Abstract:
A system for analyzing an organic photo conducting drum includes an identification system, a feature examination system, and an evaluation processing system. The identification system identifies one or more characteristic relating to the organic photo conducting drum. The feature examination system examines one or more features of the organic photo conducting drum. The evaluation processing system provides an analysis of the organic photo conducting drum based on the identified one or more characteristics and the examined one or more features.

Description:
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/563,666, filed Apr. 20, 2004, which is hereby incorporated by reference in its entirety 

   FIELD OF THE INVENTION 
   This invention generally relates to evaluation devices for printing systems and, more particularly, to a system for analyzing an organic photoconducting (OPC) drum and a method thereof. 
   BACKGROUND 
   A coating layer on an OPC drum in a printing system acts as a charge transfer layer. During printing operations, the coating layer of the OPC drum is slowly worn down. Typically, this wear rate is about one micron per one-thousand pages and one life cycle of an OPC drum is usually about ten-thousand printed pages. Often after one life cycle, the OPC drum is disposed of, even though the OPC drum may have multiple life cycles left. 
   Attempts have been made to determine which OPC drums may have additional life cycles remaining, but these attempts have not been successful. For example, after use an OPC drum may be visually inspected for obvious flaws. If the OPC drum does not appear to be damaged, then the OPC drum is reused. Additionally, a manual measurement of the coating thickness may be taken and if the operator believes there is enough coating left to complete an additional life-cycle, then the OPC drum may be reused. 
   Unfortunately, these prior techniques are often inaccurate in analyzing the remaining life span of an OPC drum. Additionally, these techniques can be time consuming and thus the OPC drum is more likely to be replaced, then reused even though remaining life cycles may be available. 
   SUMMARY 
   A method for analyzing an organic photo conducting drum in accordance with embodiments of the present invention includes identifying one or more characteristics relating to the organic photo conducting drum and examining one or more features of the organic photo conducting drum. An analysis of the organic photo conducting drum is provided based on the identified one or more characteristics and the examined one or more features. 
   A system for analyzing an organic photo conducting drum in accordance with embodiments of the present invention includes an identification system, a feature examination system, and an evaluation processing system. The identification system identifies one or more characteristic relating to the organic photo conducting drum. The feature examination system examines one or more features of the organic photo conducting drum. The evaluation processing system provides an analysis of the organic photo conducting drum based on the identified one or more characteristics and the examined one or more features. 
   The present invention provides a system and method for determining the condition of and estimating the remaining usable life of an OPC drum. The present invention enables toner cartridge remanufacturers and others to safely determine which OPC drums can be reused without risking warranty return issues directly related to the coating thickness of the OPC drum. Additionally, the present invention provides a system and method where a high volume of OPC drums can quickly be measured and evaluated. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a block diagram of an analyzing system for an OPC drum in accordance with embodiments of the present invention; 
       FIG. 2  is a flow chart of a method for analyzing an OPC drum in accordance with embodiments of the present invention; 
       FIGS. 3A-3G  are screen shots on a display of the analyzing system during an analysis in accordance with embodiments of the present invention. 
   

   DETAILED DESCRIPTION 
   An analyzing system  10  for an OPC drum  18  in accordance with embodiments of the present invention is illustrated in  FIG. 1 . The analyzing system  10  includes a thickness measuring system  12 , a surface continuity system  14 , an electrical continuity system  23 , and an OPC drum evaluation system  16 , although the analyzing system  10  can comprise other numbers and types of components in other configurations. The present invention provides a system and method for providing an analysis of an OPC drum. 
   Referring more specifically to  FIG. 1 , the OPC drum  18  is connected to the analyzing system  10  for rotational movement, although the OPC drum  18  can be connected to the analyzing  10  system in other manners. The OPC drum  18  includes a coating layer  20  which acts as a charge transfer layer and wears down during use in printing operations. 
   The thickness measuring system  12  is used to determine or measure a thickness of the coating layer  20 . In this particular embodiment, the current meter system  12  is an eddy current meter system, although other types of systems to measure the thickness of the coating layer  20  on the OPC drum  18  can be used. The current meter system  12  includes a probe  15  which is positioned adjacent a known region of wear on the coating layer  20 , although the current meter system  12  can comprise other numbers of probes and the measurement or measurements can be taken at other locations. The current meter system  12  retrieves the known region of wear from memory  24  in the OPC drum evaluation system  16  based on the identified manufacturer and model type for the OPC drum  18  being evaluated, although the location can be obtain in other manners. 
