JP7069671B2 - Toner replenishment device and image forming device - Google Patents

Description

The present invention relates to a toner replenishing device and an image forming device.

A technique for calculating the remaining amount of toner in a toner cartridge is disclosed in Japanese Patent Application Laid-Open No. 2008-33197 (Patent Document 1).

Japanese Unexamined Patent Publication No. 2008-33197

As disclosed in Patent Document 1 above, the calculated consumption amount obtained by the drive time of the toner supply device is compared with the toner consumption amount actually consumed from the toner cartridge, and the coefficient of the consumption amount calculation from the next time is compared. Toner replenishment control devices with feedback control to change the are known.

With the above configuration, the amount of residual toner in the (new) toner cartridge can be estimated from the next time, but the amount of residual toner in the toner cartridge in use cannot be estimated. Further, when the toner cartridge is replaced, the characteristics of the toner used change, so that the accuracy of estimating the amount of residual toner decreases.

The present disclosure provides a toner replenishing device and an image forming device that can accurately estimate the amount of residual toner in a toner container.

This toner replenishment device includes a toner storage container, a toner storage unit, a detection unit, and a determination unit. The toner storage container stores the toner supplied to the developing device. The toner storage unit can store the toner discharged from the toner storage container and store a certain amount of toner. The detection unit detects the amount of toner supplied from the toner storage unit to the developing apparatus. The determination unit estimates the timing at which the toner remaining in the toner container is exhausted based on the data on the toner supply until the detection unit detects the same amount of toner as the fixed amount of toner.

According to the toner replenishment device, the amount of toner supplied from the toner storage unit to the developing device is actually measured, and the estimated calculated amount of used toner is corrected to make the amount of residual toner in the toner container container highly accurate. Can be estimated.

The toner supply device described above further includes a supply unit. The supply unit supplies toner from the toner storage unit to the developing device. The data regarding the toner supply includes the driving amount of the supply unit. As a result, the amount of residual toner in the toner container can be estimated with high accuracy.

In the toner replenishment device, the determination unit estimates the timing at which the toner remaining in the toner container is exhausted when an environmental change occurs. As a result, the amount of residual toner in the toner container can be estimated with high accuracy while ensuring productivity.

In the toner replenishing device, the environmental change includes a change in temperature and humidity and a change in frequency of use. As a result, the accuracy of estimating the amount of residual toner in the toner container can be ensured.

In the toner replenishment device, the detection unit includes a detection sensor. The fixed amount is the amount of toner supplied to the developing device from the OFF state to the ON state of the detection sensor. As a result, the toner replenishing device can be configured in a simple manner.

In the toner replenishment device, when the determination unit estimates the timing at which the toner remaining in the toner storage container runs out, the above-mentioned is performed until the same amount of toner as a certain amount of toner is detected by the detection unit. Toner is not discharged from the toner storage container to the toner storage section. As a result, the accuracy of estimating the amount of residual toner in the toner container can be ensured.

In the toner replenishment device, the determination unit estimates the timing at which the toner remaining in the new toner container is exhausted after the toner container is replaced with a new one. As a result, the accuracy of estimating the amount of residual toner in the toner container can be ensured.

This image forming apparatus includes a toner replenishing device according to any one of the above aspects, and a container accommodating portion for accommodating the toner accommodating container. This makes it possible to realize an image forming apparatus that can accurately estimate the amount of residual toner in the toner container.

According to the present disclosure, it is possible to realize a toner replenishing device and an image forming device that can accurately estimate the amount of residual toner in the toner container.

It is a schematic diagram which shows the image forming apparatus of embodiment. It is the schematic sectional drawing around the toner replenishing apparatus of embodiment. It is an enlarged perspective view of the sub hopper part shown in FIG. It is a block diagram which shows the structure of the toner supply device. It is a flowchart in the control of embodiment.

Hereinafter, the toner replenishing device and the image forming device according to the embodiment will be described with reference to the drawings. In the embodiments shown below, the same or substantially the same configuration will be designated by the same reference numerals, and duplicate description will not be repeated.

(Image forming apparatus 100)
FIG. 1 is a schematic view showing an image forming apparatus 100 of an embodiment. The image forming apparatus 100 of the embodiment is a tandem type color digital copying machine. The vertical DR1 indicated by the double-headed arrow in the figure is the height direction of the image forming apparatus 100, and is the vertical direction in FIG. The image forming apparatus 100 includes an image reader unit 10, a control unit 30, and a printer unit 20.

The image reader unit 10 reads the original image placed on the original glass plate (not shown) by moving the scanner. The original image is color-separated into three colors of red (R), green (G), and blue (B), and converted into an electric signal by a CCD image sensor (hereinafter referred to as "CCD sensor") (not shown). As a result, image data of R, G, and B of the original can be obtained.

The control unit 30 performs data processing on the image data for each color component obtained by the image reader unit 10. As a result, the above image data is further converted into image data of each reproduction color of cyan (C), magenta (M), yellow (Y), and black (K) (hereinafter, cyan, magenta, yellow, and black). Each reproduction color is represented as C, M, Y, K, and the C, M, Y, K are added as subscripts to the numbers of the components related to each reproduction color).

