DEVICE FOR DETECTING LIFE OF IMAGE FORMING PROCESS UNIT, OPENING OF SEAL OF THE UNIT AND ATTACHEMENT OF THE UNIT TO AN IMAGE FORMING APPARATUS

Abstract: A device is provided for detecting the life expiry of a process unit detachably attached to an image forming apparatus for detecting the initial opening of a seal of the unit and for detecting attachment of the unit to the image forming apparatus. The device judges when the process unit has reached its life expiry by comparing the output of a sensor (65) for detecting the density of toner contained in the developing device with a predetermined value and detecting when the output of the sensor is above the predetermined value. When the process unit has a developer storage section defined by a seal member (63) for containing developer in the developing device, the seal member is normally opened whens the developing device is installed, so that developer is supplied into a developer chamber having a developing roller. The detecting device judges that the seal (63) is unopened when the output of the sensor (65) is not the output level of the normal use state. Thirdly, when attaching the process unit to the apparatus, the output terminal of the sensor (65) on the developing device and the input terminal of control means provided in the apparatus are connected with each other, so that the control means can judge that the process unit is not attached when the voltage of the input terminal of the control means is not the voltage level of the normal use state.

Description: The present invention relates to an image forming apparatus such as a copying machine and the like and to process units which are arranged as detachable parts of such apparatus. The invention is more particularly concerned with means for detecting the life of a process unit in an image forming apparatus, means for detecting the opening of a seal of a developer storage section of a process unit prior to use, and with means for detecting the attachment of a process unit to an image forming apparatus. It is conveniently known that for the purpose of facilitating maintenance and exchange of expendable parts and the like of an image forming apparatus using an electrographic system etc., a part or the whole of the image forming apparatus comprising a photosensitive drum, a developing device, a cleaning device and the like are integrated to form a process unit which is detachably attached to the image forming apparatus (see for example, Unexamined Japanese Patent Application No. 56-128958). Such a process unit is, as expendable, replaced by a new one for ensuring the quality of a copy image when the process unit ends its useful life. Then, a means for detecting the life of the process unit and informing users of the same is known which is adapted to measure the amount of used transfer paper passing through the process unit or count the number of revolutions of a photosensitive drum, and give a visible indication when the obtained value reaches a predetermined value which means a predetermined length of life of the process unit (see for example, Unexamined Japanese Patent Publication No. 58-152263). According to the abovementioned detection system, however, for example by making a large amount of copies of an original having a high density, toner is consumed before visible indication of the life of the process unit is made on the basis of the counted rotation number of the drum, which makes it difficult to detect the life of the process unit. Besides, poor copied images are produced, and so-called carrier attraction occurs; that is, a carrier is attracted to a latent image on the photosensitive surface, transferred onto a transfer paper, and further slipped in a fixing device, thereby resulting in damage to a heat roller thereof, and causing trouble in temperature control by means of a thermistor. Further, in a copying machine etc. in which the density of toner contained in a developing device is detected and the amount of toner supply is controlled to obtain a given toner density, if the toner density is below a given value, a process unit may be judged to have ended its useful life due to toner consumption. Such an arrangement is proposed in JP-A-60-87 354. In this case, however, without choosing the best timing for the judgement, the toner density cannot be accurately detected by means of a sensor, and sometimes it becomes difficult to accurately detect the life and the detection takes too much time, thereby lowering the efficiency. According to one aspect of the invention, there is provided an image forming apparatus comprising a process unit of the type having a developing device including a developing roller in a casing, and sensor means for detecting the density of the toner in said developing device to provide an indication of whether the life of the process unit has expired, the apparatus further comprising control means for an image forming operation, the control means being arranged to detect the signal from the sensor means and to determine whether a usual image forming operation is to be performed in dependence upon whether the signal from the sensor means falls within or outside a predetermined limit, said operation of the control means being arranged to be effective in a predetermined time period after the rotation of the developing roller begins. In this manner, the life of the process unit is detected after the developer is adequately stirred and the output of the sensor is stabilized, so that stabilized and reliable life detection can be achieved and a high quality image is always formed. And further, so-called carrier attraction can be prevented, which often occurs in a life detecting system including means for counting