JP3276515B2 - Image forming device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an image forming apparatus having a developing device for developing an electrostatic latent image on a photosensitive member with toner and a toner collecting container for collecting residual toner from the photosensitive member. The present invention relates to an image forming apparatus that determines a toner full state of a toner collection container without providing a special detection sensor.

[0002]

2. Description of the Related Art Conventionally, in an electrophotographic image forming apparatus, toner or paper dust remaining on an electrostatic latent image carrier (photoconductor) after a visible image (toner image) transfer process is transferred to the next image forming apparatus. It must be removed by a cleaning device in preparation for performing the forming process. As one example of the cleaning device, a blade cleaning device that removes residual toner by relatively rubbing the surface of the electrostatic latent image carrier with a cleaning blade that is in contact with the surface is known.

In the blade cleaning device, the toner scraped from the electrostatic latent image carrier by the cleaning blade is conveyed to a collection tank via a collection blade or a collection coil and collected.

[0004] Thereafter, if the collected toner becomes full in the collection container with the lapse of time, if the image forming operation is continued as it is, the toner overflows, and the toner scatters and the toner drops. Failures such as dirt, abnormal noise, and damage to various parts of the device are caused.

To prevent toner overflow, various image forming apparatuses have been proposed which issue a toner full warning by detecting a sensor or the like. For example, Japanese Patent Application Laid-Open No. Sho 62-55686 discloses an image forming apparatus. A "toner recovery device" has been proposed. This "toner recovery device"
Are located on a pair of protrusions at the top of the toner collection container,
The optical sensor has a light-emitting portion and a light-receiving portion, and a portion of the projecting portion located between the light-emitting portion and the light-receiving portion is formed of a light-transmitting material to detect the amount of collected toner.

A "toner full warning device" disclosed in Japanese Utility Model Laid-Open Publication No. Sho 62-123652 has been proposed. The "toner full warning device" is based on the amount of toner to be recovered and the recovery container is full. Is calculated until the set number of copies becomes larger than the set number of copies, the warning means is activated.

Further, there has been proposed a "full-toner recovery container detecting device" disclosed in Japanese Utility Model Laid-Open Publication No. 63-35070. The full state of the toner collection container is detected based on the displacement of the detection member pushed up.

Japanese Patent Laid-Open Publication No. 1-155383 discloses a "method of detecting the amount of collected toner of an electrophotographic image forming apparatus". This "method of detecting the amount of collected toner of an electrophotographic image forming apparatus" has been proposed. Measures the toner consumption of the developing device and informs that the toner collection container is full of toner when the measured toner consumption exceeds the preset toner consumption based on the capacity and transfer rate of the toner collection container. ing.

[0009]

However, according to JP-A-62-55686, JP-A-62-123652 and JP-A-63-35070, the toner full state of the toner collecting container is detected. Although the toner overflow is prevented, there is a problem that the number of parts increases and the cost increases because the detection means is provided in the toner collecting container.

According to Japanese Patent Application Laid-Open No. 1-155383, when the detection of the toner full state of the toner collecting container is detected,
Although the detection means of the toner collecting container is not required, it is necessary to provide the detection means in the developing device to measure the toner consumption of the developing device, which also has a problem that the number of parts increases and the cost increases. Was.

The present invention has been made in view of the above, and has as its object to prevent toner overflow and reduce the number of parts.

[0012]

According to a first aspect of the present invention, there is provided an image forming apparatus comprising: a developing device having a toner cartridge for developing an electrostatic latent image on a photosensitive member with toner; In an electrophotographic image forming apparatus having a toner collecting container for collecting residual toner from a body, a counting means for counting the number of image forming operations, and a counting means for counting the number of times the first toner cartridge is replaced. A toner collection amount calculation unit configured to calculate a collection amount of the toner collected in the toner collection container in one image formation operation based on the number of image formation operations; and a calculation result of the toner collection amount calculation unit. Predicting means for predicting the number of image forming operations in which the toner collecting container is full, warning means for issuing a warning of toner full to a user of the apparatus, and counting by the counting means. If the number of image forming operation predicted by the number of times and the predicted means of the image forming operation has become equal, in which a control means for warning of toner full by controlling the warning means.

