Method and apparatus for determining toner level in electrophotographic print engines

• US 20050007621A1
• Filed: 06/15/2004
• Published: 01/13/2005
• Est. Priority Date: 08/07/1995
• Status: Active Grant

• Current Assignee: Fiery LLC
• Original Assignee: T/R Systems, Inc. (Electronics For Imaging Incorporated)
• Inventors: Rowe, Francis A., Zuber, Peter A., Barry, Michael W., Bartholmae, Jack N., Tompkins, E. Neal
• Granted Patent: US 7,116,444 B2
• Time in Patent Office: Days
• US Class Current: 358/1.140
• CPC Class Codes: G03G 13/08 using a solid developer, e.g. powder developer
• CPC Class Codes: G03G 15/0856 Detection or control means for the developer level
• CPC Class Codes: G03G 15/5087 for receiving image data
• CPC Class Codes: G03G 15/553 Monitoring or warning means for exhaustion or lifetime end of consumables, e.g. indication of insufficient copy sheet quantity for a job
• CPC Class Codes: G03G 15/556 for toner consumption, e.g. pixel counting, toner coverage detection or toner density measurement
• CPC Class Codes: G03G 2215/0888 Arrangements for detecting toner level or concentration in the developing device
• CPC Class Codes: G06F 3/121 Facilitating exception or error detection and recovery, e.g. fault, media or consumables depleted
• CPC Class Codes: G06F 3/1235 caused by end of consumables, e.g. paper, ink, toner
• CPC Class Codes: G06F 3/1285 Remote printer device, e.g. being remote from client or server
• CPC Class Codes: G06K 15/02 using printers
• CPC Class Codes: G06K 15/12 by photographic printing , e.g. by laser printers
• CPC Class Codes: G06K 15/1823 for evaluating the resources needed, e.g. rasterizing time, ink, paper stock

Abstract

The toner in the toner cartridge is determined by taking each of the rasterized images output by the RIP and evaluating the pixel levels over the surface thereof. The average value is determined as a percentage of the maximum toner that can be applied to the page. This is then subtracted from a toner value and a remaining toner level determined. Further, all pages of the rasterized document can be evaluated to predetermine the toner level after printing. If this falls below a predetermined minimum, printing is inhibited for that document.

Claims

1. A method for determining toner usage by a designated printing device for a document of at least one page, comprising the steps of:

accumulating toner values of pixels that are on in the at least one page of the document to be printed on the designated printer, which toner values have a plurality of different values between completely off to completely on;

comparing the accumulated toner values of pixels that are on to a predetermined toner usage for a defined number of pixels that are completely on in a reference page defined for the designated printing device, which reference page was generated on the designated printing device, and which predetermined toner usage incorporates the characteristics of the designated printing device on which the document is to be printed; and

calculating the amount of toner utilized by the at least one page as a proportion of that used by the reference page.

2. The method of claim 1, wherein a pixel in the at least one page can be partially on and the step of accumulating toner values of pixels that are on comprises determining the percentage on for each of the pixels in the at least one page and the step of comparing comprises comparing the accumulated toner values of pixels that are on and the percentage on thereof compared to a predetermined toner usage for a defined number of pixels that are on to a defined percentage in a reference page.

3. The method of claim 2, wherein the defined number of pixels are all pixels for the reference page and which are on to a defined percentage.

4. The method of claim 3, wherein the defined percentage is one hundred percent.

5. The method of claim 1, wherein the defined number of pixels are all pixels for the reference page.

6. The method of claim 1 and further comprising the step of printing the document with a marking engine, the step of printing following the step of calculating.

7. The method of claim 1, wherein the step of accumulating toner values of pixels comprises:

rasterizing the document of at least one page into a rasterized image; and

determining the toner values of pixels that are on in the rasterized image of the at least one page.

8. The method of claim 7 and further comprising the step of storing the rasterized image of the at least one page after rasterizing thereof and prior to the step of determining.

9. The method of claim 1 and further comprising determining the toner usage for the defined number of pixels on the reference page by the steps of:

generating a page having the defined number of pixels contained thereon as a test page;

Initiating printing of the test page with a toner cartridge of a known toner level;

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known; and

determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page.

10. A method for determining the approximate toner level in a toner cartridge in a designated print engine that is to handle a defined input job, comprising the steps of:

rasterizing an input data file associated with the defined input job into individual pages;

determining the amount of toner that is to be disposed on each page of the defined input job prior to printing the page by accumulating in a toner density register the toner values of the non-zero valued pixels present in a given rasterized image, wherein the non-zero valued pixels have a plurality of different values;

printing the image; and

decrementing a toner count value for the designated print engine by a defined amount associated with the characteristics of the designed print engine and the determined amount of toner to be disposed on the given page.

11. The method of claim 10, wherein a multi-page document is received and all of the pages are rasterized and further comprising the step of determining the amount of toner for the entire document prior to [printing and then determining if sufficient toner is available in the toner module by comparing the toner density register value with a predetermined value and inhibiting printing if the toner density register value is less than the determined amount of toner for the rasterized multi-page document.

12. A method for determining toner usage by a designated printing device for a multi-color document of at least one page, having different color planes, comprising the steps for each plane of:

accumulating toner values of pixels that are on in the at least one page in the given plane, which toner values have a plurality of different values between completely off and completely on;

comparing the accumulated toner values of pixels that are on to a predetermined toner usage of toner associated with the given plane for a defined number of pixels that are completely on in a reference page of the given plane defined for the designated printing device and which predetermined toner usage incorporates the characteristics of the designated printing engine on which the at least one page is to be printed; and

calculating the amount of toner for the given plane, utilized by the at least one page of the given plane as a proportion of that used by the reference page for the given plane.

13. The method of claim 12, wherein a pixel in the at least one page for a given plane can be partially on and the step of accumulating toner values of pixels that are on for the given plane comprises determining the percentage on for each of the pixels in the at least one page and the step of comparing for each plane comprises comparing the accumulated toner values of pixels that are on and the percentage on thereof compared to a predetermined toner usage for a defined number of pixels that are on to a defined percentage in a reference page for the given plane.

14. The method of claim 13, wherein the defined number of pixels are all pixels for the reference page for the given plane and which are on to a defined percentage.

15. The method of claim 14, wherein the defined percentage is one hundred percent.

16. The method of claim 12, wherein the defined number of pixels are all pixels for the reference page for the given plane.

17. The method of claim 12 and further comprising the step of printing the document with a marking engine, the step of printing following the step of calculating for each plane.

18. The method of claim 12, wherein the step of accumulating toner values of pixels for a given plane comprises:

rasterizing the document of at least one page into a rasterized image for each plane; and

determining the toner values of pixels that are on in each plane in the rasterized image of the at least one page.

19. The method of claim 18 and further comprising the step of storing the rasterized image for each plane of the at least one page after rasterizing thereof and prior to the step of determining.

20. The method of claim 12 and further comprising determining the toner usage for the defined number of pixels on the reference page of the given plane by the steps of:

generating a page having the defined number of pixels contained thereon as a test page for each color plane;

initiating printing of the test page with a toner cartridge for each plane of a known toner level for that plane;

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known for that plane; and

Determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page for each plane.

21. A method for determining toner usage by a designated printing device for a multi-page document that is to be printed on the designated printing device, comprising the steps of:

accumulating toner values of pixels that are on in the multi-page document, which toner values have a plurality of different values between completely off and completely on;

comparing the accumulated toner values of pixels that are on to a predetermined toner usage for a defined number of pixels that are completely on in a reference page defined for the designated printing device, which reference page was printed on the designated printing device and which predetermined toner usage incorporates the characteristics of the designated printing device on which the document is to be printed; and

calculating the amount of toner utilized by the entire document as a proportion of that used by the reference page.

22. The method of claim 21, wherein a pixel in the document can be partially on and the step of accumulating toner values of pixels that are on comprises determining the percentage on for each of the pixels in the document and the step of comparing comprises comparing the accumulated toner values of pixels that are on and the percentage on thereof compared to a predetermined toner usage for a defined number of pixels that are on to a defined percentage in a reference page.

