JP5430336B2 - Image forming apparatus - Google Patents

Description

  BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an image forming apparatus. In particular, the present invention is employed in an image forming apparatus such as an electrostatic copying machine, a laser printer, and a facsimile machine that forms an image using toner by electrophotography, and includes a toner and a magnetic carrier. The present invention relates to an image forming apparatus using a developing device using a component developer.

  2. Description of the Related Art Conventionally, electrophotographic image forming apparatuses such as copying machines, printers, and facsimiles are known. An electrophotographic image forming apparatus forms an electrostatic latent image on the surface of a photoreceptor, for example, a photoreceptor drum, and develops the electrostatic latent image by supplying toner to the photoreceptor drum by a developing device. The toner image formed on the photosensitive drum by development is transferred to a sheet such as paper and fixed by a fixing device.

2. Description of the Related Art In recent years, two-component developers (hereinafter simply referred to as “developers”) that are excellent in toner charge stability are often used in image forming apparatuses that support full color and high image quality.
The developer is composed of toner and carrier, and the toner and the carrier are rubbed by stirring them in the developing device, and a properly charged toner is obtained by this friction.

  The toner charged in the developing device is supplied to the surface of a two-component developer carrying member, for example, a developing roller. The toner supplied to the developing roller moves to an electrostatic latent image formed on the photosensitive drum by an electrostatic attraction force. As a result, a toner image based on the electrostatic latent image is formed on the photosensitive drum.

  Recently, there has been a demand for speeding up and downsizing of the image forming apparatus, and it has become necessary to charge the developer quickly and sufficiently and to transport the developer quickly.

  In view of this, in the image forming apparatus, a circulation type developing device is employed in order to instantly disperse the replenished toner in the developer and impart an appropriate charge amount. The circulation type developing device includes a developer conveying path through which the developer is circulated, a screw auger (developer conveying member) that conveys the developer while stirring the developer in the developer conveying path, and a developer from the toner storage unit. A toner replenishing port for replenishing toner in the conveyance path and a toner concentration detection sensor for detecting the toner concentration in the developer are provided. When the toner concentration of the developer falls below a predetermined value, an instruction to replenish the toner is given. By supplying the toner to the cartridge, the toner is supplied to the developer conveyance path, and the supplied toner is conveyed while stirring the developer (see Patent Document 1).

JP 2006-106194 A

  In the above-described circulation type developing device using the two-component developer, when the toner supplied from the toner cartridge for replenishing the toner to the developing device runs out, the toner concentration in the developer gradually decreases to the photosensitive drum. Since the frequency of occurrence of carrier development (carrier adhesion) increases, it is necessary to detect toner empty.

  The toner empty detection is, for example, determined (detected) as toner empty when the toner concentration of the developer detected by the toner supply detection sensor does not increase after instructing the toner cartridge to supply toner. Is.

  However, even if a toner replenishment instruction is issued to the toner cartridge, if the toner in the toner cartridge becomes empty and no toner is supplied, the installation location of the toner concentration detection sensor is separated from the toner replenishing port where the toner is replenished. In this case, since the decrease in the toner concentration detected by the toner concentration detection sensor is slow, the detection of toner empty is delayed and the frequency of occurrence of carrier adhesion is increased.

  The present invention has been made in view of the above-described conventional problems. In the image forming apparatus, it can be accurately detected that there is no toner to be replenished to the developing device, and the carrier to the photoconductor due to a decrease in toner density. An object of the present invention is to provide an image forming apparatus capable of suppressing the occurrence of adhesion.

An image forming apparatus according to the present invention for solving the above-described problems is as follows.
The present invention includes a developer container that contains a developer containing toner and a magnetic carrier, a developer conveying member that circulates and conveys the developer in the developer container, and the developer. A developing roller for supplying toner to the photosensitive drum, a toner replenishing port for introducing replenished toner into the developer accommodating portion, a toner replenishing device for replenishing toner to the developing device, and the developing A toner replenishment detection sensor for detecting whether or not toner is replenished in the agent storage unit, and when the toner concentration of the developer in the developing device falls below a predetermined value, Toner density control means for instructing toner supply to the apparatus, and when the toner supply detection sensor does not detect toner supply after the toner density control means instructs the toner supply, An image forming apparatus comprising a toner empty detection means for determining the toner in the serial toner replenishing device is not, and as the toner empty detection means, the output difference of the toner supply detecting sensor before and after the toner supply according to the toner replenishing device When changing, the function of predicting the timing when the toner replenishment amount becomes equal to or less than a specified value by the first-order approximation formula obtained from the data of the most recent output differences, and the toner replenishment amount became equal to or less than the specified value And a function of displaying a message to replace the toner empty or the toner replenishing device.

According to the present invention, a developer accommodating portion that accommodates a developer containing toner and a magnetic carrier, a developer conveying member that circulates and conveys the developer in the developer accommodating portion, and the developer A developing roller that supplies toner contained in the photosensitive drum, a toner replenishing port that introduces replenished toner into the developer container, a toner replenishing device that replenishes toner to the developing device, and A toner replenishment detection sensor for detecting whether or not toner is replenished in the developer accommodating portion; and when the toner concentration of the developer in the developing device falls below a predetermined value, the toner replenishing device Toner density control means for instructing toner supply to the developing device, and when the toner supply detection sensor does not detect toner supply after the toner density control means instructs to supply toner. And an output of the toner supply detection sensor before and after toner supply by the toner supply device as the toner empty detection means. When the difference changes, a function for predicting the timing at which the toner replenishment amount falls below a specified value by a first-order approximation formula obtained from the data of the most recent output differences, and the toner replenishment amount below a specified value And a function for displaying a message to replace the toner empty or the toner replenishing device when the toner replenishes, thereby preventing erroneous detection of toner empty due to toner density unevenness of the developer, etc. It is possible to accurately detect that there is no replenishment toner. Furthermore, by notifying the user that there is no toner to be supplied to the toner replenishing device and prompting the user to replace the toner replenishing device, it is possible to suppress the occurrence of carrier adhesion due to a decrease in toner concentration in the developing tank .

1 is an explanatory diagram showing an overall configuration of an image forming apparatus according to an embodiment of the present invention. FIG. 2 is a cross-sectional view illustrating a schematic configuration of a toner replenishing device constituting the image forming apparatus. FIG. 3 is a DD cross-sectional view of FIG. 2. FIG. 2 is a cross-sectional view illustrating a configuration of a developing device that constitutes the image forming apparatus. It is an AA cross-sectional arrow view of FIG. It is a BB cross-sectional arrow view of FIG. It is CC sectional view taken on the line of FIG. FIG. 2 is a block diagram illustrating a configuration of a control system in the image forming apparatus. 6 is a graph based on a first-order approximation expression using an output difference of a toner replenishment detection sensor in the developing device. 7 is a table showing an example of a cumulative toner supply time when toner is supplied by the toner supply device and a value of an output difference of a toner supply detection sensor at that time. 11 is a graph showing a relationship between an output difference of a toner replenishment detection sensor based on the values of FIG. 10 and a cumulative toner replenishment time.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the drawings.
FIG. 1 is an explanatory diagram showing an overall configuration of an image forming apparatus according to an embodiment of the present invention, which is an example of an embodiment of the present invention.

  In the present embodiment, as shown in FIG. 1, a photosensitive drum 3 on which an electrostatic latent image is formed, a charger (charging device) 5 for charging the surface of the photosensitive drum 3, and the surface of the photosensitive drum 3 An exposure unit (exposure device) 1 that forms an electrostatic latent image on the surface, a developing device 2 that forms a toner image by supplying toner to the electrostatic latent image on the surface of the photosensitive drum 3, and a toner supply to the developing device 2 A toner replenishing device 22, an intermediate transfer belt unit (transfer device) 8 for transferring the toner image on the surface of the photosensitive drum 3 to a recording medium, and a fixing unit (fixing device) 12 for fixing the toner image on the recording medium. The image forming apparatus 100 that forms an image using toner by electrophotography employs the characteristic image forming apparatus configuration according to the present invention.

  The image forming apparatus 100 forms a multicolor or single color image on a predetermined sheet (recording paper, recording medium) according to image data transmitted from the outside. A scanner or the like may be provided above the image forming apparatus 100.

First, the overall configuration of the image forming apparatus 100 will be described.
As shown in FIG. 1, the image forming apparatus 100 handles image data for each color component of black (K), cyan (C), magenta (M), and yellow (Y). An image and a yellow image are formed, and a color image is formed by superimposing the images of the respective color components.

  Therefore, in the image forming apparatus 100, as shown in FIG. 1, the developing device 2 (2a, 2b, 2c, 2d) and the photosensitive drum 3 (3a, 3b, 3c) are formed so that images of the respective color components are formed. , 3d), four chargers 5 (5a, 5b, 5c, 5d) and four cleaner units 4 (4a, 4b, 4c, 4d). In other words, four image forming stations (image forming units) each including the developing device 2, the photosensitive drum 3, the charger 5, and the cleaner unit 4 are provided.

  The symbols a to d indicate that a is a member for forming a black image, b is a member for forming a cyan image, c is a member for forming a magenta image, and d is a member for forming a yellow image. It is a thing. Further, the image forming apparatus 100 includes an exposure unit 1, a fixing unit 12, a sheet conveyance path S, a paper feed tray 10, and a paper discharge tray 15.

The charger 5 uniformly charges the surface of the photosensitive drum 3 to a predetermined potential.
As the charger 5, a contact brush type charger or a non-contact charger type charger may be used in addition to the contact roller type charger shown in FIG.

  As shown in FIG. 1, the exposure unit 1 is a laser scanning unit (LSU) including a laser irradiation unit and a reflection mirror. However, in addition to the laser scanning unit, the exposure unit 1 may be an EL (electroluminescence) in which light emitting elements are arranged in an array or an LED writing head. The exposure unit 1 exposes the charged photosensitive drum 3 according to the input image data, thereby forming an electrostatic latent image corresponding to the image data on the surface of the photosensitive drum 3.

  The developing device 2 visualizes (develops) the electrostatic latent image formed on the photosensitive drum 3 with one of K, C, M, and Y toners. Above the developing device 2 (2a, 2b, 2c, 2d), there are a toner transfer mechanism 102 (102a, 102b, 102c, 102d), a toner replenishing device 22 (22a, 22b, 22c, 22d), a developing tank (developer). (Container) 111 (111a, 111b, 111c, 111d).

  The toner replenishing device 22 is disposed above the developing tank 111 and stores unused toner (powdered toner). The toner is supplied from the toner supply device 22 to the developing tank 111 via the toner transfer mechanism 102.

  The cleaner unit 4 removes and collects the toner remaining on the surface of the photosensitive drum 3 after the development and image transfer processes.

  An intermediate transfer belt unit 8 is disposed above the photosensitive drum 3. The intermediate transfer belt unit 8 includes an intermediate transfer roller 6 (6a, 6b, 6c, 6d), an intermediate transfer belt 7, an intermediate transfer belt driving roller 71, an intermediate transfer belt driven roller 72, an intermediate transfer belt tension mechanism 73, and an intermediate transfer. A belt cleaning unit 9 is provided.

  The intermediate transfer belt 6, the intermediate transfer belt drive roller 71, the intermediate transfer belt driven roller 72, and the intermediate transfer belt tension mechanism 73 stretch the intermediate transfer belt 7 and rotationally drive the intermediate transfer belt 7 in the direction of arrow B in FIG. It is something to be made.

  The intermediate transfer roller 6 is rotatably supported by an intermediate transfer roller mounting portion in the intermediate transfer belt tension mechanism 73 of the intermediate transfer belt unit 8. A transfer bias for transferring the toner image on the photosensitive drum 3 onto the intermediate transfer belt 7 is applied to the intermediate transfer roller 6.

  The intermediate transfer belt 7 is provided so as to be in contact with each photosensitive drum 3. A color toner image (multicolor toner image) is formed on the intermediate transfer belt 7 by sequentially superimposing and transferring the toner images of the respective color components formed on the photosensitive drum 3. The intermediate transfer belt 7 is formed in an endless shape using a film having a thickness of, for example, about 100 μm to 150 μm.

  Transfer of the toner image from the photosensitive drum 3 to the intermediate transfer belt 7 is performed by the intermediate transfer roller 6 in contact with the back side of the intermediate transfer belt 7. A high voltage transfer bias (a high voltage having a polarity (+) opposite to the toner charging polarity (−)) is applied to the intermediate transfer roller 6 in order to transfer the toner image.

  The intermediate transfer roller 6 is formed based on a metal (for example, stainless steel) shaft having a diameter of, for example, 8 to 10 mm, and the surface is covered with a conductive elastic material (for example, EPDM, urethane foam, or the like). With this conductive elastic material, the intermediate transfer roller 6 can uniformly apply a high voltage to the intermediate transfer belt 7. In this embodiment, a roller-shaped transfer electrode (intermediate transfer roller 6) is used as the transfer electrode, but a brush or the like can also be used.

  As described above, the electrostatic latent images on the respective photosensitive drums 3 are visualized with toners corresponding to the respective color components to become toner images, and these toner images are superimposed and laminated on the intermediate transfer belt 7. As described above, the stacked toner images are moved to a contact position (transfer portion) between the conveyed paper and the intermediate transfer belt 7 by the rotation of the intermediate transfer belt 7, and the transfer roller disposed at this position is moved. 11 is transferred onto the paper. In this case, the intermediate transfer belt 7 and the transfer roller 11 are pressed against each other at a predetermined nip, and a voltage for transferring the toner image onto the sheet is applied to the transfer roller 11. This voltage is a high voltage having a polarity (+) opposite to the charging polarity (−) of the toner.

  In order to obtain the nip constantly, either the transfer roller 11 or the intermediate transfer belt drive roller 71 is made of a hard material such as metal, and the other is a soft material such as an elastic roller (elastic rubber roller or foamable resin roller). Etc.).

  The toner adhering to the intermediate transfer belt 7 due to the contact between the intermediate transfer belt 7 and the photosensitive drum 3 and the toner image remaining on the intermediate transfer belt 7 without being transferred when the toner image is transferred from the intermediate transfer belt 7 to the sheet. The toner is removed and collected by the intermediate transfer belt cleaning unit 9 because it causes toner color mixing in the next step.

  The intermediate transfer belt cleaning unit 9 is provided with a cleaning blade (cleaning member) that contacts the intermediate transfer belt 7. The portion of the intermediate transfer belt 7 that is in contact with the cleaning blade is supported by the intermediate transfer belt driven roller 72 from the back side.

  The paper feed tray 10 is for storing sheets (for example, recording paper) used for image formation, and is provided below the image forming unit and the exposure unit 1. On the other hand, a paper discharge tray 15 provided in the upper part of the image forming apparatus 100 is for placing printed sheets face down.

  Further, the image forming apparatus 100 is provided with a sheet conveyance path S for guiding the sheet of the paper feed tray 10 and the sheet of the manual feed tray 20 to the paper discharge tray 15 via the transfer unit and the fixing unit 12. . The transfer unit is located between the intermediate transfer belt driving roller 71 and the transfer roller 11.

  Further, a pickup roller 16 (16a, 16b), a registration roller 14, a transfer unit, a fixing unit 12, a conveyance roller 25 (25a to 25h), and the like are arranged in the sheet conveyance path S.

  The conveyance rollers 25 are small rollers for promoting and assisting conveyance of the sheet, and a plurality of conveyance rollers 25 are provided along the sheet conveyance path S. The pickup roller 16 a is a pull-in roller that is provided at the end of the paper feed tray 10 and supplies sheets one by one from the paper feed tray 10 to the sheet conveyance path S. The pickup roller 16 b is a drawing roller that is provided near the manual feed tray 20 and supplies sheets from the manual feed tray 20 to the sheet conveyance path S one by one. The registration roller 14 temporarily holds the sheet conveyed in the sheet conveyance path S, and conveys the sheet to the transfer unit at a timing when the leading edge of the toner image on the intermediate transfer belt 7 and the leading edge of the sheet are aligned.

  The fixing unit 12 includes a heat roller 81, a pressure roller 82, and the like. The heat roller 81 and the pressure roller 82 rotate with the sheet interposed therebetween. The heat roller 81 is controlled by a control unit (not shown) so as to have a predetermined fixing temperature. This control unit controls the temperature of the heat roller 81 based on a detection signal from a temperature detector (not shown).

  The heat roller 81 heat-presses the sheet together with the pressure roller 82 to melt, mix, and press the color toner images transferred to the sheet, and heat-fix the sheet. The sheet on which the multicolor toner image (each color toner image) is fixed is conveyed to the reverse sheet discharge path of the sheet conveyance path S by the plurality of conveyance rollers 25 and is reversed (the multicolor toner image is on the lower side). Are discharged onto the paper discharge tray 15.

