JP6447092B2 - Toner amount detection device and image forming apparatus - Google Patents

Description

  The present invention relates to a toner amount detection device and an image forming apparatus using the same. The image forming apparatus includes various apparatuses such as a copying machine, a printer, a facsimile machine, and a multifunction machine having these functions in a complex manner.

  Conventionally, in an image forming apparatus adopting an electrophotographic method, a reflection type ultrasonic sensor has been employed as a means for non-contact detection of the amount of waste toner in a waste toner box and the amount of print toner in a toner bottle. There is something. In addition, for the purpose of improving the directivity of the ultrasonic sensor, a cylindrical sound wave reflector (directional horn) is often provided in the transmitter and the receiver constituting the ultrasonic sensor (for example, patents). Reference 1 etc.). In the ultrasonic sensor of Patent Document 1, a sound wave reflector having a common shape is used for the transmitter and the receiver.

JP 2006-350072 A

  However, in the configuration of Patent Document 1, since a sound wave reflector having a common shape is attached to both the transmitter and the receiver, for example, the surface of the toner in a toner container such as a waste toner box or a toner bottle and both sound wave reflectors. If the distance to the toner surface is too close, it becomes difficult to receive the ultrasonic wave reflected from the toner surface by the receiver, and the distance from the ultrasonic sensor to the toner surface and thus the amount of toner in the toner container may not be detected.

  The present invention has been made in view of such a current situation, and has a technical problem to further improve the toner amount detection performance in the toner container by the reflection type ultrasonic sensor.

  The invention of claim 1 comprises a reflection type ultrasonic sensor comprising a transmitter for transmitting ultrasonic waves toward a toner surface in a toner container and a receiver for receiving ultrasonic waves reflected from the toner surface, In the toner amount detection device for detecting the toner amount in the toner container based on the reception result of the receiver, a sound wave reflector extending toward at least the transmitter of the transmitter and the receiver toward a bottom portion in the toner container The transmitter of the sound wave reflector on the transmitter side is closer to the bottom in the toner container than the receiver itself or the receiver port of the sound wave reflector on the receiver side. It is.

  According to a second aspect of the present invention, in the toner amount detection device according to the first aspect, the length in the extending direction of the sound wave reflector on the transmitter side is equal to or greater than the dead distance of the receiver. is there.

  According to a third aspect of the present invention, in the toner amount detection device according to the first or second aspect, the transmitter and the receiver are arranged close to each other.

  According to a fourth aspect of the present invention, there is provided the toner amount detection device according to any one of the first to third aspects, further comprising a leveling member for leveling a toner surface in the toner container, wherein the toner is detected using the ultrasonic sensor. When detecting the amount of toner in the container, the leveling member is operated before the ultrasonic sensor is operated.

According to a fifth aspect of the present invention, in the toner amount detection device according to any one of the first to fourth aspects, the sound wave reflector is integrally provided in the toner container.
A sixth aspect of the present invention is the toner amount detection device according to any one of the first to fifth aspects, further comprising an ultrasonic control unit that controls the ultrasonic sensor, wherein the ultrasonic control unit is the transmitter. The time from when the ultrasonic wave is transmitted until the ultrasonic wave reflected from the toner surface is received by the receiver is detected, and the toner amount in the toner container is calculated using the time.

  A seventh aspect of the present invention is the toner amount detection device according to the sixth aspect, wherein the toner container is a toner bottle that stores printing toner, and the position of the transmission port of the sound wave reflector on the transmitter side is This corresponds to the position of the toner surface when the print toner in the toner bottle is in a very small state.

  According to an eighth aspect of the present invention, in the toner amount detection device according to the seventh aspect, the ultrasonic control unit receives the ultrasonic wave reflected from the toner surface after the ultrasonic wave is transmitted by the transmitter by the receiver. For example, it is determined that the printing toner in the toner bottle is in a very small state.

  According to a ninth aspect of the present invention, in the toner amount detection device according to the sixth aspect, the toner container is a waste toner box for storing waste toner, and the position of the transmission port of the sound wave reflector on the transmitter side is: This corresponds to the position of the toner surface when the waste toner in the waste toner box is full.

  According to a tenth aspect of the present invention, in the toner amount detection device according to the ninth aspect, the ultrasonic control unit receives the ultrasonic wave reflected from the toner surface after the ultrasonic wave is transmitted by the transmitter by the receiver. Otherwise, it is determined that the waste toner in the waste toner box is full.

  According to an eleventh aspect of the present invention, in the toner amount detection apparatus according to the sixth aspect, the toner container is a toner bottle that stores printing toner and a waste toner box that stores waste toner, and the ultrasonic control unit Calculates the amount of print toner in the toner bottle using the ultrasonic sensor on the toner bottle side, and determines the amount of waste toner that can be collected in the waste toner box using the ultrasonic sensor on the waste toner box side. The smaller number of printable sheets is displayed on the display unit that displays the various information by calculating and comparing the printable sheet number based on the print toner amount and the printable sheet number based on the waste toner collection amount. That's it.

  A twelfth aspect of the present invention relates to an image forming apparatus, and includes the toner amount detection device according to any one of the first to eleventh aspects.

