Apparatus, system, and method of controlling an image processing apparatus

An image processing apparatus having a collected toner container in which residual toner is accumulated is controlled by: obtaining a supplied toner amount, obtaining a total number of printed sheets, calculating an average number of printed sheets per image forming job, calculating an average printing ratio based on the supplied toner amount, the total number of printed sheets, and the average number of printed sheets per image forming job, calculating a collected toner amount based on the average number of printed sheets per image forming job and the average printing ratio, and comparing the collected toner amount with a threshold value to generate a comparison result.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is based on and claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2009-178169, filed on Jul. 30, 2009, in the Japanese Patent Office, the entire disclosure of which is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The present invention generally relates to an apparatus, system, and method of controlling an image processing apparatus, and more specifically to an apparatus, system, and method of controlling replacement of a collected toner container provided in the image processing apparatus.

BACKGROUND

An image processing apparatus such as an image forming apparatus forms a toner image on an image carrier, and transfers the toner image from the image carrier onto a recording sheet. The toner that resides on the image carrier after transfer of the toner image is removed by a cleaning device and stored in a collected toner container. The collected toner container needs to be replaced with an empty collected toner container before it becomes full of the collected toner. If the collected toner container full of the collected toner is not replaced, the collected toner may overflow and contaminate a recording sheet or nearby devices within the image processing apparatus, which may further damage the device.

In order to assist an operator to replace the collected toner container before it becomes full, the amount of collected toner that is accumulated in the collected toner container needs to be obtained. For example, the collected toner container may be provided with a detector, such as an optical sensor, that detects an amount of collected toner as described in Japanese Patent Application Publication Nos. H11-133810-A and H11-174917-A. However, a detection result output by the detector may not be accurate if toner is adhered to a surface of the detector. Further, manufacturing or maintenance cost of the image processing apparatus may increase if the detector is to be provided.

Japanese Patent Application Publication No. 2005-241676 discloses a technique that calculates an amount of collected toner accumulated in the collected toner container based on information regarding toner consumption. Alternatively, the image processing apparatus may be designed to request the operator to replace the collected toner container when a toner cartridge becomes empty, based on the assumption that the collected toner container and the toner cartridge have substantially the same life cycle. These cases, however, fail to address the problem that the amount of collected toner per printing operation varies depending on the conditions under which the printing operation is performed.

For example, when the image processing apparatus prints an image with a low printing ratio according to a user instruction, the amount of toner to be transferred onto the recording sheet decreases such that the amount of collected toner increases.

In another example, when a number of pages to be printed per printing operation is small, time in which a photoconductor or a developer is rotated without feeding a recording sheet increases with respect to the overall time required for completing printing operation. This is because the photoconductor or the developer is rotated for a predetermined time period before starting actual printing operation, either at the start of the printing operation or at the end the printing operation, in order to maintain a constant level of toner density or throughput. Accordingly, the amount of toner to be transferred onto the recoding sheet decreases such that the amount of collected toner increases.

When the image processing apparatus performs successive printing operations under either or both of the above scenarios, toner may overflow from the full collected toner container before the toner cartridge is emptied.

SUMMARY

In view of the above, there is a need for a technique of estimating the amount of collected toner with improved accuracy, while taking into account a printing condition of printing operation performed by the image processing apparatus.

Example embodiments of the present invention include an apparatus, method, system, computer program and product each capable of controlling an image processing apparatus having a collected toner container in which residual toner is accumulated. The control is performed by: obtaining a supplied toner amount indicating an amount of toner supplied to a developing unit of the image processing apparatus; obtaining a total number of printed sheets generated by the image processing apparatus; calculating an average number of printed sheets per image forming job; calculating an average printing ratio indicating an average of printing ratios of the printed sheets, based on the supplied toner amount, the total number of printed sheets, and the average number of printed sheets per image forming job; calculating a collected toner amount indicating an amount of toner accumulated in the collected toner container of the image processing apparatus based on the average number of printed sheets per image forming job and the average printing ratio; and comparing the collected toner amount with a threshold value to generate a comparison result. Based on the comparison result, whether to stop image forming operation or whether to replace the collected toner container is determined.

In addition to the above-described example embodiments, the present invention may be practiced in various other ways.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

Referring toFIG. 1, a selected portion of an image processing apparatus100is explained according to an example embodiment of the present invention. In this example, the image processing apparatus100is implemented as an image forming apparatus capable of forming an image using electrophotographic method.

The image processing apparatus100includes an optical writing device20that functions as a latent image forming device, a photoconductive drum1that functions as an image carrier such as a photoconductor, a charger2, a developing unit3, a transfer device4, a first tractor6, a sheet hopper7, a buffer8, a heating roller9, a pressure roller10, a transfer roller pair11, a swing fin12, a first paddle13, a second paddle14, a stacker table15, a second tractor16, a retractor17, a toner density detector18, a toner hopper19, a toner supply roller21, a toner empty detector22, an operation panel23, a toner cartridge24, a microprocessor25, a cleaning blade26, a cleaning brush27, a screw28, a toner pipe29, and a collected toner container30.

In example operation, the image processing apparatus100is connected to a host computer, for example, through a network. When the image processing apparatus100receives an image forming signal including dot data from the host computer, the optical writing device20irradiates and scans a laser light onto a surface of the photoconductive drum1according to the dot data.

The charger2uniformly charges the surface of the photoconductive drum1. The portion of the surface of the photoconductive drum1, which receives the laser light, is discharged to form a latent image thereon. The developing unit3supplies toner to the latent image to develop the latent image into a toner image. The transfer device4transfers the toner image to a recording sheet5.

The recording sheet5, which is transferred from the sheet hopper7, is transferred to the transfer device4through the second tractor16at a constant transfer speed. The retractor17, which is movable in the upward and downward direction, presses the recording sheet5through the transfer device4against the surface of the photoconductive drum1. At the transfer device4, the toner image formed on the surface of the photoconductive drum1is transferred onto the recording sheet5.

After the recording sheet5formed with the toner image is transferred through the first tractor6and the buffer8, the recording sheet5passes through a nip formed between the heating roller9and the pressure roller10. At the nip, the toner image formed on the recording sheet5is fixed onto the recording sheet5by heat and pressure. The recording sheet5having the fixed image thereon is transferred by the transfer roller pair11through a swing fin12to the stacker table15. The recording sheet5conveyed to the stacker table15is aligned by the first paddle13and the second paddle14.

The developing unit3is provided with the toner density detector18, which detects toner density of toner in the developing unit3, based on a ratio of the toner with respect to a carrier. When the toner density is lower than a threshold, the developing unit3drives the toner supply roller21for a predetermined time to supply toner from the toner hopper19into the developing unit3so as to maintain the toner density in the developing unit3at a predetermined level. This operation of maintaining the toner density level is controlled by the microprocessor25.

The microprocessor25is implemented as a processor and a memory, and provided with a plurality of functions including the function of detecting a supplied toner amount, counting a number of printed pages, calculating an average number of printed pages per job, calculating an average printing ratio, calculating a collected toner amount, comparing the collected toner amount with a threshold value to generate a comparison result, stopping printing operation based on the comparison result, and generating notification based on the comparison result.

For example, in order to perform the function of detecting the supplied toner amount, the microprocessor25is provided with a counter or a timer that counts a time in which the toner supply roller21is driven. Based on the time for driving the toner supply roller21, the microprocessor25determines the amount of toner supplied from the toner hopper19into the developing unit3. Further, in this example, the function of detecting the supplied toner amount is provided with a function of comparing the supplied toner amount that is counted using the timer or the counter, with a threshold that is previously set and stored in a memory such as the memory of the microprocessor25.

In order to count a number of printed pages, the microprocessor25is provided with a counter that counts a number of printed pages that have been printed by the image processing apparatus100.

In order to calculate an average number of printed pages per job, the microprocessor25is provided with a calculator that calculates an average number of printed pages per job. In this example, the average number of printed pages per job indicates how much degree the image forming unit is used for actual printing operation when performing an image forming job. For example, as described below referring toFIG. 4, the microprocessor25calculates the average number of printed pages per job based on the counted number of printed pages and the time for driving the developing unit3.

In order to calculate an average printing ratio, the microprocessor25is provided with a calculator that calculates an average printing ratio of the printed pages that have been counted. For example, the microprocessor25calculates the average printing ratio based on the average number of printed pages per job, and the supplied toner amount.

In order to calculate a collected toner amount, the microprocessor25is provided with a calculator that calculates the amount of toner collected into the collected toner container30. For example, the microprocessor25calculates the amount of collected toner, based on the average number of printed pages per job and the average printing ratio.

In order to perform comparison, the microprocessor25is provided with a comparator that compares the collected toner amount that is calculated with a threshold value that is previously set and stored in a memory such as the memory of the microprocessor25to generate a comparison result.

The microprocessor25is provided with the function of stopping printing operation based on the comparison result. For example, when the comparison result generated by the comparison function or the comparator indicates that the collected toner amount that is calculated is greater than the threshold value, the microprocessor25causes an image forming unit of the image processing apparatus100to stop printing operation. In this example, the image forming unit includes the photoconductive drum1, the charger2, the developing unit3, etc., which together perform operation of printing.

The microprocessor25is provided with the function of generating notification based on the comparison result. For example, when the comparison result generated by the comparison function or the comparator indicates that the collected toner amount that is calculated is greater than the threshold value, the microprocessor25notifies the operator, for example, by requesting the operator to replace the collected toner container30. In one example, the microprocessor25causes the operation panel23of the image processing apparatus100to display an alert message.

Referring toFIG. 1, operation of controlling printing operation, performed by the image processing apparatus100, is explained according to an example embodiment of the present invention.

In this example, the toner hopper19is provided with the toner empty detector22in its inside. The toner empty detector22determines that toner in the toner cartridge24installed onto the toner hopper19is empty, for example, when the amount of toner in the toner hopper19becomes lower than a threshold value, and sends notification to the microprocessor25. When the microprocessor25determines that toner in the toner hopper21is empty as it receives notification from the toner empty detector22, the microprocessor25causes the image forming unit to stop printing operation. Further, the microprocessor25causes the operation panel23to display a message indicating that toner is empty or is most likely to be empty in the near future. For example, the microprocessor25displays a message requesting the operator to replace the toner cartridge24with a new one. With this message, the operator removes the toner cartridge24that is determined to be empty from the toner hopper19, and installs a new toner cartridge24onto the toner hopper19.

The toner that is supplied by the toner cartridge24ends up as the toner transferred onto the recording sheet5as a part of the image, or ends up as the residual toner that remains on the photoconductive drum1. The residual toner that remains on the surface of the photoconductive drum1after the transfer device4transfers the toner image onto the recording sheet5is removed by the cleaning blade26and the cleaning brush27from the surface of the photoconductive drum1, and transferred by the screw28into the toner pipe29to the collected toner container30, and stored into the collected toner container30.

The collected toner container30may be replaced with a new one at the same time when toner is replenished by replacing the toner cartridge24. More specifically, when the message for requesting replacement of the toner cartridge24is received, the operator is requested to replace the collected toner container30in addition to the toner cartridge24. When the toner empty detector22detects that toner is replenished, for example, by replacement of the toner cartridge24, the microprocessor25causes the operation panel23to display a message requesting the operator to replace the collected toner container30. With this message, the operator is able to replace the collected toner cartridge30with a new one.

However, in the above-described method of replacing the collected toner container30at the same time the toner cartridge24is replaced, the amount of collected toner stored in the collected toner container30at the time of replacement may be low as 40% of the total amount of toner collectable by the collected toner container30, depending on a printing condition in which printing operation is performed by the image processing apparatus100, such as the printing mode and/or the printing ratio of the printing operation. This shortens the usage life of the collected toner container30. On the other hand, if the image processing apparatus100successively performs printing with less number of pages per printing job and/or with relatively low printing ratio, the amount of collected toner stored in the collected toner container30may exceed the total amount of toner collectable by the collected toner container30before the toner cartridge24is replaced, such that an excessive amount of toner may overflow from the collected toner container30. In order to prevent overflow of collected toner or extend the usage of the collected toner container30, the collected toner container30needs to be replaced at a time that is determined independently from the time the toner cartridge24is replaced under some circumstances.

FIG. 2is a graph illustrating the relationship between an average number of pages per one job and an amount of collected toner in the collected toner container30, which is obtained using the image processing apparatus100ofFIG. 1. Referring toFIG. 2, the vertical axis indicates the average number of pages per one job in number of pages, and the horizontal axis indicates the amount of collected toner in gram. In this example illustrated inFIG. 2, the toner cartridge24contains therein 1000 g of toner. The graph ofFIG. 2indicates the relationship between the average number of pages per one job and the amount of collected toner, until 1000 g of toner in the toner cartridge24is consumed, respectively for the average printing ratios of 50%, 20%, 10%, 5%, 3.5%, 2%, 1%, and 0.5%.

Further, in this example, in a printing mode that is set by default (“default printing mode”), the image processing apparatus100prints more than 1000 pages per job with the printing ratio of 3.5%. In the default printing mode, although not shown inFIG. 2, the amount of collected toner is about 200 g when 1000 g of toner is consumed.

Referring toFIG. 2, the amount of collected toner differs depending on the average number of printing pages per job and the average printing ratio. More specifically, the graph ofFIG. 2indicates that the amount of collected toner tends to increase with the decrease in average printing ratio and the decrease in average number of printed pages per job. For example, the point A in the graph ofFIG. 2indicates that the amount of collected toner is 657 g when the average printing ratio is 0.5% and the average number of printed pages is 10 pages. The point B in the graph ofFIG. 2indicates that the amount of collected toner is 136 g when the average printing ratio is 50% and the average number of printed pages is 50 pages.

Referring toFIG. 4, operation of estimating the amount of collected toner and controlling operation of the image processing apparatus100, performed by the microprocessor25, is explained according to an example embodiment of the present invention. In this example, the microprocessor25estimates the amount of collected toner collected in the image processing apparatus100based on the average printing ratio and the average number of printed pages per job, using the relationship illustrated inFIG. 2. Based on the estimated amount of collected toner, the microprocessor25determines whether the collected toner container30is full of collected toner.

The operation ofFIG. 4may be performed every time the toner supply roller21is driven to supply toner into the developing unit3to keep the toner density at a predetermined level, after the toner density is detected to have a level lower than the predetermined level. However, since the amount of toner supplied at one time is relatively small, the operation ofFIG. 4may be performed only when the accumulated amount of toner supplied by the toner supply roller21reaches a predetermined level. In this example, assuming that the toner hopper19contains 1000 g of toner, the operation ofFIG. 4is performed when the amount of toner supplied reaches 500 g, 700 g, and 900 g.

More specifically, at S1, the microprocessor25calculates the amount of supplied toner supplied from the toner hopper19into the developing unit3based on the time in which the toner supply roller21is driven, as a toner feed amount or supplied toner amount. The microprocessor25compares the calculated supplied toner amount with a predetermined threshold value, which is either one of 500 g, 700 g, and 900 g. When it is determined that the supplied toner amount reaches the threshold value (“YES” at S1), the operation proceeds to S2. When it is determined that the supplied toner amount does not reach the threshold value (“NO” at S1), the operation ends without estimating the amount of collected toner.

At S2, the microprocessor25calculates an average number of printed pages per job, which is the average number of printed pages that are sequentially printed in one printing job. The microprocessor25may calculate the average number of printing pages in various ways, for example, as follows.

The microprocessor25obtains a number of printed pages that is counted using a counter as a counted number of printed pages (“counted number A”), and a number of printed pages that is converted from a time for driving the developing unit3as a calculated number of printed pages B (“calculated number B”). At the time of starting printing operation and at the time of ending the printing operation, the image forming unit of the image processing apparatus100such as the photoconductive drum1and the developing unit3is driven for a predetermined time period while not forming any images. The average number of printed pages per job is obtained by dividing the counted number A by the calculated number B. For example, assuming that the time for driving the developing unit3at the time of starting printing operation and at the time of ending printing operation is 10 seconds, and the time required for performing printing operation per page is one second, the average number of printed pages per job is A/B=1/10=10% when only one page is printed. In the case of printing 5 pages, the average number of printed pages per job is A/B=5/10 pages=50%. With the ratio between the number of printed pages and the time for driving the developing unit3, the microprocessor25obtains the average number of printed pages per job. In one example, the microprocessor25calculates the ratio between the number of printed pages and the time for driving the developing unit3, and obtains the average number of printed pages using a look-up table. In another example, the microprocessor25calculates the average number of printed pages using the formula: A/B*Ka, where Ka is a constant value.

At S3, the microprocessor25calculates the average printing ratio, which is an average value of printing ratios respectively obtained for the printed pages that are counted. The average printing ratio may be calculated based on the counted number of printed pages and the average number of printed pages per job that are respectively obtained at S2, and the supplied toner amount that is obtained at S1.

In order to accurately calculate the printing ratio, a number of pixels contained in the dot data that is received from the host computer or any other device is obtained using a counter. In absence of the counter, in this example, the printing ratio is calculated based on the number of printed pages and the supplied toner amount. More specifically, the amount of toner consumed per page is obtained using the number of printed pages and the supplied toner amount. Based on the amount of toner consumed per page, the printing ratio can be estimated relatively easily. However, in reality, the amount of toner consumed differs depending on the average number of printed pages per job, for example, as illustrated inFIG. 3.

FIG. 3is a graph illustrating the number of printed pages as 500 g of toner is consumed. The horizontal axis ofFIG. 3indicates an average number of printed pages per job expressed in pages, and the vertical axis ofFIG. 3indicates a number of pages that can be printed expressed in pages. Referring toFIG. 3, the number of printed pages, which is shown by the vertical axis, changes in relation to the average printing ratio and the average number of printed pages per job. Using this relationship indicated byFIG. 3, the average printing ratio can be calculated based on the supplied toner amount, the average number of printed pages per job, and the number of printed pages. For example, in the case in which 500% toner is supplied, the number of printed pages is 30,000 pages, and the average number of printed pages per job is 25 pages, the average printing ratio is 2%. In alternative to the graph ofFIG. 2, the microprocessor25may previously store a lookup table indicating the relationship shown inFIG. 2. The lookup table stores a plurality of average printing ratios respectively corresponding to the average numbers of printed pages per job and the number of printed pages, each of which is prepared for a specific toner supplied amount. More specifically, the image processing apparatus100may be provided with a plurality of lookup tables prepared for a plurality of toner supplied amounts, each table correlating an average printing ratio with an average number of printed pages per job and a number of printed pages.

At S4, the microprocessor25calculates the amount of collected toner, based on the average number of printed pages per job that is obtained at S2, and the average printing ratio obtained at S3. More specifically, using these values of the average number of printed pages per job and the average printing ratio, the amount of collected toner can be estimated using the relationship indicated by the graph ofFIG. 2. More specifically, the image processing apparatus100previously stores a lookup table ofFIG. 5, and obtains the amount of collected toner using the lookup table ofFIG. 5. For example, in the case where the average printing ratio is 5% and the average number of printed pages per job is 2 pages, the amount of collected toner is 409 g.

At S5, the microprocessor25compares the amount of collected toner calculated at S4with a predetermined threshold value. When it is determined that the amount of collected toner reaches the predetermined threshold value (“YES” at S5), the microprocessor25determines that the collected toner container30is full of collected toner, and the operation proceeds to S6. When it is determined that the amount of collected toner is less than the predetermined threshold value (“NO” at S5), the operation ends.

The threshold value used at S5is previously set as a value for preventing toner from overflowing the collected toner container30, and it is different from the threshold value used at S1. For example, the threshold value may be set at 60% to 90% of a maximum toner level that can be stored in the collected toner container30.

At S6, the microprocessor25causes the operation panel23to display a message requesting the operator to replace the collected toner container30.

At S7, the microprocessor25stops printing operation so as to prevent toner from overflowing from the collected toner container30, and the operation ends.

When the operator replaces the collected toner container30with new one, the microprocessor25determines that the collected toner container30is not full. When the microprocessor25determines that the collected toner container30is not full, the microprocessor25clears the message that has been displayed onto the operation panel23, and resets the calculated data obtained at previous steps of S1to S7such as the average number of printed pages per job, the average printing ratio, the amount of collected toner, etc., and wait for next operation ofFIG. 4to be performed.

The operation ofFIG. 4may be performed in various other ways. For example, at S5, in addition to comparing the amount of collected toner with the predetermined threshold value, the microprocessor25may determine whether the toner hopper19is empty. More specifically, when it is determined that the amount of collected toner reaches the threshold value and the toner hopper19is empty, the microprocessor25may cause the operation panel23to display a message requesting the operator to replace the collected toner container30and the toner cartridge24.