Next, the sheet conveying operation by the sheet conveying path S will be described.
As shown in FIG. 1, the image forming apparatus 100 is provided with a paper feed tray 10 that stores sheets in advance and a manual feed tray 20 that is used when printing a small number of sheets as described above. Pickup rollers 16 (16a, 16b) are disposed on both trays, and the pickup rollers 16 supply sheets one by one to the sheet conveyance path S.

  In the case of single-sided printing, the sheet conveyed from the sheet feeding tray 10 is conveyed to the registration roller 14 by the conveyance roller 25a in the sheet conveyance path S, and is stacked on the leading edge of the sheet and the intermediate transfer belt 7 by the registration roller 14. Then, the toner image is conveyed to a transfer portion (contact position between the transfer roller 11 and the intermediate transfer belt 7) at a timing when the leading edge of the toner image is aligned. In the transfer portion, a toner image is transferred onto the sheet, and this toner image is fixed on the sheet by the fixing unit 12. Thereafter, the sheet is discharged onto the discharge tray 15 from the discharge roller 25c via the conveyance roller 25b.

  Further, the sheet conveyed from the manual feed tray 20 is conveyed to the registration roller 14 by a plurality of conveying rollers 25 (25f, 25e, 25d). Subsequent sheet conveyance operations are discharged to the sheet discharge tray 15 through a process similar to that for the sheets supplied from the sheet feed tray 10 described above.

  On the other hand, in the case of double-sided printing, the trailing edge of the sheet that has completed single-sided printing and passed through the fixing unit 12 as described above is chucked by the paper discharge roller 25c. Next, the sheet is guided to the conveying rollers 25g and 25h by the reverse rotation of the paper discharge roller 25c, and after the printing on the back surface is again performed through the registration roller 14, it is discharged to the paper discharge tray 15.

Next, the configuration of the toner supply device 22 of the present embodiment will be specifically described.
2 is a cross-sectional view showing a schematic configuration of a toner replenishing device constituting the image forming apparatus according to the present embodiment, and FIG. 3 is a cross-sectional view taken along the line DD in FIG.

  As shown in FIGS. 2 and 3, the toner supply device 22 includes a toner container 121, a toner stirring member 125, a toner discharge member 122, and a toner discharge port 123. The toner replenishing device 22 is disposed above the developing tank 111 and stores unused toner (powdered toner). The toner in the toner replenishing device 22 is supplied from the toner discharge port 123 to the developing tank 111 through the toner transfer mechanism 102 by rotating a toner discharge member (discharge screw) 122.

  The toner storage container 121 is a substantially semi-cylindrical container member having an internal space, and rotatably supports the toner stirring member 125 and the toner discharge member 122 to store the toner. The toner discharge port 123 is a substantially rectangular opening provided below the toner discharge member 122 and from the central portion in the axial direction, and is disposed at a position facing the toner transfer mechanism 102.

  The toner agitating member 125 rotates around the rotating shaft 125 a to draw up the toner in the toner container 121 and convey it to the toner discharge member 122 while agitating the toner accommodated in the toner container 121. And a toner pumping member 125b at the tip. The toner pumping member 125 b is made of a flexible polyethylene terephthalate (PET) sheet and is attached to both ends of the toner stirring member 125.

  The toner discharge member 122 supplies the toner in the toner storage container 121 to the developing tank 111 from the toner discharge port 123, and as shown in FIG. 3, a screw including a toner transport blade 122a and a toner discharge member rotating shaft 122b. The auger and the toner discharge member rotating gear 122c are included. The toner discharge member 122 is rotationally driven by a toner discharge member drive motor (not shown). The direction of the screw auger is set so that the toner is conveyed from both axial ends of the toner discharge member 122 toward the toner discharge port 123.

  A toner discharge member partition wall 124 is provided between the toner discharge member 122 and the toner stirring member 125. Accordingly, the toner pumped up by the toner stirring member 125 can hold an appropriate amount of toner around the toner discharge member 122.

  As shown in FIG. 2, the toner stirring member 125 rotates in the direction of arrow Z, stirs the toner, and pumps the toner toward the toner discharge member 122. At this time, the toner scooping member 125b rotates and slides along the inner wall of the toner container 121 due to its flexibility, and supplies the toner to the toner discharge member 122 side. The supplied toner is guided to the toner discharge port 123 by the rotation of the toner discharge member 122.

Next, a characteristic configuration of the image forming apparatus 100 of the present embodiment will be described with reference to the drawings.
4 is a cross-sectional view showing the configuration of the developing device constituting the image forming apparatus according to the present embodiment, FIG. 5 is a cross-sectional view taken along the line AA in FIG. 4, and FIG. 6 is a cross-sectional view taken along the line BB in FIG. 7 is a cross-sectional view taken along the line CC of FIG.

  As shown in FIGS. 1 and 4, the image forming apparatus 100 according to the present embodiment includes a toner replenishing port 115 a that introduces replenished toner into a developing tank (developer housing portion) 111 that houses a developer. 2, a toner replenishing device 22 that replenishes toner to the developing device 2, a toner replenishment detection sensor 119 that detects whether or not toner is replenished in the developer accommodating portion, and a toner of the developer in the developing device 2 When the density falls below a predetermined value, a toner concentration control means for instructing the toner replenishing device 22 to replenish toner to the developing device 2, and a toner replenishment detecting sensor 119 after the toner replenishment instruction by the toner concentration control means Toner empty detecting means for determining that there is no toner in the toner replenishing device 22 when toner replenishment is not detected. As over detecting means, characterized in that it comprises a structure of the toner empty detection means according to the present invention.

First, the characteristic developing device 2 of the present embodiment will be described with reference to the drawings.
As shown in FIG. 4, the developing device 2 has a developing roller (developer carrying member) 114 disposed in the developing tank 111 so as to face the photosensitive drum 3. 3 is a device for supplying (developing) an electrostatic latent image formed on the surface of the photosensitive drum 3 by supplying toner to the surface of the photosensitive drum 3.

  4 to 6, in addition to the developing roller 114, the developing device 2 includes a developing tank 111, a developing tank cover 115, a toner supply port 115a, a doctor blade 116, a first conveying member 112, and a second conveying member. 113, a partition plate (partition wall) 117, and a toner replenishment detection sensor 119.

  The developing tank 111 is a tank for storing a two-component developer containing toner and carrier (hereinafter simply referred to as “developer”). The developing tank 111 is provided with a developing roller 114, a first conveying member 112, a second conveying member 113, and the like. Note that the carrier of this embodiment is a magnetic carrier having magnetism.

  As shown in FIGS. 4 and 6, a removable developer tank cover 115 is provided on the upper side of the developer tank 111. Further, the developing tank cover 115 is provided with a toner supply port 115 a for supplying unused toner into the developing tank 111.

  In the developing tank 111, a partition plate 117 is disposed between the first transport member 112 and the second transport member 113. The partition plate 117 extends in parallel with each axial direction (each rotational axis direction) of the first transport member 112 and the second transport member 113. The interior of the developing tank 111 is partitioned by a partition plate 117 into a first transport path P in which the first transport member 112 is disposed and a second transport path Q in which the second transport member 113 is disposed.

  The partition plate 117 is disposed away from the inner wall surface of the developing tank 111 at both axial ends of the first transport member 112 and the second transport member 113. Thereby, in the developing tank 111, a communication path that connects the first transport path P and the second transport path Q is formed in the vicinity of both axial ends of the first transport member 112 and the second transport member 113. ing. In the following, as shown in FIG. 5, the communication path formed on the arrow X direction side is referred to as a first communication path a, and the communication path formed on the arrow Y direction side is referred to as a second communication path b.

  The first transport member 112 and the second transport member 113 are arranged in parallel so that their peripheral surfaces face each other via the partition plate 117 and their axes are parallel to each other, and rotate in opposite directions. Is set to As shown in FIG. 5, the first transport member 112 transports the two-component developer in the arrow X direction, and the second transport member 113 transports the developer in the arrow Y direction opposite to the arrow X direction. It is set to be.

  As shown in FIG. 5, the first transport member 112 includes a screw auger including a spiral first transport blade 112a and a first rotating shaft 112b, and a gear 112c. As shown in FIG. 5, the second transport member 113 includes a screw auger including a spiral second transport blade 113a and a second rotating shaft 113b, and a gear 112c. The first transport member 112 and the second transport member 113 are rotated and driven by a driving unit (not shown) such as a motor to stir and transport the developer.

  Further, as shown in FIG. 6, the first conveying member 112 has an angle formed by the first rotating shaft 112 b axis and the outer periphery of the first conveying blade 112 a when the first rotating shaft 112 b is viewed from the vertical direction, that is, The inclination angle θ of the spiral blade is 30 degrees or more and 60 degrees or less.

  Specifically, when the inclination angle θ of the spiral blade of the first conveying member 112 is not less than 30 degrees and not more than 60 degrees, the developer is replenished because the force for stirring the developer in the rotation direction of the first conveying member 112 is strong. “Floating toner” that is conveyed while the toner floats on the developer is less likely to occur. Accordingly, even after toner replenishment, the toner replenishment detection sensor 119 can accurately detect the toner concentration of the developer.

  On the other hand, when the inclination angle θ of the spiral blade is less than 30 degrees, the developer transport speed by the first transport member 112 is decreased, so that the developer is quickly worn. When the inclination angle θ of the spiral blade exceeds 60 degrees, the developer transport speed by the first transport member 112 becomes too fast, and thus floating toner is likely to be generated.

  The developing roller 114 is a magnet roller that is rotationally driven around a shaft center by a driving unit (not shown). The developer in the developing tank 111 is pumped and carried on the surface, and toner contained in the developer carried on the surface is photosensitive. This is supplied to the body drum 3.

  The developer conveyed by the developing roller 114 comes into contact with the photosensitive drum 3 at the closest portion. This contact area is the development nip N, and a development bias voltage is applied to the development roller 114 from a power source (not shown) connected to the development roller 114, and the developer on the surface of the development roller 114 is exposed to light. Toner is supplied to the electrostatic latent image on the surface of the body drum 3.

  A doctor blade (layer thickness regulating blade) 116 is disposed at a position close to the surface of the developing roller 114.

  The doctor blade 116 is a plate-like member that extends parallel to the axial direction of the developing roller 114. One end in the short direction is supported by the developing tank 111 and the other end is the developing roller below the developing roller 114 in the vertical direction. 114 is provided to be separated from the surface with a gap. As the material of the doctor blade 116, stainless steel can be used, but aluminum or synthetic resin can also be used.

  As shown in FIGS. 4 and 6, the toner replenishment detection sensor 119 is located near the toner replenishment port 115 a, on the downstream side in the developer conveyance direction (in the direction of the arrow X), and on the lower side in the vertical direction of the first conveyance member 112. Is attached to the bottom surface of the developing tank 111, that is, the bottom surface of the first transport path P, and is provided so that the sensor surface is exposed inside the developing tank 111.