The control unit 30 includes an image information acquisition unit 37 and an image memory 90. The image information acquisition unit 37 acquires the density of the image of the recording sheet S on which the image is formed (dot count). The image memory 90 stores the image data of each reproduction color for each reproduction color. The image data receives the necessary image correction for the misalignment correction. The control unit 30 reads out the image data for each scanning line in synchronization with the supply of the recording sheet S. The control unit 30 transmits a drive signal to the light emitting diode 46 (LED) described later.

The printer unit 20 prints the image read by the image reader unit 10 on the recording sheet S and reproduces it. The printer unit 20 forms an image by an electrophotographic method. The printer unit 20 includes an intermediate transfer unit 60, a toner replenishing device 1Y, M, C, K, and a connecting unit 71Y, M, C, K. The intermediate transfer unit 60 includes an intermediate transfer belt 103, a drive roller 61, a driven roller 62, a transfer drive motor 91, and an encoder 341.

The material of the endless intermediate transfer belt 103 includes polycarbonate, polyimide, polyamide-imide and the like. The intermediate transfer belt 103 of the embodiment is a polyamide-imide having a volume resistivity of about 1.0 × 10 ¹⁰ [Ω · cm].

The intermediate transfer belt 103 is stretched by the drive roller 61 and the driven roller 62. The driven roller 62 is urged by a spring in a direction away from the driving roller 61 (leftward in FIG. 1). As a result, tension is applied to the intermediate transfer belt 103.

A transfer drive motor 91 is connected to the drive roller 61. The transfer drive motor 91 rotates the drive roller 61 counterclockwise. As a result, the intermediate transfer belt 103 rotates counterclockwise. The encoder 341 is provided between the drive roller 61 and the transfer drive motor 91. The encoder 341 detects the rotation unevenness of the drive roller 61. The control unit 30 controls the transfer drive motor 91 based on the detection result of the rotation unevenness.

The intermediate transfer unit 60 further includes image forming units 40Y, M, C, K, and transfer rollers 45Y, M, C, K. The image forming portions 40Y, M, C, and K of each color of Y, M, C, and K face the intermediate transfer belt 103. The image forming portions 40Y, M, C, and K are spaced from the driven roller 62 side (hereinafter referred to as “upstream side”) of the intermediate transfer belt 103 along the drive roller 61 side (hereinafter referred to as “downstream side”). It is arranged in. Since the configurations of the image forming units 40Y, M, C, and K are the same, the configuration of one of the image forming units 40Y, M, C, and K of each color (referred to as the image forming unit 40) will be described below. .. The same applies to the transfer rollers 45Y, M, C, K, the toner replenishing device 1Y, M, C, K, and the connecting portion 71Y, M, C, K.

The image forming unit 40 includes a photoconductor drum 41, a cleaner 44, a charged charger 42, a developing device 14, and an exposure scanning unit 70. The photoconductor drum 41, the charging charger 42, the developing device 14, and the cleaner 44 constitute an image process unit. The cleaner 44, the charging charger 42, and the developing device 14 are arranged around the photoconductor drum 41.

The cleaner 44 removes residual toner on the surface of the photoconductor drum 41 before the photoconductor drum 41 is exposed. The eraser lamp (not shown) eliminates static electricity on the surface of the photoconductor drum 41. After static elimination, the charging charger 42 uniformly charges the surface of the photoconductor drum 41.

The exposure scanning unit 70 has a light emitting diode (LED) 46. The light emitting diode 46 receives a drive signal output from the control unit 30 that reads out the image data of each reproduction color and emits light. The light from the light emitting diode 46 exposes and scans the surface of the photoconductor drum 41. When the photoconductor drum 41 is exposed in a uniformly charged state, an electrostatic latent image is formed on the surface of the photoconductor drum 41.

The electrostatic latent image is developed by supplying toner to the developing device 14. When the toner adheres to the electrostatic latent image, the toner image is formed on the surface of the photoconductor drum 41. When the amount of toner in the developing device 14 is low, the developing device 14 requests the toner replenishing device 1 to replenish the toner. Depending on the amount of toner consumed in the developing device 14, the toner replenishing device 1 replenishes the developing device 14 with toner via the connecting portion 71. The details of the toner replenishing device 1 will be described later.

The transfer roller 45 is arranged so as to face the image forming unit 40 via the intermediate transfer belt 103. When a voltage is applied to the transfer roller 45 from a high voltage substrate (not shown), the toner image on the photoconductor drum 41 is transferred onto the intermediate transfer belt 103. The toner images formed on the photoconductor drums 41Y, M, C, and K are sequentially transferred onto the intermediate transfer belt 103. The operation of forming the toner image on the photoconductor drums 41Y, M, C, and K is performed from the image forming unit 40Y on the upstream side so that the toner images of each color are superimposed and transferred to the same position on the intermediate transfer belt 103. The timing is staggered toward the image forming unit 40K on the downstream side.

The intermediate transfer unit 60 further includes a secondary transfer roller 104, a secondary transfer drive motor 92, a temperature / humidity sensor 54, and an intermediate transfer belt cleaner 105. The secondary transfer drive motor 92 is connected to the secondary transfer roller 104. The secondary transfer drive motor 92 drives the secondary transfer roller 104.