23. The method of claim 22, wherein the defined number of pixels are all pixels for the reference page and which are on to a defined percentage.

24. The method of claim 23, wherein the defined percentage is one hundred percent.

25. The method of claim 21, wherein the defined number of pixels are all pixels for the reference page.

26. The method of claim 21 and further comprising the step of printing the document with a marking engine, the step of printing following the step of calculating.

27. The method of claim 21, wherein the step of accumulating toner values of pixels comprises:

rasterizing the documents into a plurality of rasterized images, each comprised of a rasterized page of the document; and

determining the toner values of pixels that are on in each of the rasterized images.

28. The method of claim 27 and further comprising the step of storing the rasterized images after rasterizing thereof and prior to the step of determining.

29. The method of claim 27, and further comprising the steps of:

determining the available toner for printing;

determining a required amount of toner utilized by the multipage document;

comparing the required amount of toner for the multi-page document with the available toner;

determining a required amount of toner required for the rasterized image of each page; and

printing only the number of pages printable using the available toner.

30. The method of claim 29, wherein the step of determining the available toner comprises the steps of:

initiating a counter at a first known toner level for a print engine;

decrementing the counter to a counter value by the required amount of toner utilized by the multipage document or a portion thereof after printing of the document; and

subtracting from the counter value a known minimum toner value that defines a toner empty condition, the counter value remaining defined as the available toner level.

31. The method of claim 21 and further comprising determining the toner usage for the defined number of pixels on the reference page by the steps of:

generating a page having the defined number of pixels contained thereon as a test page;

initiating printing of the test page with a toner cartridge of a known toner level;

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known; and

determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page.

32. A method for determining toner usage by a designated printing device for a rasterized document of at least one page that is to be printed on the designated printing device, comprising the steps of:

fetching the rasterized document;

accumulating the values of the pixels that are on in the at least one page, each on pixel having a non-zero value less than a maximum value;

comparing the accumulated values to a predetermined toner usage for a defined number of pixels that are completely on in a reference page defined for the designated printing device, which reference page was printed on the designated printing device and which predetermined toner usage incorporates the characteristics of the designated printing device on which the rasterized document is to be printed; and

calculating the amount of toner utilized by the at least one page as a proportion of that used by the reference page.

33. The method of claim 32, wherein a pixel in the at least one page can be partially on and the step of accumulating the values of the pixels that are on comprises determining the percentage on for each of the pixels in the at least one page and the step of comparing comprises comparing the accumulated values of the pixels that are on to a predetermined toner usage for a defined number of pixels that are on in the reference page.

34. The method of claim 33, wherein the defined number of pixels are all pixels for the reference page and which are on to a defined percentage.

35. The method of claim 34, wherein the defined percentage is one hundred percent.

36. The method of claim 32, wherein the defined number of pixels are all pixels for the reference page.

37. The method of claim 32 and further comprising the step of printing the document with a marking engine, the step of printing following the step of calculating.

38. The method of claim 32 and further comprising determining the toner usage for the defined number of pixels on the reference page by the steps of:

generating a page having the defined number of pixels contained thereon as a test page;

initiating printing of the test page with a toner cartridge of a known toner level;

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known; and

Determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page.

39. A method for determining toner usage by a printing device for a document of at least one page, comprising the steps of:

accumulating toner values of pixels that are on in the at least one page, which toner values have a plurality of different values between completely off to completely on;

comparing the accumulated toner values of pixels that are on to a predetermined toner usage for a defined number of pixels that are on in a reference page defined for the printing device wherein the toner usage for the defined number of pixels on the reference page is determined by;

generating a page having the defined number of pixels contained thereon as a test page, initiating printing of the test page with a toner cartridge of a known toner level, terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known, and determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page; and

calculating the amount of toner utilized by the at least one page as a proportion of that used by the reference page.