According to a second aspect of the present invention, in the image forming apparatus according to the first aspect of the present invention, the toner collection amount calculating unit is replaced based on the number of image forming operations counted by the counting unit when the toner cartridge is replaced for the second time or later. Toner cartridge 1
The number of image forming operations for the main cartridge is determined, and one of the replaced toner cartridges is determined based on the determined number of image forming operations.
The amount of toner collected in the toner collecting container in each image forming operation is calculated, and the predicting means stores the amount of toner collected in each replaced toner cartridge at one time. When the toner has been replaced, the amount of collected toner per unit is calculated from the stored amount of collected toner of each toner cartridge and the amount of collected toner newly calculated by the toner collection amount calculator. An average value is obtained, and the number of image forming operations in which the toner collecting container is full is predicted using the obtained average value.

According to a third aspect of the present invention, in the image forming apparatus, the control unit determines that the toner collection amount calculated by the toner collection amount calculation unit exceeds an abnormality determination value set in advance based on an experimental prediction calculation. In this case, the image forming operation is prohibited.

[0015]

According to the image forming apparatus of the present invention, when the first replacement of the toner cartridge in the developing device is performed, it is possible to copy with the toner of one replaced toner cartridge. The amount of toner collected per copy collected in the toner collection container is calculated based on the number of copies obtained, and the number of image forming operations for filling the toner collection container is estimated based on the calculation result. When the count value of the forming operation becomes equal to the predicted value, a warning is issued to the user.

Further, the image forming apparatus of the present invention (claim 2)
Means that each time a toner cartridge in the developing device is replaced, the toner collected in a toner collection container is collected in a toner collection container based on the number of copies that could be made with the replaced toner cartridge. The collection amount is calculated, the calculated value is averaged for each replacement, and the number of image forming operations in which the toner collection container is full is predicted based on the averaged calculation result, and the count value of the image forming operation is predicted. Warns the user when equal to the value.

Further, the image forming apparatus of the present invention (claim 3)
Prohibits the image forming operation when the calculated amount of collected toner exceeds an abnormality determination value set in advance in an experiment prediction calculation.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, an image forming apparatus according to the present invention will be described in detail in the order of [Embodiment 1], [Embodiment 2], and [Embodiment 3] with reference to the drawings.

FIG. 1 is an explanatory diagram showing a schematic configuration of an image forming system of the image forming apparatus according to the first embodiment, and includes a photosensitive member 101 as an image carrier for forming an electrostatic latent image and a toner image.
Charger 1 for charging photoconductor 101 to a predetermined potential
02, an optical mirror 103 for guiding exposure light as image data to the photosensitive member 101, an eraser 104 for removing a charged potential of a non-image portion on the surface of the photosensitive member 101,
A developing unit 10 for developing the electrostatic latent image formed on the surface of the photoreceptor 101 with toner to form a visible toner image
5, a paper feed registration roller 106 for feeding recording paper (not shown) to the photoconductor 101 at a predetermined timing, a transfer charger 107a for transferring a toner image formed on the surface of the photoconductor 101 to the recording paper, Separation charger 107 for separating recording paper after transfer processing from photoreceptor 101
b, a separation claw 108, a fixing roller 109 for fixing the toner image on the recording paper, a cleaning unit 110 for removing a residual toner adhering to the surface of the photoconductor 101, and a photosensitive unit. A static elimination lamp 111 for eliminating the residual potential of the body 101.

Reference numeral 105a denotes a toner cartridge for storing toner in the developing unit 105.