The toner image transferred onto the intermediate transfer belt 103 is conveyed to the secondary transfer nip portion N formed by the secondary transfer roller 104 and the drive roller 61. In the secondary transfer nip portion N, the secondary transfer roller 104 transfers the toner image on the intermediate transfer belt 103 to the recording sheet S (secondary transfer). The secondary transfer roller 104 has a pressure contact separation mechanism (not shown). The secondary transfer roller 104 is separated from the intermediate transfer belt 103 when printing is not performed. As a result, creep deformation of the elastic body of the secondary transfer roller 104 is suppressed.

The secondary transfer roller 104 and the transfer roller 45 are elastic rollers obtained by adding an ionic conductive substance to acrylonitrile-butadiene rubber (NBR) and foaming it. The electrical resistance of the secondary transfer roller 104 and the transfer roller 45 changes due to the influence of temperature, humidity and the like. The temperature / humidity sensor 54 is provided in the image forming apparatus 100. The temperature / humidity sensor 54 measures the temperature and humidity in the image forming apparatus 100. The control unit 30 adjusts the voltage applied to each roller so that an appropriate current flows through the secondary transfer roller 104 and the transfer roller 45 based on the temperature and humidity measured by the temperature / humidity sensor 54.

The intermediate transfer belt cleaner 105 has a cleaning blade 68, a screw 66, a cleaner housing 69, a joint 107, and a waste toner box 108. The cleaning blade 68 scrapes off the residual toner (hereinafter referred to as waste toner) remaining on the intermediate transfer belt 103 after the secondary transfer. The waste toner is conveyed toward the front on the paper surface by the screw 66 that rotates in the cleaner housing 69. After that, the waste toner is sent to the waste toner box 108 via the joint 107.

The image forming apparatus 100 further includes a panel unit 200, a paper feeding unit 50, and a fixing unit 80. The panel unit 200 displays the operation of the image forming apparatus 100, the paper jam of the printer unit 20, the life of the components of the image forming apparatus 100, and the like.

The paper feed unit 50 is arranged upstream of the transport path of the sheet S. The paper feed unit 50 includes a paper feed cassette 51, a paper feed roller 52, a resist roller 53, and a sheet detection sensor 55.

The paper cassette 51 houses the recording sheet S. The paper feed roller 52 takes out the recording sheet S from the paper feed cassette 51 and transports it toward the downstream side of the transport path. The resist roller 53 measures the timing of transporting the recording sheet S to the secondary transfer nip portion N. The sheet detection sensor 55 is provided immediately before the upstream side of the transport path with respect to the resist roller 53. The sheet detection sensor 55 detects the tip of the recording sheet S conveyed from the paper feed roller 52 to the resist roller 53. The sheet detection sensor 55 notifies the control unit 30 that the tip of the recording sheet S has been detected.

The control unit 30 receives the signal from the seat detection sensor 55. The control unit 30 emits a signal to drive the resist roller 53 to the drive unit (not shown) of the resist roller 53 while measuring the timing. Upon receiving the signal from the control unit 30, the resist roller 53 conveys the recording sheet S to the secondary transfer nip unit N. In the secondary transfer nip portion N, the toner image of each color formed in the shape of the intermediate transfer belt 103 is transferred to the recording sheet S.

After the recording sheet S has passed through the secondary transfer nip portion N, the recording sheet S is conveyed to the fixing portion 80. The fixing portion 80 is arranged downstream of the transport path of the recording sheet S with respect to the secondary transfer nip portion N. The fixing unit 80 pressurizes the recording sheet S with high heat. The fixing unit 80 melts and adheres the toner image on the surface of the recording sheet S to the surface of the recording sheet S and fixes it. The recording sheet S on which the toner image is fixed is discharged onto the paper ejection tray 81 via the paper ejection roller 82.

(Toner replenishment device 1)
FIG. 2 is a schematic cross-sectional view of the periphery of the toner replenishing device 1 of the embodiment. The toner replenishing device 1 is connected to the developing device 14 via the connecting portion 71. The toner replenishing device 1 replenishes the developing device 14 with toner via the connecting portion 71. The toner replenishing device 1 has a container accommodating portion 9, a toner accommodating container 5, and a sub hopper portion 31.

The toner storage container 5 stores the toner supplied to the developing device 14. The toner container 5 has a cylindrical shape. By rotating the toner storage container 5, the toner in the toner storage container 5 is conveyed, and the toner is discharged to the sub hopper section 31. The toner container 5 is rotated by a drive unit (not shown).

The toner storage container 5 is installed in the container storage unit 9. The container accommodating section 9 accommodates the toner accommodating container 5. The container accommodating portion 9 has a discharge portion 9a. The toner filled in the toner container 5 is discharged from the discharge unit 9a. The toner container 5 is removable from the container container 9.

When the toner storage container 5 is installed in the container storage unit 9, a toner sealing member (not shown) moves according to the installation operation. As the toner sealing member moves, the discharge unit 9a is released. As a result, the toner stored in the toner storage container 5 is discharged from the discharge unit 9a to the sub hopper unit 31.