Further, any one of the calculated values may be stored in a memory of the image processing apparatus100or any other memory accessible by the microprocessor25. For instance, the calculated values including any combination of the average number of printed pages per job, the average printing ratio, and the collected toner amount may be stored in the form of table. Based on these values, the image processing apparatus100may be able to show information indicating the trend in these values, which may be used for further analysis. Alternatively or additionally, these values stored in the memory may be used as train data that is used for generating or updating a table such as the look-up table ofFIG. 5. These values are reset when the microprocessor25determines that the collected toner container30is replaced with a new one.

As described above, the image processing apparatus100is able to estimate the amount of collected toner stored in the collected toner container30with improved accuracy, while considering a printing condition of the image processing apparatus100such as the printing mode or the printing ratio. Accordingly, the image processing apparatus100is able to notify the user to replace the collected toner container30before the collected toner container30becomes full.

Further, in this example, the image processing apparatus100may display information regarding the amount of collected toner on the operation panel23before the collected toner container30becomes full, and notifies the operator when the collected toner container30is most likely to become full of collected toner. For example, by setting the threshold value that is used for comparison with the calculated collected toner amount to a value less than the value usually set, the image processing apparatus100is able to notify the operator before the collected toner container30becomes full. In this example, the value that is usually set is determined based on a maximum level of toner that can be stored in the collected toner container30.

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 the present invention may be practiced otherwise than as specifically described herein.

In one example, any one of the above-described operations performed by the image processing apparatus100may be performed either sequentially or concurrently, depending on the processing capability of the image processing apparatus100or the microprocessor25.

In another example, the operation ofFIG. 4may be performed by any desired apparatus other than the image processing apparatus100, which controls image processing operation of the image processing apparatus100. For example, the image processing apparatus100may be connected to an information processing apparatus via a network. The information processing apparatus is provided with a processor and a memory, which together function as the microprocessor25. In such case, the image processing apparatus100does not have to be provided with an image processing control program that causes the microprocessor25to perform the function of estimating a collected toner amount. More specifically, at a predetermined timing, the image processing apparatus100requests the information processing apparatus to start communication. In response to the request, the information processing apparatus100requests the image processing apparatus100to send information regarding printing operation performed by the image processing apparatus such as a supplied toner amount and a total number of printed pages. Based on the information obtained from the image processing apparatus100, the information processing apparatus calculates an average number of printed pages per job. The information processing apparatus further calculates an average printing ratio based on the supplied toner amount, the number of printed pages, and the average number of printed pages per job. The information processing apparatus further calculates a collected toner amount based on the average number of printed pages per job and the average printing ratio. When the collected toner amount that is calculated is greater than a threshold value previously set, the information processing apparatus determines that replacement of the collected toner container30is necessary. In such case, the information processing apparatus requests the operator to replace the collected toner container30. Further, the information processing apparatus communicates with the image processing apparatus100to cause the operation panel23to display an error message as well as stopping printing operation of the image processing apparatus100.

Further, the above-described operation of estimating an amount of collected toner may be applied to a different area of technology, as long as it is desirable. For example, in alternative to collected toner amount, any consumable material may be monitored using the above-described technique.

Further, as described above, any one of the above-described and other methods of the present invention may be embodied in the form of a computer program stored in any kind of storage medium at least temporarily. Examples of storage mediums include, but are not limited to, semiconductor memory, flexible disk, hard disk, optical discs such as CD-ROM or DVD, magneto-optical discs, magnetic tapes or disks, involatile memory cards, ROM (read-only-memory), etc. Further, such computer program or any storage medium storing such computer program may be provided as package software.

In alternative to installing the computer program from the storage medium onto a computer, the computer program may be transferred to the computer through a network such as wired or wireless network such as local area network (LAN) or the Internet. The computer program that is downloaded is stored in a storage device of the computer such as a hard disk drive.

Alternatively, any one of the above-described and other methods of the present invention may be implemented by ASIC, prepared by interconnecting an appropriate network of conventional component circuits or by a combination thereof with one or more conventional general purpose microprocessors and/or signal processors programmed accordingly.