   The surface continuity system  14  comprises a probe  17  which is moved along an outer surface of the coating layer  20  by a transport system  21  to examine a substantial portion of an outer surface of coating layer on the OPC drum  18 , although the system  14  can comprise other numbers of probes which scan different portions of the coating layer  20 , such as just the known regions of wear, and other manners for scanning the coating layer  20 , such as with a stationary probe or probes can be used. A voltage is applied across the OPC drum  18  by the electrical continuity system  23  and the probe  18  is used to identify current spikes which indicate a void in the coating layer  20 , although other sources for the voltage and other techniques for checking the surface continuity of the coating layer  20  can be used. The readings from the probe  18  are transmitted to the OPC drum evaluation system  16  for evaluation. 
   The electrical continuity system  23  is coupled to the center of the OPC drum  18  and the outer surface of the coating layer  20  and a voltage is applied across the OPC drum  18 , although other types of systems for checking electrical continuity can be used. The electrical continuity system  23  measures the voltage drop across the OPC drum  18  and transmits the reading to the OPC drum evaluation system  16  for evaluation. 
   The drum identification system  29  comprises a densitometer which is positioned adjacent the OPC drum  18  to take a color reading of the OPC drum, although other types of identification systems could be used. The drum identification system  29  transmits the measured color of the OPC drum  18  to the OPC drum evaluation system  16  for evaluation to determine the manufacture and the type of model of OPC drum  18 , although other types of information could be determined and the OPC evaluation system  16  can obtain information about the OPC drum  18  in other manners as described below. 
   The OPC drum evaluation system  16  analyzes the OPC drum  18  based on the inputs from the thickness measuring system  12 , the surface continuity system  14 , the electrical continuity system  23 , and the drum identification system  29 , although the OPC drum evaluation system  16  can base the evaluation on other numbers and types of inputs. The OPC drum evaluation system  16  includes a central processing unit (CPU) or processor  22 , a memory  24 , a user input device  26 , an input/output (I/O) interface system  28 , and a display  31  which are coupled together by a bus system or other link  30 , although the OPC drum evaluation system  16  may comprise other numbers and types of components in other configurations. The CPU  22  executes a program of stored instructions for the method for analyzing an OPC drum  18  in accordance with embodiments of the present invention as described herein and as illustrated in  FIG. 2 . In this particular embodiment, those programmed instructions are stored in the memory  24 , although some or all could be stored and retrieved from other locations. A variety of different types of memory storage devices, such as a random access memory (RAM) or a read only memory (ROM) in the system or a floppy disk, hard disk, CD ROM, or other computer readable medium which is read from and/or written to by a magnetic, optical, or other reading and/or writing system that is coupled to the CPU  22 , can be used for memory  24 . 
   The input/output interface system  28  is used to operatively couple and communicate between other components, including the thickness measuring system  12 , the surface continuity system  14 , the electrical continuity system  23 , and the drum identification system  29 . In this particular embodiment, the connection is shown as a hard wire connection, although a variety of different types of connections and communication techniques can be used to transmit signals from the thickness measuring system  12 , the surface continuity system  14 , the electrical continuity system  23 , and the drum identification system  29  to the OPC drum evaluation system  16  and/or from the OPC drum evaluation system to the thickness measuring system  12 , the surface continuity system  14 , the electrical continuity system  23 , and the drum identification system  29 . 
   The user input device  26  enables an operator to generate and transmit signals or commands to the CPU  22 . A variety of different types of user input devices, such as a keyboard or computer mouse, can be used. The display  31  is a cathode ray tube which is used to provide an output to the operator on the condition of the OPC drum  20 , although other types of displays can be used. 