(Sub hopper section 31)
FIG. 3 is an enlarged perspective view of the sub hopper portion 31 shown in FIG. The sub hopper section 31 will be described with reference to FIGS. 2 and 3. The sub hopper portion 31 is provided below the toner storage container 5. The sub hopper unit 31 includes a toner storage unit 8, a stirring unit 2, a cam unit 3, a stirring shaft 4, a detection unit 7, and a supply unit 6.

The toner storage unit 8 stores the toner discharged from the toner storage container 5. The maximum storage capacity of the toner storage unit 8 (hereinafter referred to as the maximum storage capacity) is determined from the maximum load capacity of the toner storage unit 8.

The toner stored in the toner storage unit 8 is supplied to the developing device 14 through the connecting unit 71 in response to a request from the developing device 14. When the toner in the toner storage unit 8 is supplied to the developing device 14, the amount of toner in the toner storage unit 8 decreases. When the amount of toner in the toner storage unit 8 becomes smaller than the maximum capacity, the toner is replenished from the toner storage container 5, and the amount of toner in the toner storage unit 8 is maintained at the maximum capacity. A stirring unit 2, a cam unit 3, a detection unit 7, and a supply unit 6 are arranged in the toner storage unit 8.

The supply unit 6 is located below the toner storage unit 8. The supply unit 6 of the embodiment has a transfer screw 6a and a transfer pipe 6b. The transport pipe 6b covers the transport screw 6a. The conveyor screw 6a is rotated by a drive mechanism (not shown) in accordance with the toner supply request from the developing device 14, so that the toner stored in the toner storage unit 8 is supplied to the developing device 14.

The stirring shaft 4 is rotated by a drive mechanism (not shown). A cam portion 3 is provided at the end of the stirring shaft 4. The cam unit 3 rotates in conjunction with the rotation of the stirring shaft 4. A curved surface having a curvature corresponding to the rotation angle of the shaft is formed on the outer periphery of the cam portion 3.

The stirring unit 2 supplies the toner in the toner storage unit 8 toward the supply unit 6. The stirring unit 2 stirs the toner in the toner storage unit 8. As a result, the stirring unit 2 prevents the toner from aggregating. Therefore, the stirring unit 2 secures a stable toner storage state.

The detection unit 7 includes a detection member 7a and a detection sensor 7b. The detection member 7a is provided above the toner storage unit 8. The detection member 7a is configured to be movable in an arc shape about an axis. The detection member 7a is arranged on the liquid surface of the toner in the toner storage unit 8.

An actuator (not shown) is connected to the detection member 7a. The actuator operates in conjunction with the swing of the vertical DR1 of the detection member 7a. The detection sensor 7b detects the operation of the actuator. The detection sensor 7b is turned on when the actuator is operating, and turned off when the actuator is not operating. The detection sensor 7b detects the vibration of the vertical DR1 of the detection member 7a.

The detection member 7a has an installation portion 7c. The installation unit 7c is installed on the liquid level of the toner in the toner storage unit 8. The position of the installation portion 7c in the vertical DR1 changes depending on the position of the liquid level of the toner. When the liquid level of the toner is at a relatively high position (when the amount of toner in the toner storage unit 8 is relatively large), the installation unit 7c is arranged at a relatively high position in the vertical DR1. When the liquid level of the toner is relatively low (when the amount of toner in the toner storage unit 8 is relatively small), the installation unit 7c is arranged at a relatively low position in the vertical DR1.

When the amount of toner stored in the toner storage unit 8 is a predetermined amount (for example, the maximum capacity), the installation unit 7c is arranged upward with respect to the rotating cam unit 3. The installation portion 7c does not come into contact with the rotating cam portion 3. Since the installation portion 7c and the cam portion 3 do not come into contact with each other, the detection member 7a does not move in the vertical direction DR1. Therefore, the actuator does not operate. The detection sensor 7b does not detect the operation of the actuator. Therefore, the detection sensor 7b is always in the OFF state (this state is referred to as "always OFF state"). When the detection sensor 7b is always in the OFF state, the detection sensor 7b detects that the maximum amount of toner is contained in the toner storage unit 8.

When the toner in the toner storage unit 8 is supplied to the developing device 14 and the amount of toner stored in the toner storage unit 8 becomes smaller than the maximum capacity, the installation unit 7c has the amount of toner stored in the toner storage unit 8. Is placed at a relatively lower position than in the case of maximum capacity. Since the position of the liquid level of the toner is relatively low, the position of the installation portion 7c in the vertical DR1 is lowered. Therefore, the installation portion 7c comes into contact with the rotating cam portion 3. When the rotation angle of the cam portion 3 changes, the installation portion 7c and the cam portion 3 are separated from each other. The installation portion 7c repeatedly contacts and separates from the cam portion 3.

As a result, the detection member 7a swings in the vertical direction DR1. The actuator repeats operation and stop in conjunction with the movement of the vertical DR1 of the detection member 7a. When the detection sensor 7b detects the operation and stop of the actuator, the detection sensor 7b repeats the ON state and the OFF state. The amount of toner stored in the toner storage unit 8 when the ON state is long (when the contact time between the installation unit 7c and the cam unit 3 is long) is the toner stored in the toner storage unit 8 when the ON state is short. Small compared to the amount.