  Further, the toner replenishment detection sensor 119 is electrically connected to a toner density control unit (not shown). As the toner replenishment detection sensor 119, a general toner replenishment detection sensor can be used, and examples thereof include a transmitted light detection sensor, a reflected light detection sensor, and a magnetic permeability detection sensor. Among these, a magnetic permeability detection sensor is preferable.

  A power supply (not shown) is connected to the magnetic permeability detection sensor. The power source applies a drive voltage for driving the magnetic permeability detection sensor and a control voltage for outputting a detection result of the toner density to the control means. Application of a voltage to the magnetic permeability detection sensor by the power source is controlled by the control means. The permeability detection sensor is a type of sensor that receives the control voltage and outputs the toner density detection result as an output voltage value. Basically, the sensitivity near the median value of the output voltage is good. It is used by applying a control voltage to obtain a voltage. Such type of magnetic permeability detection sensors are commercially available, and examples thereof include TS-L, TS-A, and TS-K (all are trade names, manufactured by TDK Corporation).

Here, the conveyance of the developer in the developing tank of the developing device 2 will be described.
As shown in FIGS. 1 and 4, the toner accommodated in the toner replenishing device 22 is transferred into the developing tank 111 through the toner transfer mechanism 102 and the toner replenishing port 115 a, whereby the toner is transferred to the developing tank 111. To be replenished.

  In the developing tank 111, the first transport member 112 and the second transport member 113 are rotationally driven by a driving means (not shown) such as a motor to transport the developer. Specifically, in the first transport path P, the developer is transported in the arrow X direction while being stirred by the first transport member 112 and reaches the first communication path a. The developer that has reached the first communication path a passes through the first communication path a and is conveyed to the second conveyance path Q.

On the other hand, in the second transport path Q, the developer is transported in the direction of the arrow Y while being stirred by the second transport member 113 and reaches the second communication path b. Then, the developer that has reached the second communication path b passes through the second communication path b and is conveyed to the first conveyance path P.
That is, the first transport member 112 and the second transport member 113 transport the developer in the opposite directions while stirring the developer.

  In this way, the developer passes through the first conveyance path P, the first communication path a, the second conveyance path Q, and the second communication path b in the developing tank 111 from the first conveyance path P to the first communication path. Circulating movement is performed in the order of a → second conveyance path Q → second communication path b. Then, while the developer is being conveyed in the second conveyance path Q, the developer is carried on the surface by the rotation of the developing roller 114 and pumped up, and the toner in the developer that has been pumped up is transferred to the photosensitive drum 3. It moves and is consumed sequentially.

  In order to make up for the consumed toner, unused toner is replenished to the first transport path P from the toner replenishing port 115a. The replenished toner is mixed and stirred with the developer existing in the first conveyance path P.

  Next, the toner density control unit and the toner empty detection unit in the image forming apparatus 100 will be specifically described.

  As the toner density control means, general means can be used, and examples include control using a toner density detection sensor, control according to patch image density, control according to dot count, and the like. Among these, control according to dot count is preferable.

  As shown in FIG. 8, the image forming apparatus 100 includes a dot count device (dot count unit) 35 that counts dot data corresponding to image data transmitted to the exposure unit 1. In response to the dot data counted by the counting device 35, the toner supply device 22 is instructed to supply toner to the developing device 2.

  The toner empty detection unit is configured to switch from the toner supply device 22 to the developing device 2 when the toner supply detection sensor 119 cannot detect toner supply after the toner concentration control unit instructs the toner supply device 22 to supply toner to the developing device 2. It is determined that the toner is not replenished, that is, there is no toner in the toner replenishing device 22 (toner empty).

Here, a characteristic configuration of the control system of the image forming apparatus 100 according to the present embodiment will be described with reference to a block diagram.
FIG. 8 is a block diagram showing a configuration of a control system in the image forming apparatus of the present embodiment.

  As shown in FIG. 8, the image forming apparatus 100 includes an image forming counter 33 that counts the cumulative number of image forming operations, and a dot count device that detects an integrated value of the number of pixels of an image formed on the photosensitive drum 3. 35, a toner replenishment detection sensor 119 that detects the magnetic permeability of the developer near the toner replenishing port, a printer engine unit 341 that includes an image forming process unit 36 and a paper transport unit 37, and a toner discharge member 122 that replenishes the developing tank 111 with toner. And a control device 32 for controlling these.

  In the image forming apparatus 100, as shown in FIG. 8, the toner density control means mainly comprises a dot count device 35, a control device 32, and a toner discharge member drive motor 126.

  The dot counting device 35 detects an integrated value of the number of pixels of an image (electrostatic latent image) formed on the photosensitive drum 3 corresponding to a print image. The integrated value count value of the number of pixels of the image is input and stored in the control device 32 as a dot count value. From the integrated value of the number of pixels of the image detected by the dot counting device 35, the amount of toner consumed for image formation can be predicted.

  Based on the dot count value, the control device 32 obtains the toner amount consumed in the image formation, and discharges the toner so that the toner discharge member 122 of the toner replenishing device 22 is rotated according to the toner amount. An instruction is given to the member drive motor 126.

  In this way, toner corresponding to the amount of toner consumed from the developing device 2 (developing tank 111) is supplied from the toner replenishing device 22 to the developing device 2 (developing tank 111).

In the image forming apparatus 100, the toner empty detection means 400 is mainly composed of a toner replenishment detection sensor 119 and a control device 32 as shown in FIG.
In addition to the functions described above, the control device 32 includes a storage unit 401 that functions as a toner empty detection unit 400, a toner empty prediction unit 402, and a message display unit 403.

  The storage unit 401 has a function of storing an output difference or an output ratio of the toner supply detection sensor 119 before and after toner supply by the toner supply device 22.

  The toner empty predicting unit 402 supplies the toner supply with the output difference or output ratio of the toner supply detection sensor 119 obtained by using the change in the output difference of the toner supply detection sensor 119 or the change in the output ratio stored in the storage unit 401. It has a function of predicting the timing when the toner replenishment amount becomes a specified value or less, that is, the timing when the toner is exhausted (toner empty) and the toner replenishment is not normally performed by a linear approximation expression representing the relationship with the amount.

  The message display means 403 displays a message notifying that the toner replenishing device 22 has become toner empty or a message prompting the user to replace the toner replenishing device 22 when the toner replenishing amount falls below a specified value (not shown). ) Is displayed.

  In this embodiment, the toner empty detecting means 400 monitors the toner concentration of the developer in the developing tank 111 with the toner replenishment detection sensor 119, and even after the toner replenishment instruction to the toner concentration control means, the toner replenishment is performed. When the detection sensor 119 cannot detect toner replenishment, it is determined that the toner is empty. Further, using the output difference of the toner replenishment detection sensor 119, it is determined that the toner is empty when the toner replenishment amount falls below a specified value.

Next, toner supply to the developing device 2 in the image forming apparatus 100 of the present embodiment will be described.
FIG. 9 is a graph based on a first-order approximation formula using the output difference of the toner replenishment detection sensor in the developing device of this embodiment.

  Toner replenishment to the developing device 2 in the image forming apparatus 100 is performed from the toner concentration control unit to the toner replenishing device 22 when the toner concentration of the developer in the developing tank 111 of the developing device 2 decreases and falls below a predetermined value. On the other hand, the developing device 2 is instructed to replenish toner, and the toner replenishing device 22 replenishes toner to the developing device 2.

  Toner supply into the developing tank 111 is detected by a toner supply detection sensor 119. Since the toner replenishment detection sensor 119 is disposed on the bottom surface of the first conveyance path P below the toner replenishment port 115a, when the toner is replenished to the developer from the toner replenishment port 115a, the magnetic permeability of the developer is immediately measured. Changes can be detected. That is, it is possible to immediately confirm whether or not the toner supply by the toner supply device 22 has been performed.

  Accordingly, when the toner concentration control means instructs the toner replenishing device 22 to replenish the toner, if the toner replenishment detection sensor 119 does not detect a change in the magnetic permeability of the developer, the toner replenishing device 22 sends the toner. It can be determined that replenishment is not performed. In other words, the empty detection means can immediately determine that the toner in the toner replenishing device 22 is empty (toner empty).

  Specifically, the output difference of the toner replenishment detection sensor 119 before and after toner replenishment by the toner replenishment device 22 acting in conjunction with the toner replenishment signal of the apparatus main body is stored in the storage means 401, and the toner replenishment detection sensor before and after toner replenishment. The output difference when the output of 119 changes is calculated, and the latest 5 to 10 values are stored in the memory.

  For example, as shown in FIG. 9, assuming that the sensor output before toner replenishment is B and the sensor output after toner replenishment is A, an output difference (ΔB−A) is calculated for each toner replenishment.

  As shown in FIG. 9, when the remaining amount of toner in the toner replenishing device 22 is large, the amount of falling toner is also stable and the output difference (ΔB−A) shows a high value. On the other hand, when the remaining amount of toner decreases, the output difference (ΔB−A) decreases and approaches “0”.

  As shown in FIG. 9, assuming that the specified level of the toner fall amount (toner replenishment amount) is Va, the output difference when the output of the toner replenishment detection sensor 119 is changed (timing Ta1) in the toner empty prediction unit 402. From the graph of the primary approximate expression f (x) obtained from the latest 5 to 10 values of (ΔB−A), the timing Ta2 at which the toner fall amount (toner replenishment amount) becomes equal to or less than the specified level Va (threshold) is determined in advance. To predict. The message display means 403 displays a toner empty detection or cartridge replacement message at timing Ta2.

  The primary approximate expression f (x) is a primary approximate expression during the period from the timing Ta1 to the timing Ta2.

  The toner empty detection unit 400 detects toner empty when the output difference (ΔB−A) of the toner replenishment detection sensor 119 falls below the specified level Va.

  In this embodiment, the output difference (ΔB−A) is used to detect that the output of the toner replenishment detection sensor 119 has changed, but the output ratio (ΔB−A) is used instead of the output difference (ΔB−A). B / A) may be used.

(Example)
Here, the detection of toner empty using the first-order approximate expression f (x) will be specifically described with an example.
FIG. 10 is a table showing an example of the accumulated toner replenishment time at the time of toner replenishment by the toner replenishing device and the value of the output difference of the toner replenishment detection sensor at that time, and FIG. 6 is a graph showing a relationship with accumulated toner replenishment time.

  In this embodiment, as shown in FIG. 10, since the cumulative toner replenishment time T when toner is replenished by the toner replenishing device 22 is 1,480 (sec), the value of the output difference (ΔB−A) of the toner replenishment detection sensor 119 is calculated. The first-order approximate expression f (x) is obtained from the 10 most recent data when the output difference of the toner replenishment detection sensor 119 is changed, and the toner empty timing is obtained.

  In this embodiment, when the specified level Va of the toner replenishment amount is 0.3 (V) and the specified level Va is 0.3 (V), that is, the toner empty timing Tx is expressed by the linear approximation formula f ( x).

  As shown in FIG. 10, when the cumulative toner replenishment time is 1,510 (sec), the value of the output difference (ΔB−A) of the toner replenishment detection sensor 119 becomes 0.35 (V). Assuming that the output difference of the sensor 119 has changed, a linear approximation formula f (x) is obtained from the data of the last 10 output differences (ΔB−A) as shown in FIG.

