Patent Application
20140186063
1. Field of the Invention
The present invention relates generally to an image forming apparatus, and more particularly to a capacitive sensor that determines amounts of waste toner in a waste toner box.
2. Description of the Related Art
Color Electro Photographic (EP) printers typically include four image forming units that transfer toner either to an intermediate transport module or directly to a sheet that is transported under the image forming units on a transfer member. In either case the EP process generates waste toner that needs to be cleaned off photoconductive members of the image forming units and the transfer member. Some systems have a central waste toner box that collects the waste toner from the photoconductive members and the transfer member. When the waste toner box fills to its maximum capacity, the waste may backup into the image forming units and damage the imaging apparatus. Therefore, a sensor is required to detect levels of waste toner in the waste toner box.
Prior systems have used a torque sensor to measure back pressure on a toner-moving auger, or an optical sensor to detect when the waste toner box is full. However, both the torque and the optical sensor have their problems. While, the torque sensor requires that the waste toner be packed into the waste toner box, the optical sensor requires a wiper to keep the optical path clear of stray toner.
Another sensor used in the prior system is a capacitive sensor that has a capacitor, the capacitance of the capacitor changes as the medium between plates of the capacitor changes from air to waste toner. The system that uses a capacitance sensor requires that the capacitor be calibrated at the factory and the initial calibration value to be saved in a non-volatile memory. The imaging apparatus then determined a delta change in capacitance value to determine the amount of toner within the waste toner box. If non-volatile memory is not available, then the capacitive sensor has to depend on either absolute value or monitor the relative change in capacitance to determine when the waste toner box is full. However, because of the large tolerance in the absolute value of the capacitance, the size of plates of the capacitor, and the distance between the plates, using absolute values can greatly decrease the expected yield of the waste toner box.
Therefore, it would be desirable to have a capacitive sensor that eliminates the need to store the initial value of the capacitance sensor, in a non-volatile memory while maximizing the capacity of the waste toner box.
Disclosed herein is a method for determining a relative amount of waste toner in a waste toner box of an imaging apparatus including measuring a voltage at a beginning and an end of a plurality of intervals, the measured voltage corresponding to a capacitance within the waste toner box that varies with an amount of waste toner in between the pair of separated plates, determining a relative change in capacitance based on the voltage measured, the relative change in capacitance being determined by: calculating a difference between the voltage measured at the beginning and the end of each of the plurality of intervals, and dividing each voltage difference by a divisor value to determine the relative change in capacitance, comparing the determined relative change in capacitance with a predetermined threshold value, the predetermined threshold value being the predetermined minimum value for the relative change in capacitance, and determining the relative amount of waste toner in the waste toner box based on the comparison.
In some embodiments, the relative amount of waste toner in the waste toner box is determined as nearly full when the relative change in capacitance is less than the predetermined threshold value.
In some embodiments, the method further includes counting a number of pages printed by the imaging apparatus, setting a near full page count variable to the count of the number of pages printed when the relative amount of waste toner in the waste toner box is determined as being nearly full, comparing the count of the number of pages printed by the imaging apparatus with a sum of the near full page count variable and a predetermined full page delta value, and determining the relative amount of waste toner in the waste toner box as full when the count of the number of pages is greater than the sum of the near full page count variable and the predetermined full page delta value.
In another aspect, a method for determining an amount of waste toner in a waste toner box of an imaging apparatus is disclosed, the method including: measuring a voltage within the waste toner box, the voltage corresponding to a capacitance that varies with an amount of toner in the waste toner box between a pair of separated plates, comparing the measured voltage with at least one of an empirically determined value corresponding to a new waste toner box, an intermediate toner level in the waste toner box, and a full toner level in the waste toner box, and determining the amount of waste toner in the waste toner box based on the comparison.
In yet another aspect, an imaging apparatus is disclosed that includes a waste toner box that includes an inlet port for collecting waste toner, a pair of separated plates positioned within the waste toner box to form a capacitor, the capacitor having a capacitance that varies in correspondence with an amount of waste toner in between the separated plates, sensor circuitry in electrical communication with the capacitor for measuring a voltage at a beginning and an end of a plurality of intervals, the voltage value being indicative of a capacitance of the capacitor, and a controller in electrical communication with the sensor circuitry, the controller determining the amount of waste toner in the waste toner box by: determining a relative change in capacitance based on the voltage measured, the relative change in capacitance being determined by calculating a difference between the voltage measured at the beginning and the end of each of the plurality of intervals and dividing the difference by a predetermined number to determine the relative change in capacitance, the predetermined number being the number of pages printed during the plurality of intervals, comparing the determined relative change in capacitance with a predetermined threshold value, the predetermined threshold value being the predetermined minimum value for the relative change in capacitance, and determining the relative amount of waste toner in the waste toner box based on the comparison.
Additional features and advantages of the invention will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the invention as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description of the present embodiments of the invention are intended to provide an overview or framework for understanding the nature and character of the invention as it is claimed. The accompanying drawings are included to provide a further understanding of the invention and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the invention and together with the description serve to explain the principles and operation of the invention.
The above-mentioned and other features and advantages of the various embodiments of the invention, and the manner of attaining them, will become more apparent will be better understood by reference to the accompanying drawings, wherein:
a-9b illustrate the processing actions executed by the controller when the waste toner box is initialized for the first time in factory, according to one embodiment of the present invention;
a-10b illustrate the processing actions executed by the controller when the state of the waste toner box is new, according to one embodiment of the present invention;
It is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.
Reference will now be made in detail to the exemplary embodiment(s) of the invention, as illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
One embodiment of an imaging apparatus 10 according to the present invention is illustrated in
An image formation area 30, of the imaging apparatus 10, includes an imaging unit 32, a laser printhead 34, and a transfer member 36. Imaging unit 32 includes one or more imaging stations 38 that each includes a developer unit 40, a photoconductor unit 42, and a toner cartridge 44. For clarity, the units 40, 42, and cartridge 44 are labeled on only one of the imaging stations 38 in
Laser printhead 34 includes a laser that discharges a surface of photoconductive (PC) members 46 within each of the imaging stations 38. Toner from a developer unit 40 in the imaging station 38 attracts to the surface area of the PC members 46 discharged by the laser printhead 34.
The transfer member 36 extends continuously around a series of rollers 48. Transfer member 36 receives the toner images from each of the PC members 46. In one embodiment, the toner images from each of the PC members 46 are placed onto transfer member 36 in an overlapping arrangement. In one embodiment, a multi-color toner image is formed during a single pass of the transfer member 36. By way of example, the yellow toner may be placed first on the transfer member 36, followed by cyan, magenta, and black. After receiving the toner images, transfer member 36 moves the images to the transfer area 22 where the toner images are transferred to the media sheet 14. The transfer area 22 includes a nip 50 formed by a transfer roller 52 and the back up roller 54. The media sheet 14 moves along the media path 18 through the nip 50 to receive the toner images from the transfer member 36. The media sheet 14 with the toner images next moves through the fuser 24 and is then discharged at the output tray 26 or moved into the duplex path 28.
The imaging apparatus 10 maintains a count of the number of sheets (Machine_Page_Count) printed by the imaging apparatus 10, which is stored in a memory (not shown) of the imaging apparatus 10.
During the formation of toner images by the imaging apparatus 10, waste toner is generated that needs to be cleaned off the respective PC members 46 and the transfer member 36. This waste toner is then dumped into a waste toner box 56 (
The output AC voltage is provided to an Analog to Digital (A/D) converter 82 that converts the output AC voltage to an output digital voltage value of the waste toner box 56 (AVG_WTB_AD). The sensor circuitry 74 measures the output digital voltage value at a beginning and end of a plurality of intervals. In one embodiment, a predetermined number, such as 500, of pages are printed during each of the plurality of intervals. However, the interval may have fewer or more number of pages printed.
The controller 76 that is in electrical communication with the sensor circuitry 74 obtains this digital output voltage value. The memory of the imaging apparatus 10 provides the Machine_Page_Count to the controller 76. The controller 76 determines an amount of waste toner within the waste toner box 56 based on the relative change in capacitance (measured as a voltage value, AVG_WTB_AD) of the capacitor 66 with respect to the Machine_Page_Count. It is understood that controller 76 may be implemented in a number of ways, such as a state machine in an integrated circuit or a processor which executes firmware instructions stored in memory associated with controller 76.
Next, at act 98 the controller 72 determines whether the imaging apparatus 10 has printed a predetermined full page delta (FULL_PAGES_DELTA), which represents a predetermined number of pages printed from the time the waste toner box 56 is identified as nearly full to the time waste toner box 56 is identified as full. In case the condition in act 98 is true, the amount of toner in the waste toner box 56 is determined to be full (act 100). In one embodiment the FULL_PAGES_DELTA value is 2000.
When the toner is above the plates 70 (represented by point 104) of the capacitor 66, the graph 102 flattens, i.e., the relative change in capacitance with respect to the number of pages printed by the imaging apparatus 10 approaches zero. When this occurs, the waste toner box 56 is determined to be nearly full. After the waste toner box 56 is determined to be nearly full at point 104, the imaging apparatus 10 prints a predetermined (Full_Pages_Delta) number of pages, after which the waste toner box 56 is determined as full. Determining the amount of toner within the waste toner box 56 based on the relative change in the capacitance ensures that the controller 72 can determine the amount of toner within the waste toner box 56 even when the toner is above the plates 70 of the capacitor 66. Determining the amount of toner within the waste toner box 56 based on the relative change in the capacitance also ensures that the calibration value of the capacitor 66 is not required to determine the amount of waste toner in the waste toner box 56, as in prior systems.
Initially, at act 106 when the waste toner box 56 is inserted in the (new) imaging apparatus 10, the voltage value corresponding to the capacitance of the capacitor 66 is determined. Next, at act 108 the voltage value is compared with the stored predetermined values corresponding to the empty waste toner box 56, the near full waste toner box 56, the full waste toner box 56, and the waste toner box 56 missing from the imaging apparatus 10. Based on the comparisons and upon other variables and settings maintained prior to imaging apparatus 10 failing, the status of the waste toner box 56 within the imaging apparatus 10 is appropriately set (act 110).
a-9b illustrate the processing executed by the controller 76 when the waste toner box 56 was initialized for the first time in the factory (WTB_State=0). The processing of
In case the Avg_WTB_AD is not less than the value of AD_No_Box, a determination is made whether the value of Avg_WTB_AD is greater than or equal to a predetermined maximum allowed digital voltage value (AD_Max) (act 134). If the condition in act 134 is true, the status of the waste toner box 56 is determined as full (WTB_State=3), the imaging apparatus 10 displays the state of the waste box 56 as full (act 136), and the controller 76 exits the waste toner box algorithm. In one embodiment, the predetermined AD_Max value is 170, which can be seen in
Next, if the value of Avg_WTB_AD is less than the AD_Max value at act 138, a determination is made whether the toner level corresponds to the toner level of a new waste toner box 36. In particular, it is determined whether the value of Avg_WTB_AD is greater than a predetermined AD_Box_Present value, which is representative of the presence of waste toner box in the imaging apparatus 10, and less than a predetermined AD_New_Box voltage value, which is representative of a new waste toner box installed in the imaging apparatus 10. If this determination is true, the state of the waste toner box 56 is set as new (WTB_State=1); the value of AD_IN is set to Avg_WTB_AD wherein AD_IN represents the output of A/D converter 82 when waste toner box 56 is new; the Pages_Installed variable, which represents the page count when a new waste toner box is installed, is set to the value of the Machine_Page_Count variable; and the controller 76 exits the waste toner box algorithm. In one embodiment, the AD_Box_Present value is 75 and the AD_New_Box value is 110, which roughly correspond to the range of output voltages of A/D converter 82 when toner is below the plates of capacitor 66 as seen in
In case the condition in act 138 is false, a determination is made whether the value of Avg_WTB_AD corresponds to a toner level of a waste toner box just prior to successive measurements of Avg_WTB_AD showing a meaningful change in capacitance of capacitor 66. In particular, it is determined whether value Avg_WTB_AD is less than a predetermined AD_DEPOT1 voltage value, such as 125 (act 142). If this condition is true, the status of the waste toner box is determined as new (WTB_State=1) and the AD_In variable is set to 110 (act 144). Next, in act 146 it is determined whether the Machine_Page_Count value is greater than a DEPOT_PAGES value, which is representative of a threshold depot number of pages printed by the imaging apparatus 10 and in this embodiment may be 8000. In the event the condition in act 146 is false, box status variables and pointers are reset to values corresponding to a new waste toner box: the Pages_Installed variable is set to zero; the WTB_Page_Pointer variable, which tracks the number of voltage readings of A/D converter 82, is also set to zero; and variable WTB_AD_Pointer, which points to one of a set of recent voltage readings of A/D converter 82, is set to zero.
However, if the Machine_Page_Count variable is greater than 8000, such internal variables are set to other values corresponding to a waste toner box having had some amount of use. If the condition in act 146 is true, meaning that imaging apparatus 10 has printed more than 8000 pages, then a difference is calculated between the Machine_Page_Count and the DEPOT_PAGES values, and the Pages_Installed variable is set to the calculated difference value. The WTB_AD_Pointer variable is set to AD_Slope1 value which may be 16 in the present embodiment and corresponds to a number of voltage readings having been performed, and the Avg_WTB_AD values are loaded in an array of A/D converter output readings (act 148).
In case the Avg_WTB_AD value is greater than the AD_DEPOT1 value in act 142, it is determined whether Avg_WTB_AD is less than or equal to a predetermined voltage value AD_DEPOT2 corresponding to toner being at the top of the plates of capacitor 66, such as 150 (act 152). If this condition is true, the status of the waster toner box is determined to be nearly full (WTB_State=2), the variable NF_PAGE_COUNT, which corresponds to the page count of imaging apparatus 10 when waste toner box 56 is nearly full, is set to the Machine_Page_Count value. In addition, the imaging apparatus 10 displays that the waste toner box 56 is nearly full (act 154), and the controller 76 exits the waste toner box algorithm.
In the event the condition in act 152 is not satisfied, meaning that toner level is above capacitor 66, the status of the waste toner box 56 is determined as full (WTB_State=3), the imaging apparatus 10 displays that the waste toner box is full (act 156), and the waste toner box algorithm is exited.
a-10b illustrate the processing executed by the controller 76 when the state of the waste toner box 56 is new. Acts 160-166 are largely identical to acts 130-136 in
If the value Avg_WTB_AD is greater than value AD_No_Box and less than value AD_Max, it is determined whether the variable WTB_AD_Pointer is less than or equal to 2 and whether a difference between the value Avg_WTB_AD and variable AD_In is greater than 10 (act 168). If the condition in act 168 is true, the status of the waste toner box 56 is determined to be nearly full (WTB_State=2), the NF_PAGE_COUNT variable is set to the Machine_Page_Count value, the imaging apparatus 10 displays that the waste toner box 56 is nearly full (act 170), and the controller 76 exits the waste toner box algorithm. Acts 168 and 170 are used as a safety check of sorts to ensure there are no relatively sizeable spikes in successive voltage readings occur while the state of waste toner box 56 is new, and setting the state of waste toner box 56 to be nearly full upon such an occurrence.
If the condition in act 168 is not satisfied, in act 172 it is determined whether the number of pages printed exceeds a threshold amount before the slope of sequential capacitance readings is determined. In particular, it is determined whether the Machine_Page_Count variable is greater than or equal to the sum of variable Pages_Installed and value PAGES_AD multiplied by the sum of WTB_Page_Pointer and 1 (act 172), where the value PAGES_AD represents the number of pages printed between A/D converter readings which in this embodiment is 500. If the condition in act 172 is true, a predetermined number of the most recent A/D converter readings are stored in the above-described array, which in this case may be seven (act 174).
In act 176 it is determined whether the WTB_PagePointer variable is greater than the AD_SLOPE1 value, which in this embodiment may be 16. If the event the determination is negative, a slope is calculated by calculating the difference between the voltage readings stored in two consecutive array locations of the array storing values of the Avg_WTB_AD voltage readings and then dividing the difference by the PAGES_AD value (act 178). If this calculated slope is less than a Slope_Threshold value (act 180), which in this case represents a minimum amount of slope, then a slope_test variable is incremented by 1 (act 182). Otherwise, the slope_test variable is set to 0 (act 184). In this way, acts 180-184 maintain a record of successive slope calculations that fall below the Slope_Threshold value.
In act 186 it is determined whether the WTB_Page_Pointer variable is greater than a MAX_PAGE_POINTER value, which in this embodiment may be 40 and represents a maximum number of voltage readings of A/D converter 82, and whether the slope_test variable is greater than or equal to three. In the event the condition in act 186 is true, indicating that a number of Avg_WTB_AD readings have occurred and there have been three readings showing substantially no slope, the status of the waste toner box is determined to be nearly full (WTB_State=2), the NF_Page_Count variable is set to the Machine_Page_Count value, the imaging apparatus 10 displays that the waste toner box is nearly full (act 188), and the controller 76 exits the waste toner box algorithm.
If the Avg_WTB_AD variable is less than the AD_Max value and greater than the AD_NO_Box value, it is determined whether the Machine_Page_Count value is greater than the sum of the NF_Page_Count value and the FULL_PAGES_DELTA value, which in this embodiment may be 2000 (act 198). If this condition (act 198) is satisfied, meaning that imaging apparatus 10 has printed pages numbering a FULL_PAGES_DELTA value since waste toner box 56 was identified as nearly full, the status of the waste toner box 56 is determined as full (WTB_State=3), the imaging apparatus 10 displays the status of the waste box as full (act 200), and the controller 76 exits the waste toner box algorithm.
If the condition in act 198 is not satisfied, thereby indicating that waste toner box 56 is neither missing nor full, it is determined whether the Avg_WTB_AD value is less than the AD_New_Box value (act 202) which in this embodiment may be 110. If the determination of act 202 is true, thereby indicating that the voltage reading of A/D converter 82 corresponds to toner level not yet reaching plates 70 of capacitor 66, the Pages_Installed variable is set to the Machine_Page_Count value, the WTB_Page_Pointer is set to 0, the WTB_AD_Pointer is set to 0, the AD_IN variable is set to Avg_WTB_AD value, the status of the waste toner box 56 is determined as a new waste toner box (WTB_State=1) (act 204), and the controller 76 exits the waste toner box algorithm.
It is understood that the present invention is not limited to the particular order of processing activity shown in FIGS. 5 and 7-13 such that the present invention contemplates other arrangements of such processing activity. It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the spirit and scope of the invention. Thus it is intended that the present invention cover the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
This patent application is related to and claims benefit from U.S. Patent Application Ser. No. 61/182,562, filed May 29, 2009, entitled “Improved Algorithm for a Capacitance Sensor in an Electrophotographic Printer” and assigned to the assignee of the present application, the content of which is hereby incorporated by reference herein in its entirety.