In one example, the present invention may reside in: an image processing apparatus that collects residual toner resided on a surface of an image carrier into a collected toner container. The image processing apparatus includes: means for obtaining a supplied toner amount indicating an amount of toner supplied to a developing unit that forms a toner image on a surface of the image carrier; means for obtaining a number of printed pages; means for calculating an average number of pages that are sequentially printed per one job; means for calculating an average printing ratio indicating an average number of printing ratios respectively obtained for the printed pages based on the supplied toner amount, the number of printed pages, and the average number of printed pages per job; means for calculating a collected toner amount indicating an amount of toner collected in the collected toner container based on the average number of printed pages per job and the average printing ratio; means for comparing the collected toner amount with a threshold value; and means for stopping printing operation when the means for comparing indicates that the collected toner amount is greater than the threshold value. The threshold value is previously set as a value that prevents toner collected in the collected toner container from overflowing.

In the above-described example, the image processing apparatus may be provided with means for sending notification that requests an operator to replace the collected toner container when the collected toner amount is greater than the threshold value.

In the above-described example, the means for calculating an average number of printed pages per job calculates a ratio between the number of printed pages and a time for driving the developing unit, based on the number of printed pages obtained by the means for obtaining a number of printed pages, and a number of printed pages that is converted from a time for driving the developing unit. The means for calculating an average number of printed pages calculates the average number of printed pages per one job, based on the supplied toner amount and the ratio between the number of printed pages and the time for driving the developing unit.

In the above-described example, the means for calculating an average number of printing ratios uses a lookup table to refer to an average printing ratio that corresponds to an average number of printed pages per job and a number of printed pages, classified by the toner supply amount.

In the above-described example, the means for calculating an average number of pages, the means for calculating an average number of printing ratios, the means for calculating an amount of toner collected in the collected toner container, and the means for comparing, respectively perform calculation every time a predetermined amount of toner is supplied.

The calculation result of the means for calculating an average number of pages, the calculation result of the means for calculating an average number of printing ratios, and the calculation result of the means for calculating an amount of toner collected in the collected toner container are respectively reset when the collected toner container is replaced.

In another example, the present invention may reside in: a method of controlling an image processing apparatus, preformed by the image processing apparatus that collects residual toner resided on a surface of an image carrier into a collected toner container. The image processing control method includes: obtaining a supplied toner amount indicating an amount of supplied toner supplied to a developing unit that forms a toner image on a surface of the image carrier; obtaining a number of printed pages; calculating an average number of printed pages that are sequentially printed per one job; calculating an average printing ration indicating an average number of printing ratios respectively obtained for the printed pages based on the supplied toner amount, the number of printed pages, and the average number of printed pages per job; calculating a collected toner amount indicating an amount of toner collected in the collected toner container based on the average number of printed pages per job and the average printing ratio; comparing the collected toner amount with a threshold value; and stopping printing operation when the comparing indicates that the collected toner amount is greater than the threshold value. The threshold value is previously set as a value that prevents toner collected in the collected toner container from overflowing.

In another example, the present invention may reside in an image processing control program stored in a recording medium, which causes a processor to perform any one of the above-described image processing control method.

In another example, the present invention may reside in a recording medium storing a plurality of instructions that cause a processor to perform any one of the above-described image processing control method.

For example, the present invention may reside in: a recording medium storing a plurality of instructions which cause, when executed, a processor to perform a method of controlling an image processing apparatus having a collected toner container in which residual toner is accumulated, the method including: obtaining a supplied toner amount indicating an amount of toner supplied to a developing unit of the image processing apparatus; obtaining a total number of printed sheets generated by the image processing apparatus; calculating an average number of printed sheets per image forming job; calculating an average printing ratio indicating an average of printing ratios of the printed sheets, based on the supplied toner amount, the total number of printed sheets, and the average number of printed sheets per image forming job; calculating a collected toner amount indicating an amount of toner accumulated in the collected toner container of the image processing apparatus based on the average number of printed sheets per image forming job and the average printing ratio; comparing the collected toner amount with a threshold value to generate a comparison result; and causing the image processing apparatus to stop forming of the toner image when the comparison result indicates that the collected toner amount exceeds the threshold value.