   Referring to  FIGS. 3A-3G , screen shots on the interactive display  31  for the analysis of an OPC drum are illustrated, although other types of displays could be used. More specifically, the display  31  has a field  68  which can display the output of the evaluation “PASS” in the color green to indicate the OPC drum  18  has another life cycle as shown in  FIG. 3A , “TESTING” to indicate the OPC drum  18  is currently being examined as shown in  FIG. 3B , and “FAIL” in the color red to indicate the OPC drum  18  should not be reused as shown in  FIG. 3C , although OPC drum evaluation system  16  can provide other outputs, such as REUSE to indicate the OPC drum  18  has another life cycle, REMANUFACTURE to indicate the OPC drum  18  can be refurbished for further use, and RECYCLE to indicate the OPC drum should be salvaged for scrap materials. The display  31  also includes fields and drop down menus for identifying the manufacturer in field  58 , the type of printer model in filed  60 , the number of prints per job in field  62 , the intended number of prints during a life cycle for the OPC drum in field  64 , and the status of the wiper blade used on the OPC drum in field  66  as shown in  FIGS. 3D-3G , although other numbers and types of fields can be used. An operator can use the user input device  26  to access and select from the drop down menus for fields  58 ,  60 ,  62 ,  64 , and  66 . The information input in fields  58 ,  60 ,  62 ,  64 , and  66  is used by the OPC drum evaluation system  16  to evaluate the OPC drum  18 . 
   An automated loading system  25  is used to load the OPC drum  18  into the analyzing system  10 , although other devices and techniques for loading the OPC drum  18  can be used, such as loading the OPC drum  18  by hand. The automated loading system  25  may hold a plurality of the OPC drums which are individually loaded for testing. With the automated loading system  25 , the OPC drum  18  is less likely to become damaged or contaminated during handling by an operator, such as from being accidentally scraped against another surface or having oils transferred from the operator&#39;s hands. 
   A cleaning system  27  is located in the loading system  27 , although the cleaning system  27  could be in other places. The cleaning system  27  cleans the outer surface of the OPC drum  18 , for example by removing any remaining toner on the OPC drum  18 . 
   A method for analyzing an OPC drum in accordance with embodiments of the present invention will now be described with reference to  FIGS. 1-3 . In step  32 , the analyzing system  10  identifies the OPC drum  18  being evaluated and the expected operating parameters based on the information entered in the fields  58 ,  60 ,  62 ,  64 , and  66  in the display  31 , although other numbers and types of information can be entered and the OPC drum can be evaluated in other manners. For example, the OPC drum  18  could be identified by the drum identification system  29  taking a color reading of the OPC drum  18  and transmitting the identified color back to the OPC drum evaluation system  16 . The OPC drum evaluation system  18  matches the identified color to a stored color which is correlated to a particular manufacturer and model type. The manufacture and model type in fields  58  and  60  are used by the OPC drum evaluation system  16  to retrieve data about the wear rate and image quality produced by that particular type of OPC drum  18 . The prints per job and the intended life cycle entered in fields  62  and  64  are used by the OPC drum evaluation system  16  to set parameters for use of the OPC drum in the next life cycle which is used in evaluating the OPC drum  18 . The wiper blade status entered in field  66  is also used by the OPC drum evaluation system  16  in evaluating the OPC drum  18  because a reclaimed wiper blade will cause less wear on the OPC drum  18  during use. Although five fields are shown, other numbers and types of information to identify the OPC drum and the operating parameters can be used. 
   In step  33 , the thickness measuring system  12  determines a thickness of the coating layer  20  on the OPC drum  18 . In these embodiments, the probe  15  for the thickness measuring system  12  is positioned at a known region of wear on the OPC drum  18  to take a thickness measurement, although other locations and numbers of measurements can be taken. The position of the known region of wear is obtained by the OPC drum evaluation system  16  based on the information input in fields  58  and  60  and can be displayed on display  31  so the operator can position probe  15  or the positioning process could be automated. The thickness for the coating layer  20  measured by the probe  15  of the thickness measuring system  12  is transmitted to the OPC drum evaluation system  16 , although other amounts and types of information can be transmitted to the OPC drum evaluation system  16 . 