When the amount of toner in the toner storage unit 8 is further reduced, the installation unit 7c always comes into contact with the rotating cam unit 3. In this case, the detection sensor 7b is always in the ON state (this state is referred to as "always ON state"). When the detection sensor 7b is always ON, the amount of toner in the toner storage unit 8 is relatively small (storage unit empty state). In the storage unit empty state, toner supply from the toner storage container 5 to the toner storage unit 8 is required. If the amount of usable toner in the toner container 5 is zero, it is required to replace the toner container 5 with a new one.

The amount of toner (maximum capacity) in the toner storage unit 8 when the detection sensor 7b is always OFF is a known value, and the amount of toner in the toner storage unit 8 when the detection sensor 7b is always ON is also known. Is the value of. That is, the difference between the amount of toner in the toner storage unit 8 when the detection sensor 7b is always OFF and the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the ON state is a known value. .. In this way, the detection sensor 7b detects the ON state and the OFF state (detects the vibration of the vertical DR1 of the detection member 7a), thereby detecting the amount of toner in the toner storage unit 8. The detection sensor 7b detects the amount of toner supplied from the toner storage unit 8 to the developing device 14.

As a result, the toner storage unit 8 can store a certain amount of toner. The fixed amount is the difference between the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the OFF state and the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the ON state.

(Judgment unit 33)
FIG. 4 is a block diagram showing the configuration of the toner replenishing device 1. The toner supply device 1 further includes a rotation detection unit 36, a memory unit 34, a transmission unit 35, and a determination unit 33. The rotation detection unit 36 detects the drive amount of the transfer screw 6a. In the embodiment, the driving amount of the transfer screw 6a is the rotation time of the transfer screw 6a. The rotation detection unit 36 can accumulate and count the rotation time of the transfer screw 6a.

The memory unit 34 stores data regarding the amount of toner stored in the new toner storage container 5. The memory unit 34 stores data regarding the maximum capacity of the toner storage unit 8. In the memory unit 34, a fixed amount (difference between the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the OFF state and the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the ON state). Amount) data is stored. Humidity and temperature fluctuation thresholds are stored in the memory unit 34.

The determination unit 33 determines the operation or stop of toner discharge from the toner storage container 5 based on the information on the amount of toner detected by the detection sensor 7b. When the detection sensor 7b detects an ON state (including repetition of an ON state and an OFF state), the determination unit 33 operates the toner storage container 5 to replenish the toner storage unit 8. When the detection sensor 7b always detects the OFF state, the determination unit 33 stops the toner storage container 5.

Based on the command from the determination unit 33, the transmitting unit 35 has a container near empty state (a state in which the amount of toner contained in the toner storage container 5 is equal to or less than a specified amount) and a container empty state (accommodated in the toner storage container 5). The amount of usable toner used is zero).

(Estimation of the amount of residual toner in the toner container)
In a conventional toner replenishing device, the amount of toner used for image formation (the amount of toner used) may be estimated and calculated from the time when the conveyor screw is rotated to estimate the amount of residual toner in the toner container.

The characteristics of toner vary greatly depending on the installation environment and usage of the image forming apparatus (temperature, humidity, atmospheric pressure, storage condition, toner leaving time, etc.). Further, the characteristics of the toner change greatly depending on the formulation (manufacturing) of the toner, and even if the toner is intended to be manufactured in the same manner at the manufacturing stage of the toner, the characteristics such as the charge amount of the toner change every time the toner is manufactured. The characteristics of toner change not only at the manufacturing stage but also at the stage of use during image formation. In this way, the amount of toner actually consumed changes as the characteristics of the toner change. The amount of toner used that is actually consumed is a value that varies with respect to the amount of toner used that is estimated and calculated from the time that the conveyor screw rotates (hereinafter, the estimated amount of toner that is used). Due to a slight difference in toner characteristics, the accuracy of estimating the amount of residual toner in the toner container is reduced.

It is difficult to estimate and calculate the amount of toner used in consideration of all factors that change the characteristics of the toner (installation environment of image forming apparatus, usage method, toner prescription, etc.). There are a method of directly measuring the weight of the toner container and measuring the amount of residual toner, and a method of checking the amount of residual toner using a transmissive sensor, but this leads to an increase in size and cost of the image forming apparatus.

Therefore, when a situation occurs in which the toner characteristics change due to the above factors, it is preferable to actually measure the amount of toner used and correct the estimated calculated amount of toner used to estimate the amount of residual toner. By correcting the estimated and calculated amount of toner used each time the toner characteristics change, the amount of residual toner in the toner container can be estimated accurately.

(Estimated calculated correction control of the amount of toner used)
FIG. 5 is a flowchart in the control of the embodiment. In the control of the embodiment, first, in step S100, the determination unit 33 determines whether or not it is necessary to correct the estimated calculated amount of toner used. When correction is required, when the toner storage container 5 is replaced with a new one, when the installation environment (external temperature, humidity, atmospheric pressure) of the image forming apparatus 100 fluctuates, and when printing is not performed for a long time. When you are.