  According to the present invention, a reflection type ultrasonic sensor comprising a transmitter for transmitting ultrasonic waves toward the toner surface in a toner container and a receiver for receiving ultrasonic waves reflected from the toner surface is provided. In the toner amount detection device for detecting the toner amount in the toner container based on a reception result, a sound wave reflector extending toward a bottom portion in the toner container is attached to at least the transmitter of the transmitter and the receiver. The transmission port of the sound wave reflector on the transmitter side is closer to the bottom of the toner container than the reception port of the sound wave reflector on the receiver itself or the receiver side. Even if the distance between the toner surface in the container and the transmission port of the sound wave reflector on the transmitter side is short, the receiver itself or the reception port of the sound wave reflector on the receiver side Serial secured a distance to the surface of the toner tends to receive ultrasonic waves reflected the toner surface with the receiver. Therefore, in addition to improving the directivity of the ultrasonic sensor, the toner amount in the toner container can be detected with higher accuracy.

It is a schematic explanatory drawing of a printer. 2 is a functional block diagram of a printer. FIG. It is a schematic explanatory drawing of the arrangement structure of the ultrasonic sensor for printing in the 1st example. It is a schematic explanatory drawing of the arrangement structure of the printing ultrasonic sensor in 2nd Example. It is a schematic sectional drawing of the arrangement structure of the ultrasonic sensor for disposal in 3rd Example. It is a schematic sectional drawing of the arrangement structure of the ultrasonic sensor for disposal in 4th Example. 10 is a flowchart of toner amount detection processing in a fifth embodiment. It is a schematic sectional drawing which shows the structure of the ultrasonic sensor for printing in 6th Example. 14 is a flowchart of toner amount detection processing in a seventh embodiment. It is a schematic sectional drawing which shows the structure of the ultrasonic sensor for disposal in 8th Example. It is a flowchart of the toner amount detection process in the ninth embodiment. It is a table | surface table of the toner required amount and toner density for every printing condition in 10th Example. It is a schematic sectional drawing which shows the structure of the ultrasonic sensor for disposal in 11th Example.

  Hereinafter, an embodiment embodying the present invention will be described with reference to the drawings when applied to a tandem color digital printer (hereinafter referred to as a printer) which is an example of an image forming apparatus. In addition, in the following description, when using a term indicating a specific direction or position (for example, “left / right”, “up / down”, etc.) as necessary, the direction orthogonal to the paper surface in FIG. ing. These terms are used for convenience of explanation, and do not limit the technical scope of the present invention.

  First, the outline of the printer 1 will be described with reference to FIG. As shown in FIG. 1, the printer 1 includes an image process device 3, a paper feeding device 4, a fixing device 5, and the like in a housing 2. Although not shown in detail, the printer 1 is connected to a network such as a LAN, and is configured to execute printing based on the command when receiving a print command from an external terminal (not shown). Yes.

  The paper feeding device 4 located at the lower part in the housing 2 includes a paper feeding cassette 21 that accommodates the recording material P, a pickup roller 22 that feeds the recording material P in the paper feeding cassette 21 from the uppermost layer, and a fed recording material P. A pair of separation rollers 23 for separating the recording materials one by one, a pair of timing rollers 24 for conveying the recording material P separated into one sheet to the image processing apparatus 3 at a predetermined timing, and the like. The recording material P in each paper feed cassette 21 is sent out one by one from the uppermost layer to the conveyance path 30 by the rotation of the pickup roller 22 and the separation roller 23. The conveyance path 30 passes from the paper feeding cassette 21 of the paper feeding device 4 to the upper portion of the housing 2 through the nip portion of the timing roller pair 24, the secondary transfer nip portion of the image processing device 3, and the fixing nip portion of the fixing device 5. To the discharge roller pair 26 at

  The recording material P in the paper feed cassette 21 is set to a center reference that is conveyed in the arrow S direction toward the conveyance path 30 with the center of the sheet passing width (width dimension orthogonal to the arrow S direction) as a reference. Although not shown, the paper feed cassette 21 is provided with a pair of side portion regulating plates for bringing the recording material P before paper feeding into the center reference. The pair of side part restricting plates are configured to move in close proximity to each other in the sheet passing width direction. By sandwiching the recording material P in the paper feed cassette 21 from both sides in the sheet passing width direction by the pair of side portion regulating plates, the recording material P in the paper feed cassette 21 is set to the center reference regardless of the standard. Therefore, the transfer process in the image processing apparatus 3 and the fixing process in the fixing apparatus 5 are also executed on the basis of the center.

  The image processing device 3 positioned above the paper feeding device 4 plays a role of transferring a toner image formed on a photosensitive drum 13 which is an example of an image carrier to a recording material P, and is an intermediate transfer member. And a total of four image forming sections 7 corresponding to the respective colors of yellow (Y), magenta (M), cyan (C) and black (K).

  The intermediate transfer belt 6 is an endless belt made of a conductive material, and is also an example of an image carrier. The intermediate transfer belt 6 is wound around a driving roller 8 located on the right side of the central part in the housing 2 and a driven roller 9 located on the left side of the central part. A secondary transfer roller 10 is disposed outside the portion of the intermediate transfer belt 6 that is wound around the drive roller 8. The intermediate transfer belt 6 rotates in the counterclockwise direction in FIG. 1 by rotating the driving roller 8 counterclockwise in FIG. 1 by power transmission from a main motor (not shown).