the number of revolutions of a photosensitive drum. Furthermore, in a conventional process unit in which at least a developing device is included in a casing, for the purpose of preventing the dispersion of developer held in the developing device as well as preventing the photosensitive surface from being roughened by the dispersed developer, the developer is contained in a space of the developing device defined by a seal member when the process unit is in a packed state prior to use, and by opening or peeling off the seal member for use ie. at the time of installing the process unit, the developer is supplied into a developer chamber where a developing roller of the developing device is located so that images can be formed (see for example, JP-A-59-61 861). In the prior art, however, since no means is provided for detecting opening of the seal member, a user sometimes forgets to peel off the seal member and the image forming operation is carried out with the seal member being still unopened. In such a case, naturally no image is formed and transfer paper is wasted as a miscopy or blank copy. According to another aspect of the invention, there is provided image forming apparatus comprising a sealable process unit detachably mounted therein, said unit having a developing device comprising a developer storage section provided with a seal member for containing developer therein, whereby normally when the unit is attached to the apparatus the seal member is opened so that developer is supplied to a developer chamber of the unit having a developing roller, sensor means being located adjacent the developing device containing the developer storage section for detecting the presence of developer or the density of toner contained in said section, and control means cooperate with the sensor means and are responsive to a signal from said sensor means for judging whether said developing device has been placed in the image forming apparatus with or without the seal having been removed from the developer storage section and to indicate when the seal has not been opened. In this case, if a user forgets to open the seal when setting the process unit, the developer is not supplied into the developer chamber and the controller can judge and give the user information that the seal member is unopened, so that miscopying can be prevented. Further, since a conventional image forming apparatus is not provided with any means for detecting attachment of the process unit to the apparatus as well as detecting connection of a predetermined control system, the apparatus with the process unit being unattached still appears to be in an image forming or copying state. Therefore, if the copying operation is carried out with a process unit being unattached, a jam of paper often occurs, and even if the paper can be passed through, naturally no image is formed, so that transfer paper is wasted as a miscopy or blank copy. For eliminating such problems, a switch may be provided for detecting attachment of the process unit, as in JP-A-60-114 870. Such a solution, however, makes the apparatus expensive. In a further aspect of the invention there is provided image forming apparatus having means for detecting the attachment to the apparatus of a process unit comprising a developing device in a casing, sensor means being arranged to detect the presence of developer or the density of toner contained in the developing device and control means provided with an input for receiving signals from said sensor means, the sensor and control means being connected to each other by the attachment of the process unit to the apparatus, and the control means being arranged to respond to a signal at said input that does not correspond to a normal use value by issuing a signal indicating the non-attachment of the process unit. In this case, because the signal received by the control means will depend on whether or not the process unit is attached, it is possible to detect the attachment of the process unit without the use of any separate detecting switch or the like. Also, if unattached, miscopying can be prevented by calling the user's attention. The invention also includes within its scope a detachable process unit for an image forming apparatus as claimed in claims 16 and 18. Embodiments of the present invention are illustrated in the accompanying drawings, in which; Fig. 1 is a schematic sectional view of an image forming apparatus to which a device according to the present invention is attached; Fig. 2 is a perspective view of the apparatus in which an upper casing of the apparatus is opened; Fig. 3 is a rearward perspective view of a process unit to be attached to the apparatus; Fig. 4 is a sectional view of the process unit; Fig. 5 is a block diagram showing the construction of the device for detecting life of the process unit; Fig.6A, 6B, 7 are flow charts showing the operation for detecting useful life in the process unit; Fig.8 is a graph showing an output characteristic of a toner density sensor; Fig.9 is a partly sectional view of the process unit; Fig.10 is a flow chart showing the operation for detecting opening of a seal member; Figs.11 and 12 are block diagrams showing the construction of the device for detecting attachment of the process unit to the apparatus; and Fig.13 is a flow chart showing the operation for detecting attachment of the process unit to the apparatus. Fig.1 illustrates the whole construction of an image forming apparatus to which a device of the present invention is attached. In this Figure, over the upper face of a body of the image forming apparatus 1 there is provided a reciprocatable original holder 2. Inside the apparatus 1, an image forming process unit 3 is detachably attached to the apparatus 1. The process unit 3 is, as an expendable, replaced by a new one when it ends its useful life. The process unit 3 comprises a rotatable photosensitive drum 4 and a main charger 5, a developing device 6 and a cleaning device 7 arranged around the drum 4 sequentially in the direction of the rotation of the drum 4, all of which are accommodated in a casing. The image forming apparatus 1 has an exposure lamp 8 for exposing an original to light and a convergent light transmission member 9 by which an exposed and scanned original image is focused on the photosensitive drum 4 to produce a latent electrostatic image. The developing device 6, though described later in detail, has developer storage sections 10a, 10b in a part of which an initial developer and supplementary toner is sealedly contained. Further, within a developer chamber 12 into which the developer is supplied from the storage section 10a or 10b by means of a supply roller 11 are provided a stirring roller 13 for stirring the developer and a developing roller 14 opposed to the photosensitive drum 4 so as to develop a latent electrostatic image on the photosensitive drum into a toner image, and the like. The image forming apparatus 1 further has a transfer device 15 for transferring a toner image onto transfer paper, means 16 for conveying transfer paper to a transferring section of the transfer device 15, and a fixing device 17 for fixing a transferred image on the transfer paper. The transfer device 15 is located on the downstream side of the developing device 6 in the rotational direction of the photosensitive drum. The fixing device 17 is located on the downstream side of the conveying direction of the transfer paper. The fixing device 17 comprises a heat roller 17b provided with a heater 17a, a pressure roller 17c and a thermistor 17d for controlling the temperature. In Fig.1 are further illustrated a paper feed tray 18 located on the upstream side of the conveying mean 16, a paper feed roller 19, a pair of registration rollers 20, a conveying belt 21, a paper discharge roller 22, a paper discharge tray 23, and a pivot 24 for pivotally supporting an upper casing 1a and a lower casing 1b of the image forming apparatus 1 at one end thereof so that the upper casing 1a can be opened about the pivot 24 for maintenance and examination of the apparatus 1. Further, there are illustrated control means (CPU) comprising a microcomputer and others for controlling the image forming operations of the apparatus 1, an operation and indication portion 26, a front lid 27 (Fig.2 illustrates an opened position), a pull 28 provided on the front face of the process unit 3 for inserting the process unit 3 into the apparatus 1 and detaching it therefrom in the directions of the arrow illustrated in Fig.2, and rails 29, 30 provided in the apparatus 1 for guiding the process unit 3 so as to be inserted into and detached from the apparatus 1. Fig.3 illustrates the rear part of the process unit 3. In the rear side plate (not shown) of the apparatus 1 are provided a coupling 31 for a drive shaft of the drum 4, a coupling 32 for a drive shaft of the developing roller 14, a terminal 33 for supplying power to the main charger 5, and a connector 34 for receiving signals from a sensor for detecting the density of toner contained in the developing device 6. Corresponding to the above elements, in the rear side of the process unit 3, are provided a coupling 35 for the shaft of the drum 4, a coupling 36 for the shaft of the developing roller 14, a connector 37 for the main charger 5 and a connector 38 for the sensor. Accordingly, all the abovementioned elements are connected with one another by attaching the process unit 3 to the apparatus 1. Fig.4 illustrates the process unit 3. In an upper portion of a casing 61 of the developing device 6 in the process unit 3, are provided containers 62a, 62b constituting the developer storage sections 10a, 10b. Initial developer in the developer storage section 10a is supplied into the developer chamber 12 of the casing 61. Supplementary toner in the developer storage section 10b is supplied into the developer chamber 12 by means of the supply roller 11. Adjacent to the developing device 6 is provided a toner density sensor 65 comprising magnetic permeability sensor or the like for detecting the toner density of the developer contained in the developing device 6. Accordingly, the control means 25 controls, according to the output of the sensor 65, the rotation of the supply roller 11 so as to obtain the peredetermined density of the toner contained in the developing device 6. Numeral 68 indicates a header for regulating the height of the developer on the developing roller 14. Numeral 69 indicates a guide plate for helping circulation of developer. Fig.5 illustrates the construction of the main part of a device for detecting life in the process unit 3. The control means 25 includes a CPU for performing a given calculation and control and a timer 25a. The control means 25 receives signals from the toner desity sensor 65, a print key 101, a registration switch 20a for detecting that the leading edge of transfer paper is fed to the pair of registration rollers 20 by the paper feed roller 19 (referred to as first paper feeding hereinafter), and the thermistor 17d respectively. On the other hand, the control means 25 sends signals in a predetermined timing mentioned below to a paper feed clutch 19a for switching on the paper feed roller 19, a solenoid 20b for driving the pair of registration rollers 20, a life indicator 102, a high voltage output device 5a for energizing the main charger 5, a main motor 103 functioning as a driving source of the drum 4 and the developing roller 14, and the heater 17a. Figs.6A, 6B, 7 are flow charts showing the operation of the control means 25, and the operation will be now described below in accordance with the flow charts. Firstly the power source is switched on. The fixing heater 17a is then turned on (Step S₁) and the developing roller 14 starts rotating (Step S₂), and a delay time required for stabilizing the output of the sensor 65 is held by a timer (Step S₃). After lapse of the delay time, it is judged based on a detecting signal from the sensor 65 whether the life of the process unit 3 has expired (Step S₄). When the process unit still has useful life, the judgement is continued till the temperature of the fixing unit is stabilized (Step S₅). The judgement on whether the process unit life has expired is executed based on whether the output voltage of the sensor 65 is above a predetermined value. This judgement depends upon the fact that when toner contained in the process unit is consumed, the toner density of the developer (T/D) lowers and the output voltage of the sensor 65 rises. When it is judged at Step S₄ that the process unit 3 life has expired, copying is prohibited (Step S₂₀), the rotation of the developing roller 14 being stopped (Step S₂₁), the end of life of the process unit 3 being indicated on the life indicator 102 (Step S₂₂), and input acceptance of the respective keys being suspended (Step S₂₃). Subsequently, the operation ends. When the process unit 3 still has useful life, after the abovementioned Step S₅, the fixing heater 17a is turned off (Step S₆), the rotation of the developing roller 14 being stopped (Step S₇). This state is held till the print key 101 is turned on (Step S₈). When the print key 101 is turned on, by turning on the paper feed clutch to drive the paper feed roller 19, the first paper feeding is started (Step S₉). Then the developing roller 14 starts rotating (Step S₁₀), and thereafter it is judged based on a detecting signal from the sensor 65 whether the process unit 3 life has expired (Step S₁₁). The abovementioned judgement is continued till the first paper feeding is completed (Step S₂₄), and before that, when the output voltage of the sensor 65 falls below the predetermined value, it is judged that the process unit 3 has useful life and usual copying operation is started (Steps S₁₂ to S₁₉). When the output voltage of the sensor 65 is still above the predetermined value at the end of the first paper feeding, the second paper feeding for feeding transfer paper from the pair of registration rollers 20 to the transferring position is not immediately started but the start thereof is delayed for a few seconds (Step S₂₅). This delay is made with the use of the timer 25a in the control means. In the delay time, it is judged again whether the process unit 3 has reached the end of its useful life (Steps S₂₆, S₂₇). When the output voltage of the sensor 65 is below the predetermined value, the ordinary copying operation (Steps S₁₂ to S₁₉) is started in the similar manner as abovementioned. That is, the main charger 5 is turned on (Step S₁₂), and the pair of registration rollers 20 are driven to start the second paper feeding (Step S₁₃). Further, after the usual copying operation is started, the possible end of useful life of the process unit is successively detected depending upon the output voltage of the sensor 65 (Step 14). It is examined whether the transfer paper is completely discharged by turning on the discharge switch 22a (Step S₁₅). When it is judged that the process unit 3 life has expired, the steps mentioned below with reference to Fig.7 are carried out. On the other hand, while the process unit 3 still has useful life and the discharge of transfer paper is not completed, OFF signals are issued to the main charger 5 and the second paper feeding (Step S₁₆). When the signals are issued, the main charger 5 and the pair of registration rollers 20 for the second paper feeding are turned off (Step S₁₇) and then the operation is returned to the abovementioned Step S₁₄. When the discharge of transfer paper is completed at Step S₁₅, it is judged whether the copying is continuous or not (Step S₁₈). If continuous copying, the operation is returned to Step S₉. If not, the rotation of the developing roller 14 is stopped (Step S₁₉), and the operation is returned to Step S₈, and thereafter the same routine is repeated. On the other hand, when the output voltage of the sensor 65 is above the predetermined value at the end of the delayed time Step S₂₇, it is judged that the process unit life has expired, and then the operation is changed to the steps shown in Fig.7. In other words, the main charger 5 is not driven but remains in an OFF state in order to prevent so-called carrier attraction (Step S₂₈). Paper is discharged (Step S₂₉). The end of useful life of the process unit 3 is indicated on the life indicator 102 (Step S₃₀). The driving of the developing roller 14 is stopped (Step S₃₁). Input acceptance of the respective key is suspended (Step S₃₂). Execution of the steps S ₂₈ to S₃₂ prevent the carrier attraction resulting in damage to the fixing device 17 and prevents jam of the transfer sheet in the conveying means. Also, the user can be informed that the process unit 3 has to be renewed. An output curve of the sensor 65 is shown as a characteristic of toner density in Fig.8. The graph indicates that in the lapse of time from the start of the rotation of the developing roller 14, the output voltage lowers and comes to a stabilized state. Consequently, as abovementioned, by delaying the timing of the detection at Steps S₃ to S₅ or by delaying the start of the second paper feeding at Steps S₂₅ to S ₂₇, and