FIG. 2 is an explanatory diagram showing a schematic configuration of a control system of the image forming apparatus according to the first embodiment. The power switch 201 serves as a main power supply of the image forming apparatus, and a start key for instructing a copy start. 202, a copy number counting unit 203 for counting the number of copies, and a toner full warning display unit 2 for warning by displaying a toner full state by displaying
04 and various drive systems 2 which are various drive units related to image formation
05 and a control unit 206 for controlling the above-described units.

The control unit 206 is provided with the power switch 20
1, an input / output I / F (interface) 206a for interfacing with various drive systems 205, a ROM 206b storing a control program, a RAM 206c used as a work area in control operations,
Based on the control program stored in the OM 206b,
Using the RAM 206c as a work area,
/ F 206a for controlling the power switch 201, the start key 202, the copy number counting unit 203, the toner full warning display unit 204, and various driving systems 205
PU 206d.

The operation of the above configuration will be described.
First, the image forming operation of the image forming system will be described. The surface of the photoconductor 101 is uniformly charged by the charger 102, and an electrostatic latent image is formed on the surface of the photoconductor 101 by exposure light guided by the optical mirror 103. The electrostatic latent image is developed with toner by the developing unit 105 after the charge potential of the non-image area is removed by the eraser 104, and a toner image is formed on the surface of the photoconductor 101. Recording paper (not shown) is fed at a predetermined timing by the paper feed registration roller 106 in accordance with the formation of the toner image, and the toner image is transferred to the fed recording paper by the transfer charger 107a. After the transfer process, the recording paper is transferred to the separation charger 10
The toner image is separated from the photoreceptor 101 by 7b and the separation claw 108, and the toner image is fixed on the recording paper by the fixing roller 109. Note that the residual toner adhered to the surface of the photoconductor 101 is collected by the cleaning unit 110, and the residual potential on the surface of the photoconductor 101 is discharged by the discharge lamp 111.

Next, the control operation of the first embodiment will be described with reference to the flowchart shown in FIG. When the first toner cartridge 105a is replaced (S301), C
The PU 206d checks the total count number with reference to the copy number counting unit 203 (S302).
Subsequently, the CPU 206d calculates the toner collection amount per copy based on the total number of copies (total count number) that can be copied by one toner cartridge 105a (S303).

Here, a method for calculating the amount of collected toner per copy will be described. First, the amount of toner consumed per copy is calculated by dividing the amount of toner of one toner cartridge 105a by the total number of copies made by one toner cartridge 105a. Next, based on the percentage of toner actually used (transferred to recording paper) in one copy operation, that is, the toner usage rate determined in advance from experimental values and empirical values, one copy operation The ratio of the collected toner, that is, the collection ratio, is obtained, and the toner collection amount per copy is calculated from the obtained collection ratio and the toner consumption amount per copy.

After calculating the toner collection amount per copy, the CPU 206d predicts the number of copies that can be made until the toner becomes full based on the calculation result, and sets the predicted number of copies (S304). Thereafter, when the set number of copies is reached (S305), the CPU 206
d causes the toner full warning display unit 204 to display a toner full warning (S306).

As described above, according to the first embodiment, the first
The amount of toner collected per copy is calculated from the total number of copies that can be made with one replaced toner cartridge, and the number of copies that can be made until the toner is full is estimated based on the calculation result. In other words, in other words, in order to determine the toner full state from the amount of toner actually used in the image forming apparatus and the number of copies that can be made with the amount of toner, the usage state unique to the image forming apparatus, that is, The toner full state can be accurately detected in consideration of the document image ratio, and a warning is issued based on the detection result, thereby preventing toner overflow. Further, since the toner full state is detected without using a special sensor, the number of parts can be reduced.

Embodiment 2 An image forming apparatus according to Embodiment 2
Even when the toner cartridge is replaced for the second time or later, the amount of collected toner per copy is calculated from the total number of copies that can be made with one replaced toner cartridge, so that the toner can be more accurately maintained until the toner is full. This is to predict the number of copies that can be made. The configuration of the second embodiment is the same as that of the first embodiment, and the description is omitted.

Next, the control operation of the second embodiment will be described with reference to the flowchart shown in FIG. When the toner cartridge 105a is replaced (S401), the CPU 20
6d checks the total count number with reference to the copy number counting section 203 (S402). continue,
The CPU 206d is a single toner cartridge 105a.
The amount of collected toner per copy is calculated based on the total number of copies (total count number) that can be copied in step, and stored in the RAM 206c (S403). Here, the CPU 206d determines whether the replaced toner cartridge 105a is the first toner cartridge (S404). If the CPU 206d determines that the replaced toner cartridge 105a is not the first toner cartridge,
The toner collection amount per copy stored in the storage unit 206c is averaged (S405). When the toner collection amount per copy is averaged, the CPU 206d predicts the number of copies that can be made until the toner becomes full based on the calculation result, and sets the predicted number of copies (S).
406). Thereafter, when the set number of copies is reached (S407), the CPU 206d displays a toner full warning on the toner full warning display unit 204 (S408).
If the set number of copies has not been reached in step S407, the process returns to step S401. If the toner cartridge 105a is not replaced in step S401, the process proceeds to step S407.

As described above, according to the second embodiment, even when the toner cartridge is replaced for the second time or later, the toner collection amount per copy is calculated from the total number of copies that can be made with one replaced toner cartridge. In other words, the amount of toner collected per copy is
Since the correction is made as needed, even if the usage condition changes over time, the number of copies that can be made until the toner is full can be predicted more accurately, and a warning of the toner full state is issued as in the first embodiment. Thus, toner overflow can be reliably prevented. Further, since the toner full state is detected without using a special sensor, the number of parts can be reduced.

Embodiment 3 Embodiment 3 is different from Embodiment 2 in that the toner recovery amount per copy is calculated.
When the calculation result exceeds an abnormality judgment value set on the experimental prediction calculation, control is performed so that the copy operation is prohibited.

Next, the control operation of the third embodiment will be described with reference to the flowchart shown in FIG. In FIG. 5, the same step numbers as those in FIG. 4 denote the same operations as in the second embodiment, and a description thereof will be omitted. Only operations with different step numbers will be described. In step S403, the amount of collected toner per copy is calculated, and the RAM 206
When stored in c, the CPU 206d determines whether the calculated value is smaller than the abnormality determination value set in the experimental prediction calculation (S501). If it is determined that the value is smaller than the abnormality determination value, the process proceeds to step S404, and control is performed in the same manner as in the second embodiment.

On the other hand, if it is determined in step S501 that the value obtained by calculating the toner collection amount per copy is equal to or larger than the abnormality determination value, the CPU 206d prohibits the copying operation (S502). This is because when the amount of collected toner is abnormal (when it is determined that the amount of collected toner is too large), the toner may leak from the cleaning unit 110 to each part of the image forming apparatus. If the image forming operation is continued, there is a possibility that toner scattering, toner contamination, abnormal noise, damage to various parts of the apparatus, and the like may occur.

As described above, according to the third embodiment, when the amount of collected toner per copy is calculated, if the calculation result exceeds the abnormality determination value set in the experimental prediction calculation, , To control to prohibit copy operation,
It is possible to prevent a problem for an operator due to an abnormality in the image forming apparatus, that is, scattering of toner, dirt due to toner drop, abnormal sound, and damage to various parts of the apparatus.

[0035]

As described above, in the image forming apparatus according to the present invention (claim 1), when the first replacement of the toner cartridge in the developing device is performed, the replacement of one toner cartridge is performed. The amount of toner collected per copy collected in the toner collection container is calculated based on the number of copies that can be copied with the toner, and based on the calculation result, the toner collection container becomes full. The number of operations is predicted, and when the count value of the image forming operation becomes equal to the predicted value, a warning is issued to the user, so that toner overflow can be prevented and the number of parts can be reduced.