   In step  34 , the OPC drum evaluation system  16  evaluates the OPC drum  18  based on the measured thickness and the information entered in the fields  58 ,  60 ,  62 ,  64 , and  66 , although the OPC drum evaluation system  16  can evaluate the OPC drum  18  based on other factors. For example, if the measured thickness for the coating layer  20  is thick enough to last for the intended number of prints entered in field  64 , then the OPC drum evaluation system  16  would pass the OPC drum  18  through this stage. In another example, if the measured thickness for the coating layer  20  is thick enough to last for the intended number of prints entered in field  64 , but the OPC drum evaluation system  16  determines that based on the manufacturer and model type for the OPC drum  18  and the prints per job entered in field  62  would result in unacceptable print quality at the measured thickness, then the OPC drum evaluation system  16  would fail the OPC drum  18  at this stage. 
   In step  36 , the OPC drum evaluation system  16  determines whether to continue with the evaluation of the OPC drum  18 . If the OPC drum  18  has failed the evaluation for measured thickness in step  34  and/or there are no more desired evaluations, then the No branch is taken to step  54  where the display  31  would provide an output in field  68  as shown in  FIG. 3A  or  3 C based on the evaluation in step  34 . If the OPC drum  18  has not failed the evaluation for measured thickness in step  34  and additional evaluations are desired, then the Yes branch is taken to step  38 . 
   By way of example only, an evaluation of a coating layer  20  on an OPC drum  18  is described below. The thickness measuring system  12  measures the thickness of the coating layer  20  to be twenty-three microns and this is transmitted to the OPC drum evaluation system  16 . Additionally, the type of OPC drum  18  is input or otherwise provided to the OPC drum evaluation system  16 . The OPC drum evaluation system  16  retrieves from data stored in memory  24  that this particular type of OPC drum  18  should be capable of printing 10,000 pages and that the wear rate for the coating layer  20  for this OPC drum  18  is one micron per 1,000 pages. The OPC drum evaluation system  16  calculates that ten microns of wear will occur in one life-cycle and since the coating layer has a thickness of twenty-three microns, the OPC drum evaluation system  16  determines that the OPC drum  18  should be able to perform another life cycle without failure caused by issues with the thickness of the coating layer  20 . If the OPC drum evaluation system  16  determines there is less than a life cycle left, it may signal to discard the OPC drum  18 , although the OPC drum evaluation system  16  may provide other information. 
   In step  38 , the surface continuity system  14  evaluates the surface continuity of a substantial portion of the outer surface of the coating layer  20 , although other amounts of the coating layer  20  could be evaluated, such as just known regions of wear. The electrical continuity system  23  applies a voltage across the leads coupled to the center of the OPC drum  18  and to the coating layer  20 . A transport system  21  moves a probe  17  along adjacent to and spaced from the outer surface of the coating layer  20  to measure for current spikes. Once the probe  17  has traversed the length of the OPC drum  18 , the OPC drum  18  is rotated slightly and the probe  17  traverses the length of the OPC drum  18  measuring for current spikes. This process is repeated until the entire OPC drum  18  is scanned. The measured current spike or spikes indicate a void or voids in the coating layer  20  and are transmitted to the OPC drum evaluation system  16  for further evaluation. The size of the measured current spike or spikes provides an indication of the severity of the void or voids. Although one technique for determining surface continuity is described, other techniques for determining surface continuity can be used. 
   In step  40 , the OPC drum evaluation system  16  evaluates the OPC drum  18  based on the determined surface continuity and the information entered in the fields  58 ,  60 ,  62 ,  64 , and  66 , although the OPC drum evaluation system  16  can evaluate the OPC drum  18  based on other factors. For example, if the determined surface continuity identified two voids whose size did not indicate any unacceptable problems with print quality based on the identified manufacturer and type of model, then the OPC drum evaluation system  16  would pass the OPC drum  18  at this stage. 
   In step  42 , the OPC drum evaluation system  16  determines whether to continue with the evaluation of the OPC drum  18 . If the OPC drum  18  has failed the evaluation for surface continuity in step  40  and/or there are no more desired evaluations, then the No branch is taken to step  54  where the display  31  would provide an output in field  68  as shown in  FIG. 3A  or  3 C. If the OPC drum  18  has not failed the evaluation for surface continuity in step  40  and additional evaluations are desired, then the Yes branch is taken to step  44 . 