by detecting the output voltage of the sensor 65 in this delay time, the life level of the process unit 3 can be judged with the output voltage of the sensor 65 being stabilized, whereby the accuracy and reliability of the judgement is improved. Further, for accurately detecting the toner density by means of the sensor 65, the detection is carried out necessarily with the developing roller 14 being rotated. This requirement is also satisfied. Furthermore, the life level of the process unit 3 is detected after switching on the power source and before turning on the print key as mentioned above. Consequently, when it is judged that the process unit 3 life has expired at this stage, the operation is changed to the state of prohibiting copying. Consequently, the first paper feeding which is to be started by turning on the print key and the succeeding operation are inhibited. Accordingly, losses of transfer paper can be prevented. Furthermore, since the output voltage of the sensor 65 is detected during the first paper feeding at Steps S₁₁ and S₂₆, no waiting time is needed for the detection. Accordingly, the copying efficiency can be improved. Also, the life of the process unit 3 is detected at Step S ₁₄ after the operation is changed to the second paper feeding and during the usual copying operation. Consequently, if the process unit 3 life expires during the copying operation, any occurrence of the abovementioned carrier attraction can be prevented because of the turning-off of the main charger. In the abovementioned embodiment, the life of the process unit 3 can be detected at the following three timings; during the delayed time of the first and second feeding, after the turning-on of the print key; after switching on the power source and before turning on the print key; in the usual copying operation after the second paper feeding. It will be noted, however, that the detection need not necessarily be made at all the timings. It is required only in this embodiment that the detection is executed in one of the following two times; the time after the start of the rotation of the developing roller 14 and before the end of the first paper feeding and the time that the start of the second paper feeding is delayed. Accurate life detection can be similarly achieved even at each time. In the abovementioned explanation of the flow chart, as the time of detecting useful life is mentioned the time required to stabilize the fixing device 17 and the time required to complete the first paper feeding. Such time may be obtained from detecting the signal level of the thermistor 17d or the signal from the registration switch 20a. Also, such time may be obtained from a delay time of the timer on the basis of the times of turning on the print key, starting the first paper feeding, and starting the rotation of the developing roller and the like. Further, process unit 3 of the abovementioned embodiment carries a photosensitive drum 4, the developing device 6, the cleaning device 7 and the like, all the components being placed in one casing. However, it is satisfactory that only the developing device 6 is provided. Furthermore, when it is detected that the process unit still has useful life before the predetermined time lapses, the operation is immediately changed to the usual copying operation. Consequently, unnecessary waiting time is not wasted and the efficiency of the image forming operation can be improved. Fig.9 mainly illustrates developing device 6 of process unit 3. The upper part of casing 61 of developing device 6 is attached with containers 62a, 62b constituting the developer storage sections 10a, 10b. Downward openings of containers 62a, 62b are sealed by means of a seal member 63 before use. That is, one end portion 63a of the seal member 63 is stuck to one edge of one container 62b, and an intermediate portion 63b is stuck to one edge of the other container 62a and is then folded back so that the other end portion 63c is passed through a slit 3a provided in the process unit 3 to the outside. Before attaching the process unit 3 to the apparatus 1, the other end portion 63c of the seal member 63 is peeled off in the direction of the arrow in Fig.9. Subsequently, the seal is opened and initial developer D in the developer storage section 10a is supplied into the developer chamber 12 while toner T is supplied from the developer storage section 10b into a hopper 64 provided with the supply roller 11. Adjacent to the developing device 6 is provided the sensor 65 including a magnetic permeability sensor for detecting the toner density of the developer contained in the developing device 6. The control means 25 controls the rotation of the supply roller 11 according to the output of the sensor 65 so that the density of toner contained in the developing device 6 comes to a predetermined value. In Fig.9, numerals 66, 67 indicate packings made of sponge or the like for preventing the developer from being dispersed after the seal is opened. Numeral 68 indicates the header for regulating the height of the developer on the developing roller 14. Numeral 69 indicates the guide plate for helping circulation of developer. In the abovementioned construction, the sensor 65 detects the toner density of the developer passing in front of the sensor 65. Specifically, the ratio of the toner amount to the total amount of toner and carrier (T/D) is detected in the case of a two component developer. In the normal use state (e.g. T/D being 4.5% to 2%), because the carrier is added, the sensor 65 outputs a level of voltage (e.g. 1V to 4V). On the other hand, when no carrier is added, it outputs an extremely low voltage of nearly 0V. In the normal use state, the sensor does not output