  A secondary transfer roller 10 is disposed on the outer peripheral side of the portion of the intermediate transfer belt 6 that is wound around the drive roller 8. The secondary transfer roller 10 is in contact with the intermediate transfer belt 6, and a portion between the intermediate transfer belt 6 and the secondary transfer roller 10 (contact portion) is a secondary transfer nip portion as a secondary transfer region. . The secondary transfer roller 10 rotates in the clockwise direction in FIG. 1 with the rotation of the intermediate transfer belt 6 or with the movement of the recording material P that is nipped and conveyed by the secondary transfer nip portion. A transfer belt cleaner 12 for removing untransferred toner on the intermediate transfer belt 6 is disposed on the outer peripheral side of the portion of the intermediate transfer belt 6 wound around the driven roller 9. The transfer belt cleaner 12 is in contact with the intermediate transfer belt 6.

  The four image forming units 7 are arranged along the intermediate transfer belt 6 in the order of yellow (Y), magenta (M), cyan (C), and black (K) from the left in FIG. They are arranged side by side. In FIG. 1, for convenience of explanation, symbols Y, M, C, and K are attached to each image forming unit 7 according to the reproduction color. Each image forming unit 7 includes a photosensitive drum 13 as an example of an image carrier that rotates clockwise in FIG. Around the photosensitive drum 13, a charging device 14, an exposure device 19, a developing device 15, a primary transfer roller 16, and a photosensitive cleaner 17 are arranged in this order along the clockwise rotation direction in FIG. 1.

  The photosensitive drum 13 is negatively charged and is configured to rotate clockwise in FIG. 1 by power transmission from the main motor. The charging device 14 uniformly charges the surface of the photosensitive drum. The developing device 15 makes the electrostatic latent image formed on the photosensitive drum 13 visible by reversal development using toner having a negative polarity.

  The primary transfer roller 16 is located on the inner peripheral side of the intermediate transfer belt 6 and faces the photosensitive drum 13 of the corresponding image forming unit 7 with the intermediate transfer belt 6 interposed therebetween. The primary transfer roller 16 also rotates counterclockwise in FIG. 1 as the intermediate transfer belt 6 rotates. Between the intermediate transfer belt 6 and the primary transfer roller 16 (contact portion) is a primary transfer nip portion as a primary transfer region. The photoreceptor cleaner 17 is for removing untransferred toner remaining on the photoreceptor drum 13, and is in contact with the photoreceptor drum 13. An exposure device 19 is disposed below the four image forming units 7. The exposure device 19 forms an electrostatic latent image on each photosensitive drum 13 by laser light based on image information from an external terminal or the like.

  Above the intermediate transfer belt 6, bottle accommodating portions 39 corresponding to the respective image forming portions 7 (reproduced colors) are provided. A toner bottle 40 that stores printing toner supplied to each developing device 15 is detachably disposed in the bottle storage unit 39. The toner bottle 40 is an example of a toner container. In FIG. 1, for convenience of explanation, the bottle accommodating portion 39 and the toner bottle 40 are also denoted by symbols Y, M, C, and K according to the reproduced colors.

  Each toner bottle 40 has a reflection type printing including a transmitter 42 that transmits ultrasonic waves toward the surface of the printing toner in the toner bottle 40 and a receiver 43 that receives ultrasonic waves reflected from the surface of the printing toner. The ultrasonic sensor 41 is provided. After transmitting ultrasonic waves with the transmitter 42, the ultrasonic waves reflected from the print toner surface are received by the receiver 43, and the amount of print toner in the toner bottle 40 is detected based on the reception result.

  In each image forming unit 7, when a laser beam corresponding to an image signal is projected from the exposure device 19 onto the photosensitive drum 13 charged by the charging device 14, an electrostatic latent image is formed. The electrostatic latent image is reversely developed with toner supplied from the developing device 15 and becomes a toner image of each color. The toner images on the respective photosensitive drums 13 are primarily transferred from the photosensitive drum 13 to the outer peripheral surface of the intermediate transfer belt 6 in the order of yellow, magenta, cyan, and black at the corresponding primary transfer nip portions, and are superimposed. . Untransferred toner remaining on the photosensitive drum 13 is scraped off by the photosensitive cleaner 17 and removed from the photosensitive drum 13. When the recording material P passes through the secondary transfer nip portion, the superimposed four color toner images are secondarily transferred onto the recording material P all at once. Untransferred toner remaining on the intermediate transfer belt 6 is scraped off by the transfer belt cleaner 12 and removed from the intermediate transfer belt 6.

  The fixing device 5 positioned above the secondary transfer roller 10 in the image processing apparatus 3 includes a fixing roller 31 incorporating a heat source such as a halogen lamp heater, and a pressure roller 32 facing the fixing roller 31. A contact portion between the fixing roller 31 and the pressure roller 32 is a fixing nip portion which is a fixing region. The recording material P on which the unfixed toner image is passed through the secondary transfer nip portion is heated and pressurized when passing through the fixing nip portion between the fixing roller 31 and the pressure roller 32, and the recording material P An unfixed toner image is fixed thereon. Thereafter, the recording material P is discharged onto the paper discharge tray 27 by the rotation of the discharge roller pair 26.

  A waste toner box 50 that collects waste toner removed by the transfer belt cleaner 12 and each photoconductor cleaner 17 is detachably mounted on the front side (front side) of the image processing apparatus 3 in the housing 2. Yes. The waste toner box 50 is also an example of a toner container, like the toner bottle 40. The waste toner box 50 is a reflective type comprising a transmitter 52 for transmitting ultrasonic waves toward the waste toner surface in the waste toner box 50 and a receiver 53 for receiving ultrasonic waves reflected from the waste toner surface. A disposal ultrasonic sensor 51 is provided. Also in this case, after transmitting the ultrasonic wave by the transmitter 52, the ultrasonic wave reflected from the surface of the waste toner is received by the receiver 53, and the amount of waste toner in the waste toner box 50 is detected based on the reception result. .

  A control unit 28 that performs overall control of the printer 1 is disposed between the image processing apparatus 3 and the sheet feeding apparatus 4 in the housing 2. The controller 28 has a built-in controller 60 having an ultrasonic control unit 62 for controlling each printing ultrasonic sensor 41 and disposal ultrasonic sensor 51. FIG. 2 shows a functional block diagram of the controller 60. The controller 60 includes a storage unit 61 that stores image data, various setting values, and the like, an ultrasonic control unit 62 that controls each ultrasonic sensor 41 for printing and the ultrasonic sensor 51 for disposal, and a display unit that displays various information. An operation panel 63, a bottle driving motor 45 for rotating the toner bottle 40, a conveying screw driving motor 64 for rotating a conveying screw 54 group described later, an equalizing screw driving motor 65 for rotating an equalizing screw 55 described later, and bottle storage A bottle sensor 66 that detects whether or not the toner bottle 40 is attached to the part 39, a temperature sensor 67 that detects the temperature of each part in the housing 2, and the like are electrically connected. Each printing ultrasonic sensor 41 and disposal ultrasonic sensor 51 are electrically connected to an ultrasonic control unit 62.

  Although illustration is omitted, the operation panel 63 is provided on the front side (front side) of the housing 2 in the printer 1. The printing ultrasonic sensor 41, the bottle sensor 66, and the bottle drive motor 45 described above are provided corresponding to the developing device 15 for each reproduction color. The toner supply based on the detection result of each printing ultrasonic sensor 41 is controlled independently for each color toner.

  FIG. 3 is a first embodiment showing an arrangement structure of the printing ultrasonic sensor 41 with respect to the toner bottle 40. In the first embodiment, one end of the toner bottle 40 is detachably attached to the toner supply unit 44 provided in the bottle housing unit 39. The other end side of the toner bottle 40 is connected to the bottle drive motor 45 so as to be able to transmit power while being accommodated in the bottle accommodating portion 39. By continuously rotating and driving the toner bottle 40 by the bottle drive motor 45, the print toner in the toner bottle 40 is supplied from the toner supply unit 44 of the bottle storage unit 39 to the developing device 15 corresponding thereto.

  The bottle drive motor 45 also functions as a leveling member that levels the surface of the print toner in the toner bottle 40. By rotating and driving the toner bottle 40 about several times by the bottle driving motor 45, the surface of the printing toner in the toner bottle 40 is smoothed as smoothly as possible. When the amount of print toner in the toner bottle 40 is detected using the printing ultrasonic sensor 41, the bottle driving motor 45 is operated before the printing ultrasonic sensor 41 is operated to make the surface of the printing toner as possible as possible. It is configured to be smooth.

  The printing ultrasonic sensor 41 of the first embodiment includes a substrate body 46 that can be taken in and out through an opening (not shown) formed in the upper portion of a non-driven toner supply unit 44. The transmitter 42 and the receiver 43 are arranged close to each other on the protruding end side of the substrate body 46. In the first embodiment, a sound wave reflector 47 extending toward the bottom 40 a in the toner bottle 40 is attached to the transmitter 42. The sound wave emitter 47 is formed in a cylindrical shape that expands toward the transmission port 47a that opens toward the bottom 40a in the toner bottle 40. By moving the substrate body 46 in and out, the transmitter 42 and the receiver 43 with the sound wave reflector 47 can be taken in and out of the toner bottle 40 through the opening of the toner supply unit 44.

  In the first embodiment, the transmission port 47a of the sound wave reflector 47 on the transmitter 42 side is closer to the bottom 40a in the toner bottle 40 than the receiver 43 itself. Normally, the receiver 43 has a predetermined length of insensitive distance DD caused by the reverberation of ultrasonic transmission from the transmitter 42. For this reason, the length Lt in the extending direction of the sound wave reflector 47 on the transmitter 42 side is set to be equal to or greater than the dead distance DD of the receiver 43.

  According to the above configuration, the sound wave reflector 47 extending toward the bottom 40 a in the toner bottle 40 is attached to the transmitter 42 of the printing ultrasonic sensor 41, and the sound emission port 47 a of the sound wave reflector 47 on the transmitter 42 side. Is closer to the bottom 40a in the toner bottle 40 than the receiver 43 itself, so that the distance between the print toner surface in the toner bottle 40 and the transmission port 47a of the sound wave reflector 47 on the transmitter 42 side is short. Even so, the distance from the receiver 43 itself to the print toner surface can be secured, and the receiver 43 can easily receive the ultrasonic waves reflected from the print toner surface. Therefore, the amount of print toner in the toner bottle 40 can be detected with higher accuracy while improving the directivity of the printing ultrasonic sensor 41.

  Further, since the length Lt in the extending direction of the sound wave reflector 47 on the transmitter 42 side is equal to or greater than the dead distance DD of the receiver 43, it is affected by the reverberation of the ultrasonic wave transmission at the transmitter 42. Therefore, the ultrasonic wave reflected from the surface of the printing toner can be accurately received by the receiver 43. In addition, since the transmitter 42 and the receiver 43 are arranged close to each other, the printing toner is considered in consideration of the reflection characteristics of the ultrasonic wave while improving the directivity of the printing ultrasonic sensor 41. The ultrasonic wave reflected from the surface can be received more reliably by the receiver 43. Further, a bottle driving motor 45 as a leveling member for leveling the printing toner surface in the toner bottle 40 is provided, and when the amount of printing toner in the toner bottle 40 is detected using the printing ultrasonic sensor 41, Before the operation of the ultrasonic sensor 41, the bottle drive motor 45 rotates the toner bottle 40 several times, so that the surface of the printing toner is smoothed as much as possible, and the ultrasonic wave transmitted from the transmitter 42 is more The surface of the printing toner can be reflected stably, and the printing toner amount in the toner bottle 40 can be detected more accurately.

  FIG. 4 is a second embodiment showing an arrangement structure of the printing ultrasonic sensor 41 with respect to the toner bottle 40. In the second embodiment, not only the toner supply unit 44 but also the toner bottle 40 itself is not driven. A mounting port 40 b penetrating in the vertical direction is formed in the upper portion of the toner bottle 40. The mounting opening 40b of the toner bottle 40 is closed by a shutter member 49 so as to be opened and closed. In the bottle accommodating portion 39, a substrate body 46 that can be fitted into the mounting opening 40b is provided above the mounting opening 40b of the toner bottle 40 so as to be movable up and down. On the lower surface side of the substrate body 46, the transmitter 42 and the receiver 43 are arranged close to each other.

  In the second embodiment, sound wave reflectors 47 and 48 extending toward the bottom 40 a in the toner bottle 40 are attached to both the transmitter 42 and the receiver 43. The sound wave emitter 47 on the transmitter 42 side is formed in a cylindrical shape that becomes wider toward the transmitter 47 a that opens toward the bottom 40 a in the toner bottle 40. The sound wave emitter 48 on the receiver 43 side is formed in a cylindrical shape that expands toward the reception port 48 a that opens toward the bottom 40 a in the toner bottle 40. The substrate main body 46, the transmitter 42 with the sound wave reflector 47, and the receiver 43 with the sound wave reflector 48 constitute the ultrasonic sensor 41 for printing of the second embodiment.

  When the amount of print toner in the toner bottle 40 is detected using the print ultrasonic sensor 41, the substrate member 46 (printing ultrasonic sensor 41) is moved downward after the shutter member 49 is opened and operated. The printing ultrasonic sensor 41 is fitted into the mounting opening 40 b of the toner bottle 40. When the amount of printing toner is not detected, the substrate body 46 (printing ultrasonic sensor 41) is moved up and held at the raised position, and the shutter member 49 is closed to close the mounting opening 40b.

  In the state in which the ultrasonic sensor 41 for printing is fitted in the mounting opening 40b, the transmission port 47a of the sound wave reflector 47 on the transmitter 42 side is more than the reception port 48a of the sound wave reflector 48 on the receiver 43 side. It is close to the bottom 40 a in the toner bottle 40. The length Lt in the extending direction of the sound wave reflector 47 on the transmitter 42 side is longer than the length Lr in the extending direction of the sound wave reflector 48 on the receiver 43 side. Other configurations are basically the same as those of the first embodiment. Even when configured as in the second embodiment, the same effects as in the first embodiment can be obtained.

  FIG. 5 is a third embodiment showing an arrangement structure of the disposal ultrasonic sensor 51 with respect to the waste toner box 50. The waste toner box 50 according to the third embodiment has a substantially hollow box shape for storing waste toner (untransferred toner) removed from each photosensitive drum 13 and the intermediate transfer belt 6. The waste toner box 50 is connected to the photoreceptor cleaner 17 and the transfer belt cleaner 12 of each image forming unit 7 via each conveying screw 54. Each conveyance screw 54 is connected to a common conveyance screw drive motor 64 so that power can be transmitted. By rotating each conveyance screw 54 by the conveyance screw drive motor 64, waste toner is sent to the waste toner box 50 from each photoconductor cleaner 17 and the transfer belt cleaner.

  The waste toner box 50 includes a leveling screw 55 as a leveling member that transports the waste toner in the waste toner box 50. Each leveling screw 55 is connected to a leveling screw drive motor 65 so that power can be transmitted. By rotating the leveling screw 55 by the leveling screw drive motor 65, the waste toner in the waste toner box 50 is stirred and spread, and the surface of the waste toner is leveled as smoothly as possible. When detecting the amount of waste toner in the waste toner box 50 using the waste ultrasonic sensor 51, the waste screw surface is made as much as possible by rotating the leveling screw 55 before the operation of the waste ultrasonic sensor 51. It is configured to level out smoothly.

  A mounting hole 50 b penetrating in the vertical direction is formed on the upper surface of the waste toner box 50. A mounting hole 50 b of the waste toner box 50 is closed by a substrate body 56 constituting the disposal ultrasonic sensor 50. On the lower surface side of the substrate body 56, the transmitter 52 and the receiver 53 are arranged close to each other in a state of protruding into the waste toner box 50.

  In the third embodiment, a sound wave reflector 57 extending toward the bottom 50 a in the waste toner box 50 is attached to the transmitter 52. The sound wave emitter 57 is formed in a cylindrical shape that expands toward the transmission port 57a that opens toward the bottom 50a in the waste toner box 50. The transmitting port 57a of the sound wave reflector 57 on the transmitter 52 side is closer to the bottom 50a in the waste toner box 50 than the receiver 53 itself. The length Lt in the extending direction of the sound wave reflector 57 on the transmitter 52 side is set to be equal to or greater than the dead distance DD of the receiver 53.