For example, when the temperature / humidity sensor 54 detects that the humidity in the image forming apparatus 100 has fluctuated, the determination unit 33 compares the detection result with the humidity fluctuation threshold value stored in the memory unit 34. If the humidity fluctuation threshold is exceeded, it is determined that correction is necessary.

When the determination unit 33 determines that the correction is not necessary (NO in step S100), the process ends (end). If the determination unit 33 determines that correction is necessary (YES in step S100), the process proceeds to step S101.

In step S101, the determination unit 33 stores the toner in the toner storage unit 8 based on the detection result of the toner amount in the toner storage unit 8 of the detection sensor 7b when the detection sensor 7b is always in the OFF state. It is determined whether or not it is the toner amount (maximum capacity) in the unit 8. The state in which the amount of toner in the toner storage unit 8 is the maximum capacity is defined as the full state. If the toner storage unit 8 is not in the full state (NO in step S101), the process proceeds to step S102.

In step S102, the toner storage container 5 rotates, and the toner supply to the toner storage unit 8 is started. While the toner storage container 5 is being rotated, in step S103, the determination unit 33 determines whether or not the toner storage unit 8 is in the full state based on the detection result of the amount of toner in the toner storage unit 8 of the detection sensor 7b. To judge. The toner storage container 5 continues to rotate until the determination unit 33 determines that the toner storage unit 8 is in the full state, and the toner storage unit 8 is continuously replenished with toner. The determination in step S103 is repeated until the toner storage unit 8 becomes full.

After the toner storage unit 8 is in the full state, the rotation of the toner storage container 5 is stopped in step S104. Replenishment from the toner storage container 5 to the toner storage unit 8 is stopped. After that, the toner is not replenished from the toner container 5 to the toner storage unit 8 until the control is completed.

Next, the process proceeds to step S105, and the transport screw 6a rotates. When the user prints, the toner of the developing device 14 is consumed. At the request of the developing device 14, toner is supplied from the toner storage section 8 to the developing device 14 through the connecting section 71. As the user prints, the toner in the toner storage unit 8 is gradually consumed. In step S105, the rotation detection unit 36 detects the rotation time of the supply unit 6 (conveying screw 6a) that supplies toner from the toner storage unit 8 to the developing device 14. The rotation detection unit 36 accumulates and counts the rotation time of the transfer screw 6a until it detects that the detection sensor 7b is always in the ON state.

While printing by the user is continued, in step S106, the determination unit 33 is in the storage unit empty state (the detection sensor 7b is always in the ON state) based on the detection result of the toner amount in the toner storage unit 8 of the detection sensor 7b. Determine if it exists.

Printing by the user continues until the determination unit 33 detects that the detection sensor 7b is always in the ON state. The determination in step S106 is repeated until the detection sensor 7b is always in the ON state.

When the determination unit 33 determines that the storage unit is in the empty state (YES in step S106), the process proceeds to step S107. In step S107, the image information acquisition unit 37 acquires the total image density of the recording sheet S printed between the time when the detection sensor 7b always detects the OFF state and the time when the detection sensor 7b always detects the ON state. do. The rotation detection unit 36 detects the cumulative rotation time of the transport screw 6a from the time when the detection sensor 7b always detects the OFF state to the time when the detection sensor 7b always detects the ON state.

Next, the process proceeds to step S108, and the determination unit 33 determines a fixed amount (the amount of toner in the toner storage unit 8 when the detection sensor 7b is always in the OFF state and the toner storage unit 8 when the detection sensor 7b is always in the ON state). Toner storage based on the data related to toner supply until the detection sensor 7b detects that the same amount of toner as the toner of (difference from the toner amount of) is supplied from the toner storage unit 8 to the developing device 14. Estimate the timing when the toner remaining in the container 5 runs out.

The data related to toner supply is data related to the case where toner is supplied from the toner storage unit 8 to the developing device 14. The data related to toner supply is, for example, data related to the printed recording sheet S, data related to the driving amount of the driving mechanism that supplies toner from the toner storage unit 8 to the developing device 14, and the like. Specifically, the data related to the toner supply includes the cumulative rotation time of the transport screw 6a and the image information acquisition unit from the time when the detection sensor 7b always detects the OFF state to the time when the detection sensor 7b always detects the ON state. It is the total value of the image densities of all the recording sheets S acquired by 37, and the constant amount of toner supplied to the developing device 14 from the toner storage unit 8 detected by the detection sensor 7b.

For example, when the fixed amount is 25 [g] and the amount of toner stored in the new toner storage container 5 is 200 [g], the remaining 175 [g] of toner remains in the toner storage container 5. Become. When the cumulative rotation time of the transfer screw 6a detected by the rotation detection unit 36 is 1000 [s], it takes 1000 [s] to supply 25 [g] of toner from the toner storage unit 8 to the developing device 14. It will be. Since the amount of residual toner in the toner container 5 is 175 [g], it can be estimated that the timing at which the amount of residual toner in the toner container 5 runs out is when the transport screw 6a is rotated by 7,000 [s].

