Method and apparatus for measuring and displaying a toner tally for a printer

• US 5,797,061 A
• Filed: 05/12/1997
• Issued: 08/18/1998
• Est. Priority Date: 05/12/1997
• Status: Expired due to Term

• Current Assignee: Lexmark International Incorporated (Ninestar Corporation)
• Original Assignee: Lexmark International Incorporated (Ninestar Corporation)
• Inventors: Wade, Thomas Campbell, Overall, Gary Scott, Wright, Phillip Byron, Webb, James Francis
• Primary Examiner(s): Smith, Matthew S.
• Application Number:
  US08/854,875
• Time in Patent Office: 463 Days
• Field of Search: 399/24, 399/25, 399/27, 399/29, 377/2, 377/15, 377/16, 347/86, 364/525, 364/479.05, 364/479.06, 395/102, 395/109, 358/296, 358/298, 358/300, 358/454-459
• US Class Current: 399/27
• CPC Class Codes: B41J 2/17566 Ink level or ink residue control
• CPC Class Codes: B41J 2002/17589 using ink level as input for printer mode selection or for prediction of remaining printing capacity
• CPC Class Codes: G03G 15/0856 Detection or control means for the developer level
• CPC Class Codes: G03G 15/5079 for maintenance
• 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

Abstract

An improved printer is provided that predicts how many pages can be printed before the toner or ink cartridge becomes empty, and also predicts how much time remains before this toner or ink cartridge becomes empty. This prediction is based upon the previous printing history of the printer while using this particular toner cartridge. After measuring the quantity of toner left in the toner cartridge, the printer of the present invention will display the approximate quantity of toner remaining in the cartridge on a screen of a host computer that is connected to the printer, either directly or through a network. The monitor screen of the host computer can also display the predicted number of pages remaining, based on the printer'"'"'s previous usage history as described above. The toner measuring device provides a "level change" output signal when the remaining toner passes through a predetermined gradation threshold, and depending upon the size of the toner cartridge and upon the time and date at which the level change was detected, the predicted number of pages remaining and the actual amount of toner remaining are more accurately updated upon reaching one of these predetermined gradation thresholds. As each gradation level transition occurs, the printer calculates a new value for the "pages per gradation" variable, and also calculates the number of pages that have been printed since the latest cartridge was installed in the printer, the number of pages printed since the last level or gradation change, and the number of pages or sheets printed between the last two level changes. The printer also can approximate the amount of toner used in printing a particular page of print media to create a Toner Tally for each printed page, which can be used to judge the amount of toner used for one print job and compare that to the amount of toner used for a second print job. The Toner Tally uses a combination hardware/software counter to count the number of "active" pels of each page for a print job.

Claims

1. A printing apparatus, comprising:

a print engine that determines the number of pels of a print job that are being printed upon a page of print media, a memory circuit that stores information, and a processing circuit that is configured to receive said number of pels of a print job'"'"'s page from said print engine and to temporarily store said number of pels in said memory circuit as a "Toner Tally";

said print engine containing an electrical circuit that sends print data in a serial format as a first electrical signal to a printhead, and also sends a second electrical signal to a counter circuit, said counter circuit having a most significant bit ("MSB") output that produces a third electrical signal that is directed to said processing circuit, said counter circuit also having a "Clear MSB" input that receives a fourth electrical signal that is sourced at said processing circuit, wherein said MSB output third electrical signal remains at a first logic state until said counter has accumulated enough counts to set said MSB output to a second logic state, then said processing circuit is further configured to modify the value of a predetermined memory register and then to output a transition in said fourth electrical signal directed to said Clear MSB input at said counter circuit, which clears said MSB output to said first logic state; and

said counter continues to accumulate a count value at its other count outputs.

2. The printing apparatus as recited in claim 1, wherein said first logic state is equal to Logic 0, and said second logic state is equal to Logic 1.

3. The printing apparatