This patent specification claims priority from Japanese Patent Application No. 2008-130912, filed on May 19, 2008 in the Japan Patent Office, the entire contents of which are hereby incorporated by reference herein.
1. Field of the Invention
The present invention generally relates to an image forming apparatus such as a copier, a printer, a facsimile machine, and the like, and a control method therefor.
2. Discussion of the Background
In general, an electrophotographic image forming apparatus such as a copier, a printer, a facsimile machine, and a multifunction machine including at least two of these functions includes a writing unit for forming electrostatic latent images on an image carrier, a developing device for developing the latent images with developer such as toner, a transfer member for transferring the developed image onto a sheet of recording media, and a fixer for fixing the image on the sheet.
Typically, several components of the image forming apparatus, such as the writing unit, the developing device, and the fixer, generate heat. Therefore the image forming apparatus further includes a cooling fan to generate airflow to cool such components and a surrounding area.
For example, in the developing device, when a developer transport member such as a transport screw agitates and transports the developer, heat is generated due to friction between the developer transport member and the developer, which can cause the developer in the developing device to deteriorate. Further, if the temperature of the developing device itself and in the surrounding area rises excessively, it can cause a malfunction of the image forming apparatus and/or imaging failure. Therefore, typically a cooling fan is provided close to the developing device to inhibit an excessive rise in temperature of the developing device and in the surrounding area.
For example, one known image forming apparatus controls velocity (rotational frequency) of the cooling fan to cool the developing device and an area surrounding it according to ambient temperature. Because the temperature of the developing device and in the surrounding area is liable to rise when ambient temperature is higher, this image forming apparatus increases the velocity of the cooling fan when ambient temperature is higher and reduces the velocity of the cooling fan when ambient temperature is lower so as to reduce noise of as well as energy consumed by the cooling fan.
Heat generation in the developing device is described below in further detail.
During image formation, as the developer transport member agitates and transports the developer in the developing device, the developer tends to adhere to axis bearings that rotationally support a rotational axis of the developer transport member. Over time, the developer accumulates on the axis bearing, and clogs a gap between the axis bearing and the rotational axis of the developer transport member, thus hindering rotation of the developer transport member. In this state, the developer transport member slidingly contacts the axis bearing via the developer, generating frictional heat, which causes the temperature around the axis bearing to rise, and accordingly the temperature rises in the developing device and in the surrounding area.
However, in the above-described known image forming apparatus, as long as the ambient temperature does not change, the velocity of the cooling fan remains constant regardless of whether or not the above-described frictional heat is generated. That is, it is likely that the velocity of the cooling fan is set to a sufficiently high value so as to restrict a rise in the temperature of the developing device and in the surrounding area even when frictional heat is generated, which means the velocity is excessively high while frictional heat is not yet generated.
Therefore, during a period from when use of a new developing device is started until the developer has accumulated on the axis bearing of the developer transport member over time, noise of as well as energy consumed by the cooling fan are unnecessarily large.
To cope with the inconveniences described above, there is a need to control the cooling fan efficiently, which known image forming apparatuses fail to do.
In view of the foregoing, in one illustrative embodiment of the present invention, an image forming apparatus includes a latent image carrier, a latent image forming unit to form an electrostatic latent image on the latent image carrier, at least one developing device disposed to contact the image carrier to develop the latent image on the image carrier with developer contained therein, a cooling mechanism including at least one cooling device disposed close to the developing device to cool the developing device, a developer amount detector electrically connected to the developing device to detect an amount of the developer remaining in the developing device, and a cooling mechanism controller connected to the cooling mechanism to change a cooling power of the cooling device according to a detection result generated by the developer amount detector. Each developing device includes at least one rotary member whose shaft is rotationally supported by at least one bearing. A predetermined amount of developer is preliminarily contained in the developing device, and new developer is not to be supplied to the developing device with while any developer remains therein.
Another illustrative embodiment of the present invention provides a control method for the image forming apparatus described above. The control method includes detecting an amount of the developer remaining in the developing device, and setting a cooling power of the cooling mechanism according to a detected amount of the developer remaining in the developing device.
A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
In describing preferred embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner and achieve a similar result.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views thereof, and particularly to
Referring to
Each process cartridge 5 includes a drum-shaped photoreceptor 22 serving as a latent image carrier, a charger 4 to charge a surface of the photoreceptor 22, a developing device 2 to develop an electrostatic latent image formed on the photoreceptor 22, and a photoreceptor cleaner 3 to clean the photoreceptor 22. Each process cartridge 5 is detachably attachable to the image forming apparatus and can be replaced when its life expires. Thus, consumables in the process cartridge 5 can be replaced simultaneously.
In the present embodiment, the developer is one-component developer including toner, and the developing device 2 is replaced when the toner contained therein has been consumed.
In
In each process cartridge 5, the photoreceptor 22 is rotated by a driving unit, not shown, and the charger 4 charges the surface of the photoreceptor 22 uniformly. Then, the writing unit 70 scans the surface of each photoreceptor 22 with the laser beam L that is emitted from a laser diode, not shown. More specifically, the writing unit 70 directs the laser beams L onto the respective photoreceptors 22 using multiple optical lenses and mirrors while deflecting the laser beams L with a polygon mirror in a main scanning direction. Alternatively, the writing unit 70 can direct beams emitted from multiple LEDs (Light-Emitting Diodes) included in an LED array onto the respective photoreceptors 22.
Thus, electrostatic latent images for yellow, magenta, cyan, and black are formed on the respective photoreceptors 22.
Subsequently, in each process cartridge 5, the developing device 2 develops the latent image with toner into a toner image. Thus, the process cartridges 5Y, 5M, 5C, and 5K form yellow, magenta, cyan, and black images on the respective photoreceptors 22Y, 22M, 22C, and 22K in that order.
These toner images are then transferred from the photoreceptors 22 onto the intermediate transfer belt 66 that rotates counterclockwise in
In the transfer unit 65, the intermediate transfer belt 66 is looped around a driving roller 17, a driven roller 69, four primary transfer rollers 83Y, 83M, 83C, and 83K serving as transfer bias members. The driving roller 17 is driven by a driving source, not shown, and rotates the intermediate transfer belt 66.
The transfer unit 65 further includes a secondary transfer roller 80 disposed outside the loop of the intermediate transfer belt 66, a belt cleaner 81 that contacts the outer surface of the intermediate transfer belt 66, and a backup roller 82 disposed to face the belt cleaner 81 via the intermediate transfer belt 66.
The primary transfer rollers 83 sandwich the intermediate transfer belt 66 together with the respective photoreceptors 22. Thereby, primary transfer nips are formed between an outer surface of the intermediate transfer belt 66 and the respective photoreceptors 22.
Each primary transfer roller 83 receives primary transfer bias from a transfer bias power source, not shown, and thus a transfer electrical field is formed between the electrostatic latent image formed on the photoreceptor 22 and the primary transfer roller 83. Alternatively, transfer chargers or transfer brushes can be used as the transfer bias members instead of the primary transfer rollers 83.
More specifically, as the respective photoreceptors 22 rotate, the yellow, magenta, cyan, and black toner images formed thereon sequentially reach the respective primary transfer nips, where the toner images are primarily transferred from the respective photoreceptors 22 onto the intermediate transfer belt 66 with an effect of the transfer electrical field and nip pressure. The yellow, magenta, cyan, and black toner images are superimposed one on another on the intermediate transfer belt 66 in that order, forming a multicolor toner image thereon.
The secondary transfer roller 80 sandwiches the intermediate transfer belt 66 together with the driven roller 69, thus forming a secondary transfer nip between the secondary transfer roller 80 and the outer surface of the intermediate transfer belt 66. The secondary transfer roller 80 receives secondary transfer bias from a transfer bias source, not shown, which forms a secondary transfer electrical field between the secondary transfer roller 80 and the driven roller 69 that is grounded.
The image forming apparatus further includes a sheet cassette 84, disposed beneath the transfer unit 65, that contains multiple sheets P of recording media, a feed roller 85, a sheet feed path 86, and a post-transfer path 88. A pair of registration rollers 87 is disposed close to an end of the sheet feed path 86.
The sheet cassette 84 is slidable into and out of a housing of the image forming apparatus. The feed roller 85 contacts the sheet P on the top in the sheet cassette 84 and feeds the sheet P to the sheet feed path 86 by rotating counterclockwise in
The registration rollers 87 stop rotating with a leading edge portion (hereinafter also “first edge portion”) of the sheet P sandwiched therebetween and then forward the sheet P to the secondary transfer nip, timed to coincide with the multicolor toner on the intermediate transfer belt 66.
When the sheet P laps over the multicolor toner image on the intermediate transfer belt 66 in the secondary transfer nip, the multicolor toner image is secondarily transferred onto a first surface of the sheet P with an effect of the secondary transfer electrical field and nip pressure. On the sheet P, white is added to the multicolor image, making the image into a natural-colored image, which is so-called a full-color image, which is yet unfixed on the sheet P. Then, the sheet P leaves both the secondary transfer roller 80 and the intermediate transfer belt 66 through curvature separation. The sheet P is then transported along the post-transfer path 88.
After the toner image is thus transferred from the intermediate transfer belt 66, the belt cleaner 81 removes any toner remaining on the intermediate transfer belt 66. The backup roller 82 supports the intermediate transfer belt 66 from its inner surface to facilitate cleaning of the intermediate transfer belt 66.
The image forming apparatus further includes a fixer 34 disposed downstream from the secondary transfer roller 80 in a direction in which the sheet P is transported (hereinafter “sheet transport direction”), a post-fixing path 89, a discharge path 90, a pair of discharge rollers 91, a hinged sheet reverse unit 40 that is a right side edge portion of the image forming apparatus in
The fixer 34 includes a fixing roller 34a and a pressure roller 34b that rotates while pressing against the fixing roller 34a, forming a fixing nip therebetween. The fixing roller 34a includes a heat source, not shown, such as a halogen heater. The sheet P is sandwiched in the fixing nip so that the first surface of the sheet P on which the unfixed toner image is formed closely contacts the fixing roller 34a, and the toner image is fixed on the sheet P with heat and pressure.
After passing through the fixing nip, the sheet P is transported along the post-fixing path 89 to a branch point provided with a switch pawl 42 that can block an end portion of the post-fixing path 89 to guide the sheet P to a first reverse path 41 leading to the sheet reverse unit 40 by pivoting about a rotation axis 42a. More specifically, when the fixer 34 sends out the sheet P, the switch pawl 42 is at a position indicated by a solid line in
The image forming apparatus according to the present embodiment can accommodate both a single-side printing in which an image is formed on only one side (first surface) of the sheet P and a duplex printing in which images are formed on both sides of the sheet P. Either single-side printing or duplex printing can be set according to an input operation of a user through an operation panel, not shown, provided with numeric keys or control signals from a computer.
When single-side printing is selected, after the image is fixed on its first surface, the sheet P is discharged by the discharge rollers 91 onto an upper surface of the upper cover 50 serving as a stack table.
By contrast, in duplex printing, the sheet P is transported along the discharge path 90 with the leading edge portion thereof sandwiched between the discharge rollers 91 until a trailing edge portion of the sheet P has passed through the post-fixing path 89. It is to be noted that the leading edge portion and the trailing edge portion of the sheet P in the sheet transport direction are hereinafter referred to as a first edge portion and a second edge portion, respectively.
Subsequently, the switch pawl 42 pivots about the rotation axis 42a to a position indicated by a dotted line shown in
The sheet reverse unit 40 and turning the sheet P over therein are described in further detail below with reference to
The hinged sheet reverse unit 40, that is, the right side edge portion of the image forming apparatus in
The sheet P that is forwarded by reverse rotation of the discharge rollers 91 is transported downward in
Subsequently, the sheet P reversed in the sheet reverse unit 40 is again transported through the sheet feed path 86 to the second transfer nip, where another image is transferred onto a second surface of the sheet P. The sheet P is further transported through the post-transfer path 88, the fixer 34, the post-fixing path 89, and the discharge path 90 and then discharged by the discharge rollers 91 outside the image forming apparatus.
The outer cover 45 of the sheet reverse unit 40 can rotate around the rotation axis 40a provided on the housing of the image forming apparatus. When the outer cover 45 is pulled down, both the outer cover 45 and the rotary member 46 held therein open to expose the interior of the image forming apparatus as indicated by dotted lines in
In other words, the sheet feed path 86, the secondary transfer nip, the post-transfer path 88, the fixing nip, the post-fixing path 89, the discharge path 90, which are formed between a main body of the image forming apparatus and the sheet reverse unit 40, can be respectively divided into two in a vertical direction in
Further, the outer cover 45 includes a rotation axis, not shown, about which the rotary member 46 can rotate when the outer cover 45 is opened. When the rotary member 46 is opened with respect to the outer cover 45, the first reverse path 41 and the second reverse path 44 can be respectively divided into two, being exposed to facilitate removal of a jammed sheet therefrom.
The upper cover 50 is rotatable about a shaft 51 counterclockwise in
In the image forming apparatus described above, because the developing units 2 generate heat while agitating and transporting the developer in image formation, the image forming unit according to present embodiment further includes a cooling mechanism, which is described below with reference to
Referring to
As shown in
The developing device 2 is described in further detail below with reference to
Referring to
The developing roller 24 supplies the toner that is magnetically attracted to its surface to the photoreceptor 22, and an end portion of its shaft 24a is rotationally supported by a bearing 29. The supply roller 25 supplies the toner to the developing roller 24, and an end portion of its shaft 25a is rotationally supported by a bearing 30. The agitation and transport screw 32 transports the toner while agitating it, and an end portion of its shaft 32a is rotationally supported by a bearing 31.
Although not shown in
The developing roller 24 contacts the supply roller 25, and the developing roller 24 and the supply roller 25 rotate in an identical direction. Thus, the toner is supplied from the supply roller 25 to the developing roller 24 and further to a development range that is a contact area between the developing roller 24 and the photoreceptor 22, where the toner adheres to the electrostatic latent image formed on the photoreceptor 22, developing it into a toner image. Because the developing roller 24 and the supply roller 25 rotate in an identical direction, frictional heat is generated.
As each of the developing roller 24, the supply roller 25, and the agitation and transport screw 32 transports the developer in each developing device 2 in image formation, the developer tends to accumulate in a gap between the shafts (24a, 25a, or 32a) and the bearings (29, 30, or 31) that rotationally support the shaft. When a certain amount of the developer has been consumed in image formation, that is, when an amount of the developer remaining in the developing device 2 is relatively small, the gap can be clogged with the developer, generating frictional heat between the shafts and the bearings via the developer. This is because a relatively large amount of toner has already been agitated and transported in the developing device 2, and accordingly, the amount of toner accumulated on the bearing can be relatively large. In other words, the amount of toner consumption substantially equals the amount of the toner that has been transported through the developing device 2 to the photoreceptor 22, and therefore the amount of the toner remaining in the developing device 2 is inversely proportional to the amount of the toner that has been agitated and transported in the developing device 2.
Therefore, as shown in
As the toner amount calculator 14 is provided not in the developing devices 2 but in the main body of the image forming apparatus, the cost of the image forming apparatus can be lower compared with a case in which the toner amount calculator 14 is provided in the developing devices 2 that are consumables.
In the present embodiment, the amount of toner consumed to develop one dot of the electrostatic latent image formed on the photoreceptor 22 is preliminarily obtained in a test run. For example, when used of a new developing device 2 is started, counting of the number of dots of the exposure light the writing unit 70 directed to the corresponding photoreceptor 22 is started, and the amount of toner consumed in each developing units 2 is calculated based on the accumulated number of dots of the exposure light. Thus, the remaining toner amount in the developing device 2 is calculated based on the number of dots of exposure light directed to the photoreceptor 22 by the writing unit 70.
Next, a control system of the image forming apparatus according to the present embodiment is described below with reference to a block diagram shown in
As shown in
The controller 13 includes a time count unit that can be a clock or timer, and a count calculation unit that can be a counter. The clock measures both an image formation time, which is a time period during which a driving motor of the driving unit 15 drives the developing roller 24, and the like of the developing device 2 to rotate (hereinafter “driving time of the driving unit 15”), and as a standby time, which is a time period during which the driving motor is not activated (hereinafter “non-driving time of the driving unit 15”). The count calculation unit of the controller 13 calculates the temperature count value that represents temperature inside the image forming apparatus.
More specifically, during the image formation time, the temperature count value is incremented at a first predetermined or given rate to respond to an increase in temperature inside the image forming apparatus and is decremented at a second predetermined or given rate to respond to a decrease in the temperature inside the image forming apparatus. In the present embodiment, the temperature count value is incremented by 2 for each second during the image formation time and is decremented by 3 for each second during the standby time.
It is to be noted that the temperature inside the image forming apparatus means temperature around the developing devices 2.
When the temperature count value thus calculated is less than 0 or greater than 5000, the temperature count value is corrected to 0 and 5000, respectively. The temperature count value 0 imitates a state in which the temperature inside the image forming apparatus is substantially similar to the ambient temperature and will not fall further. That is, keeping the temperature count value equal to or greater than 0 can make the temperature count value dovetail with a fact that the temperature inside the image forming apparatus decreases to a constant temperature when the image forming apparatus has been unused for a sufficiently long time period.
Similarly, the temperature count value 5000 imitates a state in which the temperature inside the image forming apparatus is kept at a certain temperature and will not rise further.
When temperature inside the image forming apparatus is represented by the above-described temperature count value, it is not necessary to provide a temperature sensor inside the image forming apparatus to detect temperature therein, and thus cost of the image forming apparatus can be lower compared with a case in which such a temperature sensor is provided on or close to the developing device 2. Needless to say, alternatively, temperature inside the image forming apparatus can be detected with such a temperature sensor although the cost increases accordingly.
An example of control of the image forming apparatus according to the present embodiment performed by the controller 13 is described below with reference to a flowchart shown in
In the present embodiment, the controller 13 sets the cooling mode of the axial-flow fans 8a and 8b according to ambient temperature, an estimated temperature inside the image forming apparatus, and the amount of the toner remaining in the developing device 2.
Referring to
By contrast, when the ambient temperature is not lower than the predetermined temperature (YES at S1), at S2 the controller 13 checks whether or not the temperature count value is equal to or greater than a predetermined or given value, for example, 4800. When the temperature count value is less than the predetermined value (NO at S2), the first cooling mode is kept.
By contrast, when the temperature count value is not less than the predetermined value (YES at S2), at S3 the controller 13 checks whether or not the remaining toner amount is not greater than a predetermined or given percentage, for example, 15%, of a maximum storage amount of the toner in the developing device 2.
When the remaining toner amount is greater than the predetermined percentage of the maximum storage amount (NO at S3), the axial-flow fans 8a and 8b are still kept at the first cooling mode.
By contrast, when the remaining toner amount is not greater than the predetermined percentage of the maximum storage amount (YES at S3), at S4 the axial-flow fans 8a and 8b are set to a second cooling mode in which the axial-flow fans 8a and 8b rotate at the full velocity, for example, 4500 rpm.
It is to be noted that, in the present embodiment, when the amount of toner remaining in at least one of the developing devices 2Y, 2M, 2C, and 2K is the predetermined percentage or less at S3, both axial-flow fans 8a and 8b can be set to the second cooling mode.
As described above, in the present embodiment, the axial-flow fans 8a and 8b are set to the second cooling mode only when all three conditions: (1) the remaining toner amount is not greater than the predetermined percentage (e.g. 15%) of the maximum storage amount, (2) ambient temperature is not lower than the predetermined temperature (e.g. 27° C.), and (3) the temperature count value is not less than the predetermined value (e.g. 4800), are satisfied. That is, the axial-flow fans 8a and 8b rotate at a higher velocity that in the present embodiment is the full velocity (e.g. 4500 rpm) when these conditions are satisfied.
By contrast, the axial-flow fans 8a and 8b are controlled to operate in the first cooling mode to rotate at a lower velocity that in the present embodiment is about half the full velocity (e.g. 4200 rpm) when at least one of the above-described conditions is not satisfied.
Thus, noise of as well as energy consumed by the axial-flow fans 8a and 8b are not unnecessarily large because the axial-flow fans 8a and 8b are set to rotate at the higher velocity only when the above-described three conditions are satisfied, which is likely to increase the temperature around the developing devices 2.
Control of the axial-flow fans according to a variation of the above-described embodiment is described below.
An image forming apparatus according to this variation has a configuration similar to that of the image forming apparatus shown in
More specifically, in this variation, the controller 13 sets the axial-flow fan 8a, which is close to the developing device 2K and 2C, to the second cooling mode to rotate at the higher velocity when all three conditions: (1A) the remaining toner amount in at least one of the developing device 2K and 2C is not greater than the predetermined percentage (e.g. 15%) of the maximum storage amount, (2) ambient temperature is not lower than the predetermined temperature (e.g. 27° C.), and (3) the temperature count value is not less than the predetermined value (e.g. 4800), are satisfied. The remaining toner amount is calculated by the toner amount calculator 14 shown in
Similarly, the axial-flow fan 8b, which is close to the developing device 2Y and 2M, is controlled to operate at the higher velocity when the above-described conditions 2 and 3 as well as a new condition (1B), in which the remaining toner amount in at least one of the developing device 2Y and 2M is not greater than the predetermined percentage (e.g. 15%) of the maximum storage amount, are satisfied.
Similarly to the above-described embodiment, when at least one of the three conditions is not satisfied, each of the axial-flow fans 8a and 8b is set to the first cooling mode to rotate at the lower velocity.
As described above, in this variation, when one of the developing devices 2 is under such conditions that are likely to increase the temperature of the developing device 2, only the axial-flow fan 8a or 8b that is close to that developing device 2 can be rotated at the higher velocity. Therefore, noise of as well as energy consumed by the axial-flow fans 8a and 8b can be reduced.
Control of the axial-flow fans according to another illustrative embodiment of the present invention is described below with reference to
The results shown in
In
It is to be noted that, although a temperature sensor was disposed close to the developing device 2 to detect the temperature around the developing device 2 in the experiment, such a temperature sensor is not necessary in standard image formation because, also in the present embodiment, the controller 13 shown in
As represented by line A shown in
Therefore, the temperature count value 4800 or greater represents a temperature close to a predetermined temperature at which the temperature around the developing device 2 is kept constant or substantially constant. When the image formation was further continued from this state, the temperature around the developing device 2 was kept substantially constant until the remaining toner amount decreased to 15% or less. When the remaining toner amount was 15% or less, the temperature around the developing device 2 reached 45° C. This is because, in such a state, the gap between the shafts (24a, 25a, and 32a) of the rotary members (24, 25, and 32) and the respective bearings (29, 30, and 31) are clogged with the developer, and the developer serves as resistance between the shaft and the bearing, generating frictional heat therebetween.
Here, the increase in the temperature around the developing device 2 is due not to the number of the output sheet but to the remaining toner amount in the developing device 2, which is described in further detail below with reference to the graph shown in
The graph shown in
As shown in
In other words, the amount of toner adhering to the bearing 29, 30, and/or 31 in the developing device 2 depends on the amount of toner that has been consumed. While the amount of toner adhering to the bearing 29, 30, and/or 31 is relatively small, it does not affect the temperature inside the image forming apparatus significantly. However, when the remaining toner amount is 15% or less, as has been noted above, a relatively large amount of toner has already been agitated and transported in the developing device 2, and accordingly, the amount of toner accumulated on the bearing can be relatively large. In such a state, the toner serves as resistance between the shaft and the bearing, generating frictional heat therebetween, which increase the temperature inside the developing device 2, especially in an area close to the bearing.
Referring to
However, as represented by line B shown in
Therefore, in the present embodiment, when ambient temperature is 32° C. or higher, the rotation frequency of the axial-flow fans 8a and 8b is set to the higher velocity (full velocity) so as to keep the temperature around the developing device 2 at 47° C. or lower, and thus maintaining sufficiently high image quality.
Additionally, because the rotation frequency of the axial-flow fans 8a and 8b is set to the higher velocity only when the temperature around the developing device 2 is likely to increase, noise of as well as energy consumed by the axial-flow fans 8a and 8b can be reduced similarly to the embodiment described above.
Control of the axial-flow fans according to another illustrative embodiment of the present invention is described below. Similarly to the above-described embodiment, an image forming apparatus according to this embodiment has a configuration similar to that of the image forming apparatus shown in
In the present embodiment, the rotation frequency of the axial-flow fans 8a and 8b is increased in multiple semi-continuous steps according to the amount of the toner remaining in the developing device 2, rather than just the tow modes as in the above-described embodiments.
The amount of toner adhering to the bearings 29, 30, and 31 shown in
Therefore, a degree of the toner adhering to the bearings 29, 30, and 31 can be estimated based on the detection result generated by the toner amount calculator 14.
Therefore, in the present embodiment, the controller 13 increases the cooling power, that is, rotation frequency, of the axial-flow fans 8a and 8b step-by-step according to the detection result generated by the toner amount calculator 14. With this control, the cooling power of the axial-flow fans 8a and 8b can be set to a proper power to prevent or reduce an excessive increase in the temperature around the developing device 2 due to friction between the bearings 29, 30, and 31 and the respective shafts 24a, 25a, and 32a.
Additionally, neither noise of nor energy consumed by the axial-flow fans 8a and 8b is unnecessarily large because rotation frequency of the axial-flow fans 8a and 8b is increased step-by-step.
Combinations of the remaining toner amount and rotation frequency of the axial-flow fans 8a and 8b to be increased step-by-step depend on the configuration of the developing device 2 and/or an extent to which the noise and/or energy consumption is reduced. Therefore, such combinations can be determined by observing temperature increase in the developing devices 2 as well as cooling performance of the cooling devices (axial-flow fans 8a and 8b) through an experiment.
Further, when the rotation frequency of the axial-flow fans 8a and 8b is set considering ambient temperature and/or the temperature inside the image forming apparatus in addition to the remaining toner amount as in the embodiment described above with reference to
As described above, in an illustrative embodiment of the present invention, the image forming apparatus includes the photoreceptor 22 serving as the latent image carrier, the wiring unit 70 serving as the latent image forming unit, at least one developing device 2 containing developer including toner to develop the latent image, and the axial-flow fans 8a and 8b serving as the cooling mechanism including at least one cooling device to cool the developing device 2.
The developing device 2 includes, as the rotary members, the developing roller 24, the supply roller 25, and the agitation and transport screw 32 that are rotationally supported by the respective bearings 29, 30, and 31. New developer is not supplied to the developing device 2 while any developer remains therein. Instead, the developing device 2 is replaced or new developer is supplied thereto after all or substantially all the developer preliminarily contained therein is consumed.
The image forming apparatus further includes the toner amount calculator 14 and the controller 13. The toner amount calculator 14 serves as the developer amount detector to detect an amount of the toner remaining in each developing device 2 after use of that developing device 2 in which a predetermined amount of developer is preliminarily contained is started. The controller 13 serves as the cooling mechanism controller that changes the cooling power of the axial-flow fans 8a and 8b according to a detection result generated by the toner amount calculator 14.
Thus, even when the toner accumulates on the bearings 29, 30, and 31 over time, and accordingly friction heat is generated between the shafts 24a, 25a, and 32a of the rotary members 24, 25, and 32 and the respective bearings 29, 30, and 31, the cooling power of the axial-flow fans 8a and 8b can be set properly to prevent an excessive increase in the temperature in and around the developing device 2 by changing the cooling power of the axial-flow fans 8a and 8b according to the remaining toner amount.
Additionally, neither noise of nor energy consumed by the axial-flow fans 8a and 8b is unnecessarily large while such friction heat is not yet generated because the cooling power of the axial flow fans 8a and 8b is determined according to the degree of accumulation of the toner on the bearings 29, 30, and 31 that is estimated based on the remaining toner amount.
The controller 13 checks whether or not the first condition, the remaining toner amount detected by the toner amount calculator 14 is not greater than the predetermined amount, is satisfied. Then, the controller 13 operates the axial-flow fans 8a and 8b in the first cooling mode when the first condition is not satisfied and in the second cooling mode whose cooling power is higher than that of the first cooling mod when first condition is satisfied.
When the image forming apparatus includes multiple developing devices 2, the remaining toner amount in each developing device 2 can be detected, and the controller 13 can increase the cooling power of the cooling mechanism when the remaining toner amount in at least one of the multiple developing devices 2 is not greater than the predetermined amount. The cooling power of the axial-flow fans 8a and 8b can be easily increased by increasing their rotation frequency.
Alternatively, the controller 13 increases the cooling power of the axial-flow fans 8a and 8b step-by-step as the remaining toner amount decreases so that the cooling power can match an increase in the temperature around the developing device 2, that is, the degree of accumulation of the toner on the bearings 29, 30, and 31.
The image forming apparatus can further include the temperature sensor 11 to detect ambient temperature, and the controller 13 can further checks whether or not the second condition, ambient temperature is not lower than the predetermined temperature (e.g. 27° C.), is satisfied. Then, the controller 13 can set the axial-flow fans 8a and 8b to the second cooling mode only when both the first condition and the second condition are satisfied, otherwise, sets the axial-flow fans 8a and 8b to the first cooling mode. Thus, the noise of and energy consumed by the axial-flow fans 8a and 8b can be further reduced.
Further, controller 13 can measure an image formation time period as well as a standby time period, and calculate a temperature count value representing the temperature inside the image forming apparatus based on those time periods. Thus, the controller 13 can also serve as the time count unit as well as the count calculation unit.
In this case, the controller 13 can check whether or not the third condition, the temperature count value is not less than the predetermined value (e.g. 4800), is satisfied. Then, the controller 13 can set the axial-flow fans 8a and 8b to the second cooling mode only when both the first condition and the third condition are satisfied, otherwise, sets the axial-flow fans 8a and 8b to the first cooling mode.
Thus, the noise of and energy consumed by the axial-flow fans 8a and 8b can be further reduced. Additionally, as the temperature inside the image forming apparatus can be detected without a temperature sensor, the cost of the image forming apparatus can be relatively low.
Further, because the driving time and the non-driving time of the driving unit 15 is measured as the image formation time period and as the standby time period, respectively, the image formation time period as well as the standby time period can be measured relatively accurately.
Alternatively, the controller 13 can set the axial-flow fans 8a and 8b to the second cooling mode only when all the first condition, the second condition, and the third condition are satisfied, otherwise, sets the axial-flow fans 8a and 8b to the first cooling mode.
Additionally, in the above-described embodiment, the image forming apparatus includes multiple developing devices 2Y, 2M, 2C, and 2K divided into at least two groups (2Y and 2M; and 2C and 2K), and multiple axial-flow fans 8a and 8b each of which cools the developing devices 2Y and 2M, or 2C and 2K, that belong to the different groups. The remaining toner amount in at least one developing device 2 in each group is detected, and the axial-flow fans 8a and 8b are separately controlled. Thus, controller 13 can set the cooling power of one of the multiple cooling devices that cools the developing device 2 to be cooled to the second cooling mode.
Further, the present invention can be embodied as a control method for the image forming apparatus described above. The control method includes detecting an amount of the toner remaining in the developing device 2, and setting the cooling power of the axial-flow fans 8a and 8b according to a detected amount of the developer remaining in the developing device 2.
In the step of setting the cooling power of the axial-flow fans 8a and 8b, the cooling power is set to the first cooling mode initially, and then whether or not the first condition is satisfied is checked. When the first condition is satisfied, the axial-flow fans 8a and 8b are set to the second cooling mode. As the first cooling mode and the second cooling mode, the velocity of the axial-flow fans 8a and 8b, serving as the cooling devices, is set to different velocities.
Alternatively, in the step of setting the cooling power of the axial-flow fans 8a and 8b, the cooling power can be increased step-by-step as the remaining toner amount decreases.
The control method can further include detecting ambient temperature with the temperature sensor 11.
The control method can further includes measuring an image formation time period (driving time of the driving unit 15) as well as a standby time period (non-driving time of the driving unit 15), and calculating a temperature count value representing a temperature inside the image forming apparatus based on the image formation time period and the standby time period.
In the step of calculating the temperature count value, the temperature count value is incremented at the first predetermined rate (e.g., 2 for each second) during the image formation time period and decremented at the second predetermined rate (e.g., 3 for each second) during the standby time period, and the temperature count value is constantly set to a value equal to or greater than 0.
In setting the cooling power of the axial-flow fans 8a and 8b, wither or not first condition and at least one of the second condition and the third condition can be satisfied is checked.
As can be appreciated by those skilled in the art, the elements of the various embodiment described above can be combined freely.
Numerous additional modifications and variations are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein.
Number | Date | Country | Kind |
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2008-130912 | May 2008 | JP | national |