  According to the above configuration, the sound wave reflector 57 extending toward the bottom 50 a in the waste toner box 50 is attached to the transmitter 52 of the waste ultrasonic sensor 51, and the sound wave outlet of the sound wave reflector 57 on the transmitter 52 side is attached. Since 57a is closer to the bottom 50a in the waste toner box 50 than the receiver 53 itself, the distance between the waste toner surface in the waste toner box 50 and the transmission port 57a of the sound wave reflector 57 on the transmitter 52 side. Even when is close, the distance from the receiver 53 itself to the waste toner surface can be secured, and the receiver 53 can easily receive the ultrasonic waves reflected from the waste toner surface. Therefore, the amount of waste toner in the waste toner box 50 can be detected with higher accuracy while improving the directivity of the waste ultrasonic sensor 51.

  In addition, since the length Lt in the extending direction of the sound wave reflector 57 on the transmitter 52 side is equal to or greater than the dead distance DD of the receiver 53, it is affected by the reverberation of the ultrasonic transmission at the transmitter 52. The receiver 53 can accurately receive the ultrasonic wave reflected from the waste toner surface. In addition, since the transmitter 52 and the receiver 53 are arranged close to each other, the waste toner is considered in consideration of the reflection characteristics of the ultrasonic wave while improving the directivity of the waste ultrasonic sensor 51. The ultrasonic wave reflected from the surface can be received more reliably by the receiver 53. Furthermore, when a leveling screw 55 as a leveling member for leveling the waste toner surface in the waste toner box 50 is provided and the waste toner amount in the waste toner box 50 is detected using the waste ultrasonic sensor 51, Since the waste toner surface is smoothed as much as possible by the rotation of the leveling screw 55 before the operation of the waste ultrasonic sensor 51, the ultrasonic wave transmitted from the transmitter 52 reflects the waste toner surface more stably. In addition, the detection accuracy of the amount of waste toner in the waste toner box 50 can be improved.

  FIG. 6 is a fourth embodiment showing an arrangement structure of the disposal ultrasonic sensor 51 with respect to the waste toner box 50. In the fourth embodiment, sound wave reflectors 57 and 58 extending toward the bottom 50 a in the waste toner box 50 are attached to both the transmitter 52 and the receiver 53. The sound wave emitter 57 on the transmitter 52 side is formed in a cylindrical shape that expands toward the transmitter port 57 a that opens toward the bottom 50 a in the waste toner box 50. The sound wave emitter 58 on the receiver 53 side is formed in a cylindrical shape that expands toward the reception port 58 a that opens toward the bottom 50 a in the waste toner box 50. The substrate main body 56, the transmitter 52 with the sound wave reflector 57, and the receiver 53 with the sound wave reflector 58 constitute the disposal ultrasonic sensor 51 of the fourth embodiment.

  The transmission port 57a of the sound wave reflector 57 on the transmitter 52 side is closer to the bottom 50a in the waste toner box 50 than the reception port 58a of the sound wave reflector 58 on the receiver 53 side. That is, the length Lt in the extending direction of the sound wave reflector 57 on the transmitter 52 side is longer than the length Lr in the extending direction of the sound wave reflector 58 on the receiver 53 side. Other configurations are basically the same as those of the third embodiment. Even when configured as in the fourth embodiment, the same effects as in the third embodiment can be obtained.

  The flowchart in FIG. 7 is a fifth embodiment illustrating the toner amount detection processing by the ultrasonic sensors 41 and 51. The toner amount detection process can be applied to both the printing ultrasonic sensors 41 of the first and second embodiments and the discarding ultrasonic sensor 51 of the third and fourth embodiments. Now, description will be made by taking the printing ultrasonic sensor 41 of the first embodiment as an example.

  After starting the print toner amount detection process, the ultrasonic control unit 62 first determines whether it is the detection timing (S01). Examples of the detection timing in this case include an example in which the printing toner surface is smoothed and smoothed by the operation of the bottle driving motor 45, and during the printing operation or after the printing is completed. Of course, any timing can be set. If it is the detection timing (S01: YES), an ultrasonic wave is transmitted from the transmitter 42 toward the print toner surface, and the transmission start time is set to t0 (S02).

  Then, if the receiver 43 does not receive the ultrasonic wave reflected from the print toner surface even when the preset time-out time is reached (S04: YES), the process ends as it is, but if the ultrasonic wave is received by the receiver 43 ( (S03: YES), the time t1 required for the reception is stored in the storage unit 61 (S05), and from the ultrasonic sensor 41 for printing based on t1-t0 (seconds) that is the time from the ultrasonic transmission to the reception. The distance L (m) = 346 × (t1−t0) / 2 to the print toner surface is calculated (S06). Here, the speed of sound in the air at 25 ° C. is 346 (m / s). Note that the sound speed value may be corrected by the temperature inside the housing 2 detected by the temperature sensor 67, and the calculation accuracy of the distance L may be improved. For example, the relationship between temperature and sound speed is stored in the storage unit 61, and if the detected temperature is 50 ° C., 360 (m / s) is used as the sound speed value.

  Thereafter, the print toner amount in the toner bottle 40 is calculated based on the distance L calculated in S06 (S07). In this case, the print toner amount may be calculated from a calculation formula based on the volume of the toner bottle 40 that can be grasped in advance, or a table indicating the relationship between the distance L and the print toner amount is stored in the storage unit in advance. The print toner amount may be obtained by referring to this. By controlling in this way, the print toner amount in the toner bottle 40 is obtained based on the time from ultrasonic transmission to reception, so that the print toner amount can be calculated in detail.

  FIGS. 8A and 8B are a sixth embodiment showing the structure of the sound wave reflector 47 of the ultrasonic sensor 41 for printing. (A) is a diagram in a normal state where the print toner is still sufficient, and (b) is a diagram in which the print toner is scarce. In the sixth embodiment, the length Lt in the extending direction of the sound wave reflector 47 on the transmitter 42 side is extended so that the light emission port 47a of the sound wave reflector 47 faces the bottom 40a in the toner bottle 40. (I'm confronted.) The position of the transmission port 47a of the sound wave reflector 47 on the transmitter 42 side corresponds to the position of the surface of the print toner when the print toner in the toner bottle 40 is in a very small state (near empty state near the toner shortage). Yes. Here, the insignificant state indicates when the amount of print toner is equal to or less than a predetermined value corresponding to a slight amount.

  With this configuration, if the print toner is sufficient, the transmitter 47 a of the sound wave reflector 47 is immersed in the print toner, so that the ultrasonic wave transmitted by the transmitter 42 is not received by the receiver 43. When the print toner becomes insignificant, the transmission port 47a of the sonic reflector 47 is exposed from the surface of the print toner and is spaced from each other. Therefore, the ultrasonic wave transmitted from the transmitter 42 reflects the print toner surface and receives the receiver 43. Received at. Due to the structure (form) of the sonic reflector 47, the low state of the print toner can be accurately detected, and the reliability of the low state detection of the print toner by the printing ultrasonic sensor 41 can be improved.

  The flowchart of FIG. 9 is a seventh embodiment showing a toner amount detection process in the printing ultrasonic sensor 41 of the sixth embodiment. In the seventh embodiment, after starting the print toner amount detection process, the ultrasonic control unit 62 first determines whether or not it is the detection timing (S11), and if it is the detection timing (S11: YES), the print toner is determined. It is determined whether or not an empty flag indicating a slight state is set (S12). If the empty flag is not set (S12: NO), an ultrasonic test is transmitted from the transmitter 42 toward the print toner surface (S13).

  If the ultrasonic wave reflected from the print toner surface is not received by the receiver 43 even after the preset set time (S14: NO), the transmission port 47a of the sound wave reflector 47 is immersed in the print toner and printed. Since the toner is in the normal state, the process ends as it is. However, if the ultrasonic wave is received by the receiver 43 (S14: YES), an empty flag is set (S15). The subsequent flow is the same as that after step S02 in the fifth embodiment (FIG. 7). However, if the test transmission is received but the ultrasonic transmission cannot be received again by the receiver 43 even when the time-out period is reached (S18: YES), the empty flag is reset (S19) and the process is terminated.

  By controlling in this way, it is only necessary to determine the amount of print toner in the toner bottle 40 between the low state and the empty state of the print toner, so that it is not necessary to frequently operate the ultrasonic sensor 41 for printing. The load of the sound wave control unit 62 can be reduced.

  FIGS. 10A and 10B show an eighth embodiment showing the structure of the sound wave reflector 57 of the discarding ultrasonic sensor 51. (A) is a diagram in a normal state where the waste toner can be sufficiently accommodated, and (b) is a diagram in a state where the waste toner is full. In the eighth embodiment, the length Lt in the extending direction of the sound wave reflector 57 on the transmitter 52 side is shortened. The position of the transmission port 57a of the sound wave reflector 57 is made to correspond to the position of the waste toner surface when the waste toner in the waste toner box 50 is full. Here, the full state indicates when the amount of waste toner becomes equal to or greater than a predetermined value corresponding to full.

  With this configuration, if the amount of waste toner is still small, the transmission port 57a of the sonic reflector 57 is exposed from the surface of the waste toner and is spaced from the surface of the waste toner. Is reflected and received by the receiver 53. When the waste toner is full, the transmission port 57a of the sonic reflector 57 is immersed in the waste toner, so that the ultrasonic wave transmitted from the transmitter 52 cannot be received by the receiver 53. Therefore, the waste toner full state can be accurately detected due to the structure (form) of the sonic reflector 57, and the reliability of the waste toner full state detection by the waste ultrasonic sensor 51 can be improved.

  The flowchart of FIG. 11 is a ninth embodiment showing a toner amount detection process in the disposal ultrasonic sensor 51 of the eighth embodiment. The basic flow of the ninth embodiment is the same as that of the fifth embodiment (FIG. 7). However, if the ultrasonic wave transmission cannot be received by the receiver 53 even when the time-out period is reached (S34: YES), it is determined that the waste toner is full (S35) and the process ends. By controlling in this way, the waste toner full state can be grasped only by non-detection of the ultrasonic wave at the receiver 53, so that the load on the ultrasonic control unit 62 can be reduced.

  The table shown in FIG. 12 is a tenth embodiment showing the required amount of toner and the toner density for each printing condition such as the recording material size and color / monochrome. The table of the tenth embodiment is stored in the storage unit 61 in advance. In the tenth embodiment, the ultrasonic control unit 62 calculates the print toner amount in each toner bottle 40 using each printing ultrasonic sensor 41 and also uses the waste ultrasonic sensor 51 to discard the waste toner box 50. The amount of waste toner is calculated. Then, a waste toner recoverable amount is obtained from the relationship between the waste toner amount and the volume of the toner bottle 40. Next, the table table in the storage unit 61 is read, and the number of printable sheets based on the print toner amount is calculated based on the print toner required amount and print toner density in the table table and the previously calculated print toner amount. Based on the waste toner generation amount and waste toner density in the table and the waste toner recoverable amount calculated earlier, the number of printable sheets is calculated based on the waste toner recoverable amount as a reference. Then, compare the number of printable sheets based on the print toner amount and the number of printable sheets based on the waste toner recoverable amount, and compare the smaller number of printable sheets and the standard toner amount (print toner amount or waste toner recoverable) Amount) is displayed on the operation panel 63. By controlling in this way, the user who uses the printer 1 can grasp in advance the number of printable sheets in the future, the replacement timing of each toner bottle 40 and the waste toner box 50, and the usability of the printer 1 is improved.

  FIGS. 13A and 13B show an eleventh embodiment showing the structure of the sound wave reflectors 57 and 58 of the discarding ultrasonic sensor 51. In the eleventh embodiment, a sound wave reflector 57 on the transmitter 52 side and a sound wave reflector 58 on the receiver 53 side are integrally provided on the upper inner surface of the disposal ultrasonic sensor 51. 13A and 13B, upper and lower through-hole mounting holes 77 and 78 communicating with the inner peripheral side of the sound wave reflectors 57 and 58 are formed on the upper surface of the waste toner box 50. The transmitter 52 of the disposal ultrasonic sensor 51 is fitted into one mounting hole 77, and the receiver 53 is fitted into one mounting hole 78. With this configuration, the ultrasonic transducers 51 and 58 are attached to the upper surface of the waste toner box 50 so that the transmitters and receivers 52 and 53 are fitted in the mounting holes 77 and 78, respectively. The transmitter / receiver 52, 53 can be configured.

  The present invention is not limited to the above-described embodiment, and can be embodied in various forms. For example, a printer has been described as an example of the image forming apparatus. However, the image forming apparatus is not limited thereto, and may be a copier, a facsimile, or a complex machine having these functions combined. In addition, the configuration of each unit is not limited to the illustrated embodiment, and various modifications can be made without departing from the spirit of the present invention.

1 Printer (image forming device)
39 Bottle container 40 Toner bottle 40a Bottom 41 Ultrasonic sensor for printing 42 Transmitter 43 Receiver 45 Bottle drive motors 47, 48 Sonic reflector 47a Transmitting port 48a Receiving port 50 Waste toner box 50a Bottom 51 Ultrasonic sensor for disposal 52 Transmitter 53 Receiver 55 Leveling screw 57, 58 Sound wave emitter 57a Transmission port 58a Reception port 60 Controller 61 Storage unit 62 Ultrasonic control unit 63 Operation panel

Claims (12)

A reflection type ultrasonic sensor comprising a transmitter for transmitting ultrasonic waves toward the toner surface in the toner container and a receiver for receiving ultrasonic waves reflected from the toner surface, and based on the reception result of the receiver In a toner amount detection device for detecting the amount of toner in a toner container,
A sound wave reflector extending toward the bottom in the toner container is attached to at least the transmitter of the transmitter and the receiver,
The transmitter of the sound wave reflector on the transmitter side is closer to the bottom in the toner container than the receiver itself or the receiver port of the sound wave reflector on the receiver side.
Toner amount detection device. The length in the extending direction of the sound wave reflector on the transmitter side is equal to or greater than the dead distance of the receiver,
The toner amount detection device according to claim 1. The transmitter and the receiver are arranged close to each other;
The toner amount detection device according to claim 1 or 2. A leveling member for leveling the toner surface in the toner container;
When the amount of toner in the toner container is detected using the ultrasonic sensor, the leveling member is operated before the ultrasonic sensor is operated.
The toner amount detection device according to claim 1. The acoustic reflector is provided integrally with the toner container;
The toner amount detection device according to claim 1. An ultrasonic control unit for controlling the ultrasonic sensor;
The ultrasonic control unit detects a time from when an ultrasonic wave is transmitted by the transmitter until the ultrasonic wave reflected from the toner surface is received by the receiver, and using the time, the toner in the toner container is detected. Calculate the quantity,
The toner amount detection device according to claim 1. The toner container is a toner bottle containing printing toner;
The position of the transmission port of the sound wave reflector on the transmitter side corresponds to the position of the toner surface when the print toner in the toner bottle is in a very small state.
The toner amount detection device according to claim 6. The ultrasonic control unit determines that the print toner in the toner bottle is in a low state if the receiver receives ultrasonic waves reflected from the toner surface after transmitting ultrasonic waves with the transmitter.
The toner amount detection device according to claim 7. The toner container is a waste toner box for storing waste toner;
The position of the transmitting port of the sound wave reflector on the transmitter side corresponds to the position of the toner surface when the waste toner in the waste toner box is full.
The toner amount detection device according to claim 6. The ultrasonic control unit determines that the waste toner in the waste toner box is full unless the receiver receives the ultrasonic wave reflected from the toner surface after the ultrasonic wave is transmitted by the transmitter. ,
The toner amount detection device according to claim 9. The toner container includes a toner bottle that stores printing toner and a waste toner box that stores waste toner.
The ultrasonic control unit calculates the amount of print toner in the toner bottle using an ultrasonic sensor on the toner bottle side, and uses the ultrasonic sensor on the waste toner box side to discard waste in the waste toner box. Calculating a toner recoverable amount, comparing the printable number of sheets based on the print toner amount with the printable number of sheets based on the waste toner recoverable amount;
The display unit that displays various information displays the smaller number of printable pages.
The toner amount detection device according to claim 6. The toner amount detection device according to claim 1.
Image forming apparatus.

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