The amount of toner used for the density of a certain image may be a predetermined value, but by using the data of the total value of the image densities of all the recording sheets S acquired by the image information acquisition unit 37, the data is used. It is possible to determine the amount of toner to be used for a certain image density corresponding to the characteristics of the toner actually used. As a result, the amount of residual toner can be estimated more accurately.

(Action effect)
When the amount of residual toner in the toner container becomes less than or equal to the specified amount, the transmitter may transmit that the toner container is in the near empty state of the container. This configuration is used in a system that automatically delivers a replacement toner container to the user. In this system, if the transmission of the container near empty state is delayed, the replacement toner container may not arrive at the user in time and the image forming apparatus may become unusable.

On the other hand, if the near empty state of the container is transmitted too early, there is a possibility that the toner storage container will be replaced with a new one even though there is sufficient toner remaining in the toner storage container, and the toner is stored at the user's site. Container storage space may be required. Therefore, in order to effectively operate the automatic delivery system of the toner container, it is necessary to accurately estimate the amount of residual toner in the toner container.

In the toner replenishment device 1 of the embodiment, the determination unit 33 determines that the toner storage container 5 remains based on the data regarding the toner supply until the detection sensor 7b detects the same amount of toner as a certain amount of toner. Estimate the amount of toner. By actually measuring the amount of toner supplied from the toner storage unit 8 to the developing device 14 and correcting the estimated calculated amount of used toner, the amount of residual toner in the toner storage container 5 can be estimated with high accuracy.

Further, after the toner storage container 5 is emptied, not only the amount of residual toner in the new toner storage container 5 after replacement can be estimated, but also the toner storage container 5 currently used can be the toner storage container 5. The amount of residual toner can be estimated with high accuracy.

The data regarding the toner supply includes data regarding the driving amount of the supply unit 6. In the embodiment, the driving amount of the supply unit 6 is the rotation time of the transfer screw 6a. By using the rotation time of the transfer screw 6a as data related to toner supply, the amount of residual toner in the toner container 5 can be estimated with high accuracy.

The determination unit 33 estimates the timing at which the toner remaining in the toner container 5 runs out when an environmental change occurs. When an environmental change occurs, control for correcting the estimated calculated amount of toner used is started. The environmental change means a case where the environment of the image forming apparatus 100 changes (for example, a change in temperature / humidity and atmospheric pressure).

When the control for correcting the estimated used toner amount is performed, the toner supply from the toner storage container 5 to the toner storage unit 8 is stopped. After the toner storage container 5 is in the empty state of the storage unit, the toner storage unit 8 is replenished with toner. Printing cannot be performed while the toner is being supplied from the toner container 5 to the toner storage unit 8. Therefore, the productivity of the image forming apparatus 100 is lowered.

Only when the characteristics of the toner change due to environmental changes, the estimated amount of toner used is corrected and controlled to ensure productivity and the amount of residual toner in the toner container 5 is estimated with high accuracy. can do.

Environmental changes include changes in temperature and humidity around the image forming apparatus 100, and changes in the frequency of use of the image forming apparatus 100. The temperature and humidity in the toner replenishing device 1 also change due to the change in the temperature and humidity around the image forming apparatus 100. This changes the characteristics of the toner. Comparing the case where the toner is left without using the image forming apparatus 100 for a long time and the case where the image forming apparatus 100 is used at short time intervals and the toner is continuously consumed, the characteristics of the toner in each case are different.

By controlling the image to be corrected each time according to the installation status of the image forming apparatus 100 (temperature and humidity around the image forming apparatus 100) and the usage condition at the user's site (frequency of use of the image forming apparatus 100). It is possible to correct the estimated calculated amount of toner used according to the situation of the forming apparatus 100. By setting the estimated and calculated correction conditions for the amount of toner used corresponding to each situation of the image forming apparatus 100 and re-correcting when the environment changes, the estimation accuracy of the remaining toner amount in the toner storage container 5 can be obtained. Can be secured.

The detection sensor 7b detects the amount of toner supplied from the toner storage unit 8 to the developing device 14 between the time when the OFF state is always detected and the time when the ON state is always detected. The amount of toner in the toner storage unit 8 in the always OFF state and the amount of toner in the toner storage unit 8 in the always ON state are known values. The detection sensor 7b can detect a certain amount of toner supplied from the toner storage unit 8 to the developing device 14. By using the detection sensor 7b to detect a certain amount of toner, the toner replenishing device 1 can be configured in a simple manner.

When the determination unit 33 estimates the timing at which the toner remaining in the toner container 5 runs out (when the estimated calculated correction control of the used toner amount is performed), the detection unit 7 contains the same amount of toner as a certain amount of toner. Toner is not discharged from the toner storage container 5 to the toner storage unit 8 until it is detected. When the control for correcting the estimated used toner amount is performed, the toner supply from the toner storage container 5 to the toner storage unit 8 is stopped. As a result, the estimation accuracy of the residual toner amount in the toner container 5 can be ensured.

The determination unit 33 estimates the timing at which the toner remaining in the new toner container 5 runs out after the toner container 5 is replaced with a new one. Due to differences in the manufacturing method, toner storage condition, etc., the characteristics of the toner contained in the new toner container 5 and the toner in the toner container 5 used in the image forming apparatus 100 before the replacement are different. Strictly different. By correcting the amount of toner used estimated and calculated when the characteristics of the toner change, the accuracy of estimating the amount of residual toner in the toner container 5 can be ensured.

The drive amount may be the rotation speed of the transfer screw 6a. The rotation detection unit 36 may detect the rotation speed of the transport screw 6a and accumulate and count the rotation speed. The rotation detection unit 36 may detect the rotation speed and the rotation time of the toner storage container 5, and may accumulate and count them.

In the embodiment, the rotation detection unit 36, the memory unit 34, the transmission unit 35, and the determination unit 33 are configured to be included in the toner replenishment device 1, but are included in the control unit 30. It is also good.

It should be considered that the embodiments disclosed this time are exemplary in all respects and not restrictive. The scope of the present invention is shown by the scope of claims rather than the above description, and is intended to include all modifications within the meaning and scope equivalent to the scope of claims.

1 Toner supply device, 2 Stirring unit, 3 Cam unit, 4 Stirring shaft, 5 Toner storage container, 6 Supply unit, 6a transfer screw, 6b transfer tube, 7 detection unit, 7a detection member, 7b detection sensor, 7c installation unit, 8 Toner storage, 9 Container storage, 9a Discharge, 10 Image reader, 14 Developer, 20 Printer, 30 Control, 31 Sub hopper, 33 Judgment, 34 Memory, 35 Transmitter, 36 Rotation detection Unit, 37 Image information acquisition unit, 40Y, 40C, 40K, 40M image drawing unit, 41Y, 41C, 41K, 41M Photoreceptor drum, 42 charged charger, 44 cleaner, 45Y, 45C, 45K, 45M transfer roller, 46 light emitting diode , 50 paper feed section, 51 paper feed cassette, 52 paper feed roller, 53 resist roller, 54 temperature / humidity sensor, 55 sheet detection sensor, 60 intermediate transfer unit, 61 drive roller, 62 driven roller, 66 screw, 68 cleaning blade, 69 Cleaner housing, 70 exposure scanning unit, 71Y, 71C, 71K, 71M connecting unit, 80 fixing unit, 81 paper ejection tray, 82 paper ejection roller, 90 image memory, 91 transfer drive motor, 92 secondary transfer drive motor, 100 Image forming device, 103 intermediate transfer belt, 104 secondary transfer roller, 105 intermediate transfer belt cleaner, 107 joint, 108 waste toner box, 200 panel section, 341 encoder, DR1 vertical direction, N secondary transfer nip section.

Claims (8)

A toner container that stores the toner supplied to the developing device,
A toner storage unit that can store the toner discharged from the toner storage container and store a certain amount of toner,
A detection unit that detects the amount of toner supplied from the toner storage unit to the developing device, and
A determination unit for estimating the timing at which the toner remaining in the toner container is exhausted based on the data on the toner supply until the same amount of toner as the fixed amount of toner is detected by the detection unit is provided.
The detection unit includes a detection member and a detection sensor.
The detection member is arranged on the liquid surface of the toner in the toner storage portion, and is arranged.
The detection member is provided so as to be able to move up and down in an arc shape about an axis according to the position of the liquid level of the toner.
The detection sensor detects the amount of toner supplied from the toner storage unit to the developing device based on the vertical movement of the detection member.
The detection member is provided above the toner storage portion and is provided.
An actuator is connected to the detection member, and an actuator is connected to the detection member.
The detection sensor detects the operation of the actuator and
The detection sensor is in the ON state when the actuator is operating, and is in the ON state.
The detection sensor is in the OFF state when the actuator is not operating.
When the detection sensor detects the operation and stop of the actuator, the detection sensor repeats the ON state and the OFF state, and the amount of toner stored in the toner storage unit when the ON state is long is the ON state. Is determined to be small compared to the amount of toner stored in the toner storage unit when is short.
Toner replenishment device. Further, a supply unit for supplying toner from the toner storage unit to the developing device is provided.
The toner replenishing device according to claim 1, wherein the data includes a driving amount of the supply unit. The toner replenishing device according to claim 1 or 2, wherein the determination unit estimates the timing at which the toner remaining in the toner container is exhausted when an environmental change occurs. The toner replenishing device according to claim 3, wherein the environmental change includes a change in temperature and humidity and a change in frequency of use. The detection unit includes a detection sensor.
The toner replenishing device according to any one of claims 1 to 4, wherein the fixed amount is the amount of toner supplied to the developing device from the OFF state to the ON state of the detection sensor. When the determination unit estimates the timing at which the toner remaining in the toner storage container runs out, the toner from the toner storage container is used until the same amount of toner as the certain amount of toner is detected by the detection unit. The toner replenishing device according to any one of claims 1 to 5, wherein the toner is not discharged to the storage unit. The toner replenishment according to any one of claims 1 to 6, wherein the determination unit estimates the timing at which the toner remaining in the new toner container is exhausted after the toner container is replaced with a new one. Device. The toner replenishing device according to any one of claims 1 to 7.
An image forming apparatus comprising a container accommodating portion for accommodating the toner accommodating container.

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