From the data of the last 10 output differences (ΔB−A), as a first-order approximation formula f (x),
f (x) = − 0.032x + 49.037
Is obtained.

The timing Tx at which the specified level Va becomes 0.3 (V) by the primary approximation formula f (x) is
x = 1523 (= Tx)
Is obtained.

  In this embodiment, when the cumulative toner replenishment time is 1,523 (sec), a message for replacing the toner empty or the toner replenishing device is displayed.

  As described above, according to the present embodiment, the output difference (ΔB−A) of the toner replenishment detection sensor 119 before and after toner replenishment by the toner replenishment device 22 is used as the toner empty detection unit 400 in the image forming apparatus 100. Alternatively, 1 obtained by using the storage unit 401 for storing the output ratio (B / A) and the stored output difference (ΔB−A) or output ratio (B / A) of the toner replenishment detection sensor 119. Toner empty predicting means 402 for predicting the timing when the toner replenishment amount falls below a specified value by the following approximate expression f (x), and when the toner replenishment amount falls below the specified value, the toner empty or the toner replenishing device is replaced. A message display means 403 for displaying a message, so that the toner density unevenness of the developer It is possible to prevent the toner empty from being erroneously detected and accurately detect that the toner replenishing device 22 does not have the replenishing toner. Furthermore, by notifying the user that the toner replenishing device 22 has no replenished toner and prompting the user to replace the toner replenishing device 22, occurrence of carrier adhesion due to a decrease in toner concentration in the developing tank 111 can be suppressed. .

  Further, according to the present embodiment, the toner replenishment amount becomes equal to or less than the specified value by using a primary approximation expression obtained from a plurality of latest output differences (ΔB−A) as the primary approximation expression f (x). Timing can be easily predicted.

  Further, according to the present embodiment, in the image forming apparatus 100, the toner replenishment detection sensor 119 is located near the toner replenishing port 115a of the developing device 2 and on the bottom surface of the first transport path P below the toner replenishing port 115a. Thus, it is possible to immediately detect that the magnetic permeability of the developer has changed when the toner is supplied by the toner supply device 22.

  Accordingly, when the toner concentration of the developer in the developing device 2 falls below a predetermined value, the toner replenishment detection sensor 119 is instructed when the toner concentration control means instructs the toner replenishing device 22 to replenish the toner. When the change in magnetic permeability is not detected, the empty detection unit can immediately determine that the toner in the toner replenishing device 22 is empty (toner empty). Thereby, when a toner image is formed on the photosensitive drum 3, it is possible to suppress the occurrence of carrier adhesion to the photosensitive drum 3 due to a decrease in toner density.

  In addition, according to the present embodiment, the first conveying member 112 is configured such that the inclination angle θ of the spiral blade is not less than 30 degrees and not more than 60 degrees, so that the developer is stirred in the rotation direction of the first conveying member 112. Therefore, the “floating toner” that is conveyed while the supplied toner floats on the developer is less likely to be generated. Thus, even after toner replenishment, the toner replenishment detection sensor 119 can accurately detect the change in the magnetic permeability of the developer.

  In the above-described embodiment, an example in which the configuration of the image forming apparatus according to the present invention is applied to the image forming apparatus 100 as shown in FIG. 1 has been described. As long as the image forming apparatus controls the toner density of the developer, the image forming apparatus is not limited to the image forming apparatus and the copying machine having the above-described configuration, and can be developed to other image forming apparatuses. is there.

  As described above, the present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the claims. That is, embodiments obtained by combining technical means appropriately changed within the scope not departing from the gist of the present invention are also included in the technical scope of the present invention.

1 Exposure unit (exposure equipment)
2 Developing device 3 Photosensitive drum 5 Charger (charging device)
8 Intermediate transfer belt unit (transfer device)
12 Fixing unit (fixing device)
22 toner replenishing device 32 control device 33 image forming counter 35 dot count device 36 image forming process unit 37 paper transport unit 100 image forming device 111 developing tank (developer containing unit)
112 First conveying member (developer conveying member)
112a First conveying blade 112b First rotating shaft 113 Second conveying member (developer conveying member)
114 Developing roller 115 Developing tank cover 115a Toner replenishment port 119 Toner replenishment detection sensor 341 Printer engine unit 400 Toner empty detection means 401 Storage means 402 Toner empty prediction means 403 Message display means θ Inclination angle P First transport path Q Second transport path f (x) First order approximate expression Ta1, Ta2, Tx Timing Va Specified level

Claims (1)

A developer container that contains a developer containing toner and a magnetic carrier, a developer conveying member that circulates and conveys the developer in the developer container, and photosensitive the toner contained in the developer. A developing roller that supplies the developing drum, a toner replenishing port that introduces replenished toner into the developer accommodating portion, a toner replenishing device that replenishes toner to the developing device, and the developer accommodating portion. A toner replenishment detection sensor for detecting whether or not toner is replenished; and a toner to the developing device when the toner concentration of the developer in the developing device falls below a predetermined value. Toner density control means for instructing replenishment, and when the toner replenishment detection sensor does not detect toner replenishment after the toner density control means has instructed toner replenishment, the toner An image forming apparatus comprising a toner empty detection means for determining the toner in the charging device is not, and
The toner empty detection means may perform the toner replenishment according to a first order approximate expression obtained from data of a plurality of recent output differences when the output difference of the toner replenishment detection sensor before and after toner replenishment by the toner replenishing device changes. A function of predicting a timing when the amount of toner replenishes below a specified value; and a function of displaying a message for replacing toner empty or the toner replenishing device when the amount of toner replenishment falls below a specified value. Image forming apparatus.

Images