such a low voltage. When such a low output vosltage is sent to the control means 25, it is judged that no developer is being supplied into the developing device 6 i.e. into the developer chamber 12 and that the seal member 63 is unopened. The judging operation of the control means 25 will be described below with reference to the flow chart in Fig.10. Firstly, the power source is switched on. Then, it is judged whether the output voltage of the sensor 65 is nearly 0V (Step n₁). When the answer is YES, it is judged that the seal is unopened, which is indicated at Step n₂. This can be realized by making a suitable indication on the operation and indication portion 26 so as to call it to the user's attention. On the other hand, when the answer is NO, it is judged that the apparatus is in the normal state and the operation is changed to the normal copying operation. The judgement that the developer is used up and not left in the developer chamber (i.e. that it is time to renew the process unit 3) can be made by detecting that the output voltage of the sensor 65 reaches a predetermined value (e.g. 4V) for preventing the degradation of the image quality. Further, the abovementioned judgement on whether the seal is opened is preferably made before the first paper feeding is started by turning on the print key. According to the abovementioned embodiment, detection that the seal is unopened is executed by the toner control sensor 65 which is a conventional sensor. In other words, it is not required to make a particular sensor for executing this operation. Consequently a reduction of cost is obtained. Further, in the abovementioned embodiment, a two component developer is used and a sensor signal from the toner control sensor 65 is used. However, the present invention is not limited to the abovementioned embodiment. For example, when a one component developer is used, a level sensor or a pressure sensor is used which can detect the presence of developer in the developer chamber 12 and can provide an output in the form of analog signals. Subsequently, the presence of the seal can be detected according to the sensor signals. When the seal is unopened, the output of the sensors is 0V or nearly 0V. On the other hand, the output of the sensor for judging that developer is consumed and not left in the developer chamber is set at a higher value than that for judging the presence of the seal. Accordingly, the difference between the output voltages makes it possible to distinguish the presence of the seal from the exhaustion of the developer. Further, the output voltage of the sensor is changed when the seal member 63 is peeled off by sticking a magnetic piece to a portion of the seal member 63 and placing the seal member in such a manner that the magnetic piece is positioned in front of the toner control sensor 65, though not illustrated. This is because the magnetic piece in front of the sensor 65 is removed. Accordingly, opening of the seal can be also detected in this way. Figs.11, 12 illustrate a construction of the present invention for detecting attachment of the process unit 3 to the image forming apparatus 1. An input terminal 25a of the control means 25 is connected to a resistance R (preferably having a high impedance) which is connected to a predetermined Vcc (e.g. 5V) potential or to Vss ( earth=0V). In the abovementioned construction, when the process unit 3 is not attached to the appratus, the voltage level of the input terminal 25a of the control means 25 is Vcc or Vss. On the other hand, whens the process unit 3 is attached to the apparatus 1, the output terminal of the sensor 65 is connected to the input terminal 25a of the control means 25 by the connecters 38, 34. Then, the sensor 65 located adjacent to the developing device 6 detects the toner density of the developer passing in front of the sensor 65, that is, the ratio of the toner amount to the combined total amount of carrier and toner (T/D) when a two component developer is used. In the usual use state (e.g. T/D being 4.5% to 2%), the sensor 65 outputs a level of voltage (e.g. 1V to 4V) due to the presence of the carrier. Consequently, the voltage level of the input terminal 25a of the control means 25 is the same as the output level of the sensor 65, though somewhat influenced by a bias potential due to the presence of the resistance R. It will be noted that when using the resistance R having a high impedance, such an influence is almost removed. In other words, there is a difference between the potential level of the input terminal 25a of the control means 25 when the process unit 3 is attached to the apparatus and the potential level when it is not attached thereto. Consequently, when the voltage of the input terminal 25a of the control means 25 (0V to 4V or 4V to 5V) is different from the voltage level of the use state (e.g. 1V to 4V), the control means 25 can judge that the process unit 3 is not attached to the apparatus 1. This judging operation of the control means 25 will be described below with reference to the flow chart in Fig.13. Firstly, the power source is switched on. Then, it is judged whether the output voltage of the sensor 65 is Vcc (or Vss) or not (Step n₁₁). When the answer is YES, the process unit 3 is judged to be unattached, which is indicated at Step n₁₂. This can be realized by making a suitable indication on the operation and indication portion 26 so as to attract the user's attention. For the purpose of more surely attracting attention, besides making such an indication, the image forming operation may be stopped. On the other hand, when the answer is NO, it is judged that the process unit is attached to the apparatus 3 and the operation is changed to the usual copying operation (Step n₁₃). The judgement that the developer in the developer chamber is used up (i.e. that it is the time to renew the process unit 3) can be made by detecting that the output voltage of the sensor 65 reaches a predetermined level (e.g. 4V for preventing the degradation of the image quality). As abovementioned, for detecting the attachment of the process unit 3, a particular switch for executing this operation is not required. Consequently, a reduction of cost can be obtained. It will be apparent that the potential Vcc or Vss, to which the input terminal 25a of the control means 25 is connected by the resistance R, is needed to be set at a value different from the output level of the sensor 65 of the usual use state. Further, when the control means 25 includes a microcomputer, the input terminal is usually provided with an A/D converting circuit. Subsquently, an unstabilized voltage, though of a slight amount, caused due to a remaining charge of a capacitor of this circuit has an influence when no circuit is connected to the input terminal 25a. However, connection of the input terminal 25a to a potential of a predetermined voltage level by the resistance R eliminates the abovementioned influence. Consequently, non-attachment of the process unit 3 can be accurately detected. Further, non-attachment of the process unit 3 can be detected by using a level sensor, a pressure sensor or the like as abovementioned as well as the toner control sensor 65. The potential of the input terminal 25a is Vcc or Vss when the process unit is unattached. On the other hand, the output level used for judging that the developer in the developer chamber is consumed up is set at a predetermined value different from Vcc or Vss. Consequently, such a difference between the two potentials of the input terminal 25a makes it possible to distinguish non-attachment of the process unit 3 from exhaustion of developer.

Claims: An image forming apparatus (1) comprising a process unit (3) of the type having a developing device (6) including a developing roller (14) in a casing, and sensor means (65) for detecting the density of the toner in said developing device to provide an indication of whether the life of the process unit has expired, the apparatus further comprising control means (25) for an image forming operation, the control means (25) being arranged to detect the signal from the sensor means (65) and to determine whether a usual image forming operation is to be performed in dependence upon whether the signal from the sensor means falls within or outside a predetermined limit, characterised in that said operation of the control means being arranged to be effective in a predetermined time period after the rotation of the developing roller begins. Apparatus according to claim 1, wherein said predetermined time period is measured by a timer (25a) of the control means (25) and is arranged to provide for stabilizing the output of said sensor means (65). Apparatus according to claim 1 or claim 2, wherein said control means (25) is operable to provide for continued operation of the image forming apparatus when said signal is within said predetermined limit and to preclude operation when said signal is outside said predetermined limit. Apparatus according to any one of claims 1 to 3, comprising means for switching on a power source and enabling a print key (101) to initiate a copying operation, said control means (25) being operable to detect said signal and to make said determination between switching on said power source activating said print key such that the life of the process unit is detected prior to initiating a copying operation with said print key. Apparatus according to claim 4, wherein paper feeding means (19,19a) are arranged to be disabled by said control means (25) to preclude actuation of said feeding means by operation of the print key when the control means (25) have determined that said signal from said sensor means is outside said predetermined limit. Apparatus according to any one of claims 1 to 5, comprising a print key to initiate operation of a copying operation which includes feeding sheets of paper to be copied, said signal which is detected during said predetermined time period being a first signal, the control means (25) detecting a second signal from said sensor means during the time that the first sheet of paper is fed and being operable to determine whether or not said second signal is within said predetermined limit. Apparatus according to claim 6, wherein when it is determined that said second signal exceeds said predetermined value, said control means (25) is operable to provide a delayed time period between the time of completion of feeding of said first sheet of paper and starting of feeding of a second sheet of paper, and to detect a third signal from said sensor means during said delayed time period in order to determine whether or not said third signal is within said predetermined limit. Apparatus according to claim 6 or claim 7, wherein when the second signal is determined to be below said predetermined value, the control means (25) is operable to commence a continuous copying operation which includes activation of a main charger (5) and of means (19,19a) to initiate feeding of subsequent sheets of paper, the signal detecting means being operable to detect further signals from said sensor means after commencement of the continuous copying operation and to determine whether or not said further signals are within said predetermined limit during said operation. Apparatus according to any one of claims 1 to 8, wherein a print key (101) is operable to initiate rotation of the developing roller (14) and the feeding