Further, the image forming apparatus of the present invention (Claim 2)
Means that each time a toner cartridge in the developing device is replaced, the toner collected in a toner collection container is collected in a toner collection container based on the number of copies that could be made with the replaced toner cartridge. The collection amount is calculated, the calculated value is averaged for each replacement, and the number of image forming operations in which the toner collection container is full is predicted based on the averaged calculation result, and the count value of the image forming operation is predicted. When the value is equal to the value, a warning is issued to the user, so that toner overflow can be reliably prevented and the number of parts can be reduced.

An image forming apparatus according to the present invention (claim 3)
Is to prevent the image forming operation when the calculated amount of collected toner exceeds the abnormality judgment value set in advance by the experimental prediction calculation. Therefore, toner scattering, dirt due to toner drop, abnormal sound, damage to each part of the device Can be prevented.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram illustrating a schematic configuration of an image forming system of an image forming apparatus according to a first embodiment.

FIG. 2 is an explanatory diagram illustrating a schematic configuration of a control system of the image forming apparatus according to the first embodiment.

FIG. 3 is a flowchart illustrating a control operation according to the first embodiment.

FIG. 4 is a flowchart illustrating a control operation according to the second embodiment.

FIG. 5 is a flowchart illustrating a control operation according to the third embodiment.

[Explanation of symbols]

105 Developing unit 105a Toner cartridge 203 Copy number counting section 204 Toner full warning display section 206 Control section 206a CPU

Continuation of the front page (56) References JP-A-63-247783 (JP, A) JP-A-62-159171 (JP, A) JP-A-64-4748 (JP, A) JP-A-1-271767 (JP) , A) Japanese Utility Model 1-57766 (JP, U) Japanese Utility Model 57-115065 (JP, U) Japanese Utility Model 60-172177 (JP, U) (58) Fields surveyed (Int. Cl. ⁷ , DB G03G 21/10-21/12 G03G 21/00 370-540 G03G 21/14

Claims (3)

(57) [Claims] 1. An electrophotographic image forming apparatus comprising: a developing device having a toner cartridge for developing an electrostatic latent image on a photosensitive member with toner; and a toner collecting container for collecting residual toner from the photosensitive member. Counting means for counting the number of forming operations, and collecting the toner in the toner collecting container in one image forming operation based on the number of image forming operations counted by the counting means when the first toner cartridge is replaced. A toner collection amount calculating unit for calculating the collected toner collection amount, a prediction unit for predicting the number of image forming operations for filling the toner collection container based on the calculation result of the toner collection amount calculation unit, and an apparatus. A warning unit that issues a warning of toner full to the user, and the number of image forming operations counted by the counting unit is equal to the number of image forming operations predicted by the prediction unit. An image forming apparatus comprising: a control unit that controls the warning unit to give a warning that the toner is full when the error occurs. 2. The image forming apparatus according to claim 1, wherein the toner collecting amount calculating unit is configured to perform an image forming operation for one replaced toner cartridge based on the number of image forming operations counted by the counting unit when the toner cartridge is replaced for the second time or later. Is calculated, and the amount of toner collected in the toner collecting container in one image forming operation of the replaced toner cartridge is calculated based on the obtained number of image forming operations. Storing the amount of collected toner per one time of each replaced toner cartridge, and when the toner cartridge is replaced, storing the amount of collected toner per one time of each toner cartridge and newly storing the amount of collected toner. An average value of the amount of collected toner per one time is obtained from the amount of collected toner calculated by the toner collection amount calculating means, and the toner is obtained by using the obtained average value. 2. The image forming apparatus according to claim 1, wherein the number of image forming operations in which the collection container is full is predicted. 3. The image forming apparatus according to claim 1, wherein the control unit prohibits the image forming operation when the toner collection amount calculated by the toner collection amount calculation unit exceeds an abnormality determination value set based on an experimental prediction calculation. The image forming apparatus according to claim 1, wherein: