Then, the control device 8 obtains the remaining amount of toner by subtracting the total consumption amount (A2) from the maximum storage amount (A1) of the toner stored in the container side storage unit 23. The control device 8 communicates with the integrated circuit board 20 via the read / write unit 25, and reads / writes data to / from the container side storage unit 23.

By the way, it is known that the amount of toner consumed (image density) changes depending on the temperature and humidity (installation environment) of the place where the image forming apparatus 1 is installed. The image forming apparatus 1 according to the present embodiment includes a thermo-hygrometer 27 for measuring the temperature and humidity of the installation location (see FIG. 2). The thermo-hygrometer 27 is electrically connected to the interface unit 32 of the control device 8. The control device 8 controls the charging power supply 15B, the developing power supply 16B, and the transfer power supply 17B based on the output (temperature, humidity) from the thermo-hygrometer 27, and controls the charging bias (V1) and the developing bias (V2). And adjust the charge bias (V1). For example, since the photoconductor drum 14 is less likely to be charged in a low temperature and low humidity environment, the control device 8 of the image forming apparatus 1 raises the charging bias (V1) above the reference value to make the photoconductor drum 14 appropriate. It is controlled to charge the battery. The control device 8 also changes the reference value of the development bias (V2) and the reference value of the transfer bias (V3) in the same manner as the charge bias (V1).

From the above, in order to accurately detect the remaining amount of toner contained in the toner container 11, it is necessary to make a correction in consideration of the charging bias (V1) and the like that change depending on the installation environment. Therefore, the image forming apparatus 1 according to the present embodiment has a mechanism for accurately determining the remaining amount of toner by making corrections according to changes in the charging bias (V1) and the like.

[Toner remaining amount check unit]
A toner remaining amount confirmation unit 33 for determining the remaining amount of toner contained in the toner container 11 will be described with reference to FIGS. 2A to 4C. FIG. 4A is an explanatory diagram showing a first table T1 stored in the storage unit 31. FIG. 4B is an explanatory diagram showing a second table T2 stored in the storage unit 31. FIG. 4C is an explanatory diagram showing a third table T3 stored in the storage unit 31.

As shown in FIG. 2, the toner remaining amount confirmation unit 33 is provided as a function of the control device 8. The toner remaining amount confirmation unit 33 includes a density correction unit 40, a transfer correction unit 41, a dot count unit 42, a consumption amount calculation unit 43, a remaining amount determination unit 44, and a notification unit 45. .. Each of the units 40 to 45 constituting the toner remaining amount confirmation unit 33 is stored in the arithmetic processing unit 30, the program executed in the arithmetic processing unit 30, and the storage unit 31 and the container side storage unit 23, and is used for the program. It is realized by the data that is created.

First, the data stored in the storage unit 31 will be described. As shown in FIG. 4A, the storage unit 31 stores a first table T1 in which the ratio of the charge bias (V1) and the first concentration correction value (V1C) are associated with each other. Further, as shown in FIG. 4B, the storage unit 31 stores a second table T2 in which the ratio of the development bias (V2) and the second density correction value (V2C) are associated with each other. Further, as shown in FIG. 4C, the storage unit 31 stores a third table T3 in which the ratio of the transfer bias (V3) and the transfer efficiency correction value (V3C) are associated with each other.

The ratios of the charging bias (V1), the developing bias (V2), and the transfer bias (V3) are set according to the installation environment, respectively. The ratio of each bias (V1) to (V3) is, for example, a reference ratio corresponding to a reference installation environment (for example, temperature 20 ° C., humidity 40% (hereinafter, also referred to as “reference environment”)). When at least one of temperature and humidity (hereinafter, also referred to as "temperature, etc.") rises by a predetermined amount from the standard environment, the ratio increases, and when the temperature, etc. falls by a predetermined amount from the standard environment, the ratio decreases. Has been done. The first concentration correction value (V1C) is set corresponding to the charging bias (V1) that changes depending on the installation environment. The second density correction value (V2C) is set corresponding to the development bias (V2) that changes depending on the installation environment. The transfer efficiency correction value (V3C) is set corresponding to the transfer bias (V3) that changes depending on the installation environment. The ratio of each bias (V1) to (V3), a predetermined amount such as temperature, and each correction value (V1C) to (V3C) are experimentally obtained.

<Density correction unit>
The density correction unit 40 calculates a density correction value (VC) corresponding to the charge bias (V1) and the development bias (V2). Specifically, the concentration correction unit 40 receives the output result (installation environment) from the thermo-hygrometer 27, and the ratio of the charging bias (V1) adapted to the output result from the first table T1 and the first concentration. The correction value (V1C) is acquired. Similarly, the density correction unit 40 acquires the ratio of the development bias (V2) adapted to the output result and the second density correction value (V2C) from the second table T2. Then, the density correction unit 40 sets the product of the first density correction value (V1C) and the second density correction value (V2C) as the density correction value (VC). The concentration correction unit 40 stores the output result of the thermo-hygrometer 27 and the calculated concentration correction value (VC) in the storage unit 31.

<Transfer correction unit>
The transfer correction unit 41 calculates a transfer efficiency correction value (V3C) corresponding to the transfer bias (V3). Specifically, the transfer correction unit 41 acquires (calculates) the transfer bias (V3) ratio and the transfer efficiency correction value (V3C) adapted to the output result of the thermo-hygrometer 27 from the third table T3. The transfer correction unit 41 stores the transfer efficiency correction value (V3C) in the storage unit 31.

<Dot count part>
The dot counting unit 42 calculates the number of dots (DC) of the image data used for forming the toner image. Specifically, the dot counting unit 42 counts the dots constituting the toner image from the image data, and calculates the integrated value as the number of dots (DC). The dot counting unit 42 stores the calculated number of dots (DC) in the storage unit 31. The number of dots varies depending on the resolution of the toner image (printed image).

<Consumption calculation unit>
The consumption amount calculation unit 43 calculates the total toner consumption (A2) based on the density correction value (VC), the transfer efficiency correction value (V3C), and the number of dots (DC). Specifically, the consumption amount calculation unit 43 sets the product of the toner consumption per dot, the number of dots (DC), the density correction value (VC), and the transfer efficiency correction value (V3C) by 1. It is defined as a unit consumption amount (UA), which is the amount of toner consumed per sheet of paper P. The consumption amount calculation unit 43 adds the calculated unit consumption amount (UA) to the total consumption amount (A2) stored in the container side storage unit 23 of the toner container 11. In this way, the consumption amount calculation unit 43 integrates the unit consumption amount (UA) and calculates the total consumption amount (A2). The amount of toner consumed per dot is obtained in advance and stored in the storage unit 31 (or the container-side storage unit 23).

<Remaining amount judgment unit>
The remaining amount determination unit 44 determines the remaining amount of toner contained in the toner container 11 based on the total consumption amount (A2). Specifically, the remaining amount determination unit 44 refers to the maximum capacity (A1) and the total consumption (A2) stored in the container-side storage unit 23 of the toner container 11, and is the total from the maximum capacity (A1). The remaining amount of toner (A3) is calculated by subtracting the consumption amount (A2). The remaining amount determination unit 44 stores the remaining amount of toner (A3) in the storage unit 31.

<Notification unit>
The notification unit 45 displays a toner gauge (not shown) indicating the remaining amount of toner (A3) on the operation panel 26. The toner gauge shows 100% when a new toner container 11 is mounted on the container mounting portion, gradually decreases by repeating image formation, and shows 0% when it is determined that there is no toner. When the user performs a display operation of the toner gauge from the operation panel 26, the toner gauge is displayed on the operation panel 26.

[Toner remaining amount judgment method]
Next, with reference to FIG. 5, a toner remaining amount determination method using the toner remaining amount confirmation unit 33 will be described. FIG. 5 is a flowchart showing a toner remaining amount determination method.

The control device 8 executes the toner remaining amount determination process shown in FIG. 5 in parallel with the image forming process shown in FIG.

When the image data is input from the external terminal, the density correction unit 40 refers to the first table T1 and the second table T2 based on the output result of the thermo-hygrometer 27, and determines the ratio of the charge bias (V1). The ratio of the development bias (V2), the first density correction value (V1C) and the second density correction value (V2C) are acquired (calculated) (density correction step S10). Further, in the density correction step S10, the density correction unit 40 calculates the product of the first density correction value (V1C) and the second density correction value (V2C), and the calculation result is the density correction value (VC). Is stored in the storage unit 31. The transfer correction unit 41 refers to the third table T3 based on the output result of the thermo-hygrometer 27, and acquires (calculates) the transfer bias (V3) ratio and the transfer efficiency correction value (V3C) (transfer correction). Step S11). The various acquired (calculated) values are temporarily stored in the storage unit 31.

The control device 8 calculates various biases (V1) to (V3) suitable for the installation environment by multiplying the reference values of various biases (V1) to (V3) by the acquired ratios. The control device 8 executes the charging step S1, the developing step S3, and the transfer step S4 using the various calculated biases (V1) to (V3) (see FIG. 3).

The dot counting unit 42 calculates the number of dots (DC) of the input image data (dot counting step S12). Next, the consumption amount calculation unit 43 calculates the unit consumption amount (UA) (= toner consumption per dot × number of dots (DC) × density correction value (VC) × transfer efficiency correction value (V3C)). Then, the unit consumption amount (UA) is added to the total consumption amount (A2) stored in the container side storage unit 23 (consumption amount calculation step S13). That is, in the consumption amount calculation step S13, the unit consumption amount (UA) is integrated to calculate the total consumption amount (A2).

The remaining amount determination unit 44 calculates (determines) the remaining amount of toner (A3) by subtracting the total consumption amount (A2) from the maximum capacity (A1) stored in the container side storage unit 23 (remaining amount determination). Step S14). The calculated remaining amount (A3) is temporarily stored in the storage unit 31. The notification unit 45 reflects the calculated remaining amount (A3) on the toner gauge (notification step S15). When the user performs a display operation, the notification unit 45 displays the toner gauge on the operation panel 26.

When the remaining amount (A3) of the toner becomes zero or an arbitrarily set predetermined amount or less in the remaining amount determination step S14, the remaining amount determination unit 44 sends the replacement information of the toner container 11 to the notification unit 45. Send. The notification unit 45 controls to display information prompting the replacement of the toner container 11 on the operation panel 26, and controls to output a warning sound or a voice from a speaker (not shown).

In the image forming apparatus 1 (toner remaining amount determination method) according to the present embodiment described above, various correction values (VC) corresponding to various biases (V1) to (V3) that change depending on the installation environment (temperature, humidity) are used. ) ((V1C, V2C)), (V3C) were calculated, and the total toner consumption (A2) was calculated based on various correction values (VC), (V3C) and the number of dots (DC). .. According to this configuration, the total toner consumption (A2) adapted to the installation environment of the image forming apparatus 1 can be obtained, and the remaining amount of toner in the toner container 11 (A2) is obtained based on the total consumption (A2). A3) can be determined. As a result, the remaining amount (A3) can be accurately determined as compared with the case where the remaining amount (A3) is predicted based only on the image data.

Further, according to the image forming apparatus 1 according to the present embodiment, the first density correction value (V1C) corresponding to the charge bias (V1) and the second density correction value (V2C) corresponding to the development bias (V2). By taking the product of and, the density correction value (VC) reflecting the change in the installation environment of the image forming apparatus 1 can be obtained.

Further, according to the image forming apparatus 1 according to the present embodiment, the toner consumed for each paper P can be reflected in the total consumption amount (A2), and the accurate toner can be obtained based on the total consumption amount (A2). The remaining amount can be calculated.

Further, according to the image forming apparatus 1 according to the present embodiment, since the toner container 11 has a container-side storage unit 23 for storing the total consumption amount (A2) and the like, the data before replacement may be reset. Even without it, the remaining amount (A3) of the toner container 11 after replacement can be accurately determined. Further, even if the capacity of the toner container 11 is changed, it is not necessary to change the data (parameter) or the like stored in the storage unit 31 of the control device 8. That is, it is possible to flexibly respond to changes in the capacity of the toner container 11.

In the image forming apparatus 1 (toner remaining amount determination method) according to the present embodiment, the density correction value (VC) is a value considering both the charging bias (V1) and the developing bias (V2). The invention is not limited to this. The density correction value (VC) may be a value corresponding to only one of the charging bias (V1) and the developing bias (V2). That is, in the density correction step S10, the density correction unit 40 may calculate the density correction value (VC) corresponding to the charge bias (V1) or the development bias (V2).

Further, in the image forming apparatus 1 according to the present embodiment, the control apparatus 8 changes various biases (V1) to (V3) based on the output result (installation environment (temperature, humidity)) of the thermohygrometer 27. However, the present invention is not limited to this. For example, the control device 8 may change various biases (V1) to (V3) based on the number of images formed (number of prints), the elapsed time, and the like.

Further, in the image forming apparatus 1 according to the present embodiment, the ratios of the respective biases (V1) to (V3) and the respective correction values (V1C) to (V3C) are acquired (calculated) by referring to the tables T1 to T3. ), But the present invention is not limited to this. For example, the respective biases (V1) to (V3) and the corresponding correction values (V1C) to (V3C) are calculated using a predetermined calculation formula having the installation environment (temperature, humidity) as variables. You may.

Further, in the image forming apparatus 1 according to the present embodiment, the consumption amount calculation unit 43 integrates the unit consumption amount (UA) to calculate the total consumption amount (A2), but the present invention is not limited to this. For example, the consumption amount calculation unit 43 may calculate the unit consumption amount (UA) as the total consumption amount (A2) (A2 = UA). That is, the total consumption (A2) may be regarded as the unit consumption (UA). In this case, the total consumption amount (A2) is not stored in the container side storage unit 23, and the consumption amount calculation unit 43 calculates only the unit consumption amount (UA) (= total consumption amount (A2)) and the remaining amount. The determination unit 44 may subtract the unit consumption amount (UA) (= total consumption amount (A2)) from the maximum capacity (A1).

Further, in the image forming apparatus 1 according to the present embodiment, the total toner consumption (A2) and the maximum capacity (A1) are stored in the container-side storage unit 23 of the integrated circuit board 20 mounted on the toner container 11. However, the present invention is not limited to this. The total toner consumption (A2) and the maximum capacity (A1) may be stored in the storage unit 31 of the control device 8.

Further, in the image forming apparatus 1 according to the present embodiment, the non-contact integrated circuit board 20 is mounted on the toner container 11, but the present invention is not limited to this. For example, instead of the integrated circuit board 20, a non-volatile memory such as a flash memory may be mounted on the toner container 11 (not shown). In this case, with the toner container 11 mounted on the container mounting portion, the terminal of the non-volatile memory comes into contact with the terminal provided on the container mounting portion, and the control device 8 gives priority to the non-volatile memory for data. You may read and write.

Further, in the image forming apparatus 1 according to the present embodiment, the toner (toner image) is supported on the exposed portion of the photoconductor drum 14, but the present invention is not limited to this. On the contrary, the photoconductor drum 14 may carry the toner on the unexposed portion. In this case, in the photosensitive layer of the negatively charged photoconductor drum 14, the charged portion of the exposed portion is depleted, and an electrostatic latent image is formed on the unexposed portion. In the developing step S3, the positively charged toner adheres to the unexposed portion (electrostatic latent image), and the toner image is formed. The polarities and potentials of the development bias (V2) and the transfer bias (V3) may be set in consideration of the polarities and potential differences between the photoconductor drum 14 and the toner.

Further, the image forming apparatus 1 according to the present embodiment is a monochrome printer, but the present invention is not limited to this, and the present invention may be applied to, for example, a color printer, a copying machine, a facsimile, a multifunction device, or the like. When the image forming apparatus forms a color image, the remaining amount of toner (A3) is determined for the toner container 11 of each color.

The description of the above embodiment shows one aspect of the image forming apparatus and the toner remaining amount determination method according to the present invention, and the technical scope of the present invention is not limited to the above embodiment. The present invention may be variously modified, replaced or modified without departing from the spirit of the technical idea, and the claims include all embodiments that may be included within the scope of the technical idea.

1 Image forming device 11 Toner container 13 Exposure device 14 Photoreceptor drum (photoreceptor)
15 Charging device 16 Developing device 17 Transfer roller (transfer device)
23 Container side storage unit 40 Concentration correction unit 41 Transfer correction unit 42 Dot count unit 43 Consumption amount calculation unit 44 Remaining amount determination unit P Paper (medium)
S1 Charging process S2 Exposure process S3 Development process S4 Transfer process S10 Concentration correction process S11 Transfer correction process S12 Dot count process S13 Consumption calculation process S14 Remaining amount determination process

Claims (7)

An image forming apparatus that forms an image on a medium using toner contained in a toner container.
A charging device that charges the photoconductor by applying a charging bias,
An exposure apparatus that exposes the charged photoconductor to form an electrostatic latent image on the surface of the photoconductor.
A developing device that develops the electrostatic latent image on the surface of the photoconductor into a toner image by using the toner supplied from the toner container by applying a development bias.
A transfer device that transfers the toner image on the surface of the photoconductor to the medium by applying a transfer bias, and a transfer device.
A density correction unit that calculates a density correction value corresponding to at least one of the charge bias and the development bias, and
A transfer correction unit that calculates the transfer efficiency correction value corresponding to the transfer bias, and
A dot count unit that calculates the number of dots in the image data used to form the toner image, and
A consumption amount calculation unit that calculates the total consumption amount of the toner based on the density correction value, the transfer efficiency correction value, and the number of dots.
An image forming apparatus comprising: a remaining amount determination unit for determining the remaining amount of the toner contained in the toner container based on the total consumption amount. The first aspect of the present invention is characterized in that the density correction unit uses the product of the first density correction value corresponding to the charge bias and the second density correction value corresponding to the development bias as the density correction value. The image forming apparatus according to the description. The consumption amount calculation unit calculates the total consumption amount by integrating the unit consumption amount which is the consumption amount of the toner per the medium.
The image forming according to claim 1 or 2, wherein the remaining amount determination unit calculates the remaining amount by subtracting the total consumption amount from the maximum storage amount of the toner that can be stored in the toner container. Device. The image according to claim 3, wherein the toner container is interchangeably attached to the image forming apparatus and has a container-side storage unit for storing the total consumption amount and the maximum storage amount. Forming device. A method for determining the remaining amount of toner in an image forming apparatus that forms an image on a medium using toner contained in a toner container.
A charging process that charges the photoconductor by applying a charging bias,
An exposure step of exposing the charged photoconductor to form an electrostatic latent image on the surface of the photoconductor.
A developing step of developing the electrostatic latent image on the surface of the photoconductor into a toner image by applying the development bias with the toner supplied from the toner container.
A transfer step of transferring the toner image on the surface of the photoconductor to the medium by applying a transfer bias,
A density correction step of calculating a density correction value corresponding to at least one of the charge bias and the development bias, and
A transfer correction step for calculating a transfer efficiency correction value corresponding to the transfer bias, and a transfer correction step.
A dot counting step for calculating the number of dots in the image data used to form the toner image, and
A consumption amount calculation step of calculating the total consumption amount of the toner based on the density correction value, the transfer efficiency correction value, and the number of dots.
A toner remaining amount determination method comprising: a remaining amount determination step of determining the remaining amount of the toner contained in the toner container based on the total consumption amount. 5. The density correction step is characterized in that the product of the first density correction value corresponding to the charge bias and the second density correction value corresponding to the development bias is the density correction value. The toner remaining amount determination method described in 1. In the consumption amount calculation step, the total consumption amount is calculated by integrating the unit consumption amount which is the consumption amount of the toner per the medium.
The toner according to claim 5 or 6, wherein in the remaining amount determination step, the remaining amount is calculated by subtracting the total consumption amount from the maximum capacity of the toner that can be stored in the toner container. Remaining amount judgment method.

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