of a first sheet of paper, and said control means (25) is operable to provide a delay period to delay the start of feeding of a second sheet of paper, said delay period corresponding to said predetermined time period. Apparatus according to claim 9, wherein said delay period commences upon completion of feeding of said first sheet and continues until the start of feeding of said second sheet. Apparatus according to claim 9 or claim 10, wherein a timer (25a) of the control means determines said delay period for feeding said second sheet. Apparatus according to any one of claims 9 to 11, wherein a judgement determination is provided of whether or not said signal is within said predetermined limit while said first sheet of paper is being fed, said control means being operable alternatively to provide said delay period when said judgement determination exceeds said predetermined value or to commence feeding said second sheet of paper after completion of feeding of said first sheet and without such delay period when said judgement determination is below said predetermined value. Apparatus according to any one of claims 1 to 12, wherein the process unit (3) has a container (62a,62b) with a removable seal member (63), said control means (25) being operable by the signal from said sensor means (65) and to provide an output indicative of whether said process unit has been placed in the image forming apparatus with or without the seal having been opened. Apparatus according to claim 13, wherein said control means (25) is operable to provide the seal condition output signal after a print key (101) has been enabled and prior to initiation of a copying operation thereby. Apparatus according to any one of claims 1 to 14, wherein the sensor means (65) are operable to provide a signal to the control means (25) indicative of whether or not the process unit has been attached to the apparatus. A detachable process unit for an image forming apparatus, said process unit having a developing device (6) including a developing roller (14) in a casing, characterised in that sensor means (65) known per se for detecting the density of the toner in said developing device to provide an indication of whether the life of the process unit has expired is disposed in the process unit and also disposed in the process unit is a control means (25) arranged to detect the signal from the sensor means (65) and to determine whether a usual image forming operation is to be performed in dependence upon whether the signal from the sensor means falls within or outside a predetermined limit, said operation of the control means being arranged to be effective in a predetermined time period after the rotation of the developing roller begins. Image forming apparatus (1) comprising a sealable process unit detachably mounted therein, said unit having a developing device (6) comprising a developer storage section (10) provided with a seal member (63) for containing developer therein, whereby normally when the unit is attached to the apparatus the seal member is opened so that developer is supplied to a developer chamber (12) of the unit having a developing roller (13), characterised in that sensor means (65) are located adjacent the developing device (6) containing the developer storage section (10) for detecting the presence of developer or the density of toner contained in said section; and control means (25) co-operate with the sensor means and are responsive to a signal from said sensor means (65) for judging whether said developing device has been placed in the image forming apparatus (1) with or without the seal (63) having been removed from the developer storage section and to indicate when the seal has not been opened. A sealable and detachable process unit for an image forming apparatus said unit having a developing device (6) comprising a developer storage section (10) provided with a seal member (63) for containing developer therein, whereby normally when the unit is attached to the apparatus the seal member is opened so that developer is supplied to a developer chamber (12) of the unit having a developing roller (13), characterised in that sensor means (65) known per se for detecting the presence of developer or the density of toner are located adjacent the developing device (6) containing the developer storage section (10) for detecting the presence of developer or the density of toner contained in said section; and the process unit further comprises control means (25) which co-operate with the sensor means (65) and which are responsive to a signal from said sensor means for judging whether said developing device has been placed in the image forming apparatus (1) with or without the seal (63) having been removed from the developer storage section and to indicate when the seal has not been opened. Image forming apparatus having means for detecting the attachment to the apparatus (1) of a process unit (3) comprising a developing device (6) in a casing, characterised in that sensor means (65) are arranged to detect the presence of developer or the density of toner contained in the developing device (6); control means (25) are provided with an input for receiving signals from said sensor means; the sensor and control means are connected to each other by the attachment of the process unit (3) to the apparatus (1); and the control means are arranged to respond to a signal at said input that does not correspond to a normal use value by issuing a signal indicating the non-attachment of the process unit.

Inventors: HIROBE, JUNICHI, HORI, KAZUTO, TADA, TOMIO, TAKAMATSU, JUNICHI
Applicants: MITA INDUSTRIAL CO. LTD.
Application year: 1988
Main classification: G03G15
IPC codes: G03G21, G03G15