40. A method for determining toner usage by a printing device for a multi-color document of at least one page, having different color planes, comprising the steps for each plane of:

accumulating toner values of pixels that are on in the at least one page in the given plane, which toner values have a plurality of different values between completely off and completely on;

comparing the accumulated toner values of the pixels that are on to a predetermined toner usage of toner associated with the given plane for a defined number of pixels that are on in a reference page of the given plane defined for the printing device wherein the toner usage for the defined number of pixels on the reference page of the given plane is determined by;

generating a page having the defined number of pixels contained thereon as a test page for each color plane, initiating printing of the test page with a toner cartridge for each plane of a known toner level for that plane, terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known for that plane, and determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page for each plane; and

calculating the amount of toner for the given plane, utilized by the at least one page of the given plane as a proportion of that used by the reference page for the given plane.

41. A method for determining toner usage by a printing device for a multi-page document, comprising the steps of:

accumulating toner values of pixels that are on in the multi-page document, which toner values have a plurality of different values between completely off and completely on;

comparing the accumulated toner values of the pixels that are on to a predetermined toner usage for a defined number of pixels that are on in a reference page defined for the printing device wherein the toner usage for the defined number of pixels on the reference page is determined by;

generating a page having the defined number of pixels contained thereon as a test page,

initiating printing of the test page with a toner cartridge of a known toner level,

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known, and

determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page; and

calculating the amount of toner utilized by the entire document as a proportion of that used by the reference page.

42. A method for determining toner usage by a printing device for a rasterized document of at least one page, comprising the steps of:

fetching the rasterized document;

accumulating the values of pixels that are on in the at least one page, each on pixel having a non-zero value less than a maximum value;

comparing the accumulated values to a predetermined toner usage for a defined number of the pixels that are on in a reference page defined for the printing device wherein the toner usage for the defined number of pixels on the reference page is determined by;

generating a page having the defined number of pixels contained thereon as a test page,

initiating printing of the test page with a toner cartridge of a known toner level,

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known, and

determining an average value of total toner utilized for the printing of the test page as a function of the pixels that are on for the total toner utilized for the printing of the test page; and

calculating the amount of toner utilized by the at least one page as a proportion of that used by the reference page.

43. A method for determining toner usage for a document of at least one page prior to printing to page, comprising the steps of:

determining the number of pixels that are on in the at least one page;

comparing the number of pixels that are on compared to a predetermined toner usage for a defined number of pixels that are on in a reference page and which predetermined toner usage incorporates the characteristics of the printing device; and

calculating the amount of toner utilized by the at least one page as a proportion of that used by the reference page.

44. The method of claim 43, wherein a pixel in the at least one page can be partially on and the step of determining the number of pixels that are on comprises determining the percentage on for each of the pixels in the at least one page and the step of comparing comprises comparing the number of pixels that are on and the percentage on thereof compared to a predetermined toner usage for a defined number of pixels that are on to a defined percentage in a reference page.

45. The method of claim 44, wherein the defined number of pixels are all pixels for the reference page and which are on to a defined percentage.

46. The method of claim 45, wherein the defined percentage is one hundred percent.

47. The method of claim 43, wherein the defined number of pixels are all pixels for the reference page.

48. The method of claim 43 and further comprising the step of printing the document with a marking engine, the step of printing following the step of calculating.

49. The method of claim 43, wherein the step of determining the number of pixels comprises rasterizing the document of at least one page into a rasterized image;

and

determining the number of pixels that are on in the rasterized image of the at least one page.

50. The method of claim 49 and further comprising the step of storing the rasterized image of the at least one page after rasterizing thereof and prior to the step of determining.

51. The method of claim 43 and further comprising determining the toner usage for the defined number of pixels on the reference page by the steps of:

Generating a page having the defined number of pixels contained thereon as a test page;

initiating printing of the test page with a toner cartridge of a known toner level;

terminating printing of the test page after the toner level in the toner cartridge has reached a known lower limit such that total toner utilized is known; and

determining an average value of total toner utilized on a given one of the printed test pages as a function of the pixels that are on for the total toner utilized for the printed test pages.