   In step  44 , the electrical continuity system  14  evaluates the electrical continuity of the OPC drum  18  with the coating layer  20 , although other factors could be evaluated. The electrical continuity system  23  applies and measures a voltage across the leads coupled to the center of the OPC drum  18  and to the coating layer  20 . The measured voltage is transmitted to the OPC drum evaluation system  16  for further evaluation. Although one technique for determining electrical continuity is described, other techniques can be used. 
   In step  46 , the OPC drum evaluation system  16  evaluates the OPC drum  18  based on the determined electrical continuity and the information entered in the fields  58 ,  60 ,  62 ,  64 , and  66 , although the OPC drum evaluation system  16  can evaluate the OPC drum  18  based on other factors. For example, if the measured voltage for electrical continuity corresponds within a range which is acceptable for the identified manufacture and type of model of OPC drum  18 , then the OPC drum evaluation system  16  would pass the OPC drum  18  at this stage. 
   In step  48 , the OPC drum evaluation system  16  determines whether to continue with the evaluation of the OPC drum  18 . If the OPC drum  18  has failed the evaluation for electrical continuity in step  46  and/or there are no more desired evaluations, then the No branch is taken to step  54  where the display  31  would provide an output in field  68  as shown in  FIG. 3A  or  3 C. If the OPC drum  18  has not failed the evaluation for electrical continuity in step  46  and additional evaluations are desired, then the Yes branch is taken to step  50 . 
   In step  50 , an additional evaluation of the OPC drum  18  can be performed and then the results can be evaluated in step  52 . For example, the gears of the OPC drum  18  may be examined to determine if any teeth are missing and the results of this evaluation can be transmitted to the OPC drum evaluation system  16  for further evaluation to provide an analysis of the future life of the OPC drum. To examine the gears of the OPC drum  18 , a visual inspection system could be positioned adjacent each of the gears of the OPC drum  18  to inspect and identify any missing or damaged gear teeth and this information would be transmitted to the OPC drum evaluation system  16  for evaluation. The OPC drum evaluation system  16  based on visual inspection data and corresponding stored visual inspection data for gears for the identified manufacturer and model type of OPC drum  18  would determine whether the extent of the damage would preclude further use of the OPC drum  18  or require other action, such as replacement of the damaged gear or gears or recycling of the OPC drum  18 . Although one example of inspecting the gears is disclosed, other types of inspection systems could be used to inspect the gears, such as a system which would measure the torque to turn the OPC drum  18  by engaging the gear of the OPC drum  18  and transmitting the measured torque data to the OPC drum evaluation system  16  for evaluation. The OPC drum evaluation system  16  based on received torque data and corresponding stored torque data for gears for the identified manufacturer and model type of OPC drum  18  would determine whether the extent of the damage would preclude further use of the OPC drum  18  or require other action, such as replacement of the damaged gear or gears or recycling of the OPC drum  18 . Although examples of different evaluations or failure modes are set forth above, other numbers and types of evaluations can be performed and in other orders. In another example, two or more of the measurements and/or determinations can be made before an evaluation of the OPC drum  18  is performed. 
   In step  54 , the field  68  in the display  31  provides an output on the results of the analysis of the OPC drum  18 , although other types of displays and methods for providing the results can be used. As described earlier, in these embodiments, the provided output in field  68  is PASS or FAIL, although other types of outputs can be provided, such as REUSE, REMANUFACTURE, or RECYCLE. In step  56 , the analysis of the OPC drum  18  ends. 
   Accordingly, the present invention provides an accurate indication of whether an OPC drum  18  has another life cycle available and can provide other information, such as recommendations to remanufacture or recycle the OPC drum  18 . Additionally, the present invention is very easy to use and is able to quickly provide a reliable evaluation of the OPC drum  18 . 
   Having thus described the basic concept of the invention, it will be rather apparent to those skilled in the art that the foregoing detailed disclosure is intended to be presented by way of example only, and is not limiting. Various alterations, improvements, and modifications will occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested hereby, and are within the spirit and scope of the invention. Additionally, the recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefore, is not intended to limit the claimed processes to any order except as may be specified in the claims. Accordingly, the invention is limited only by the following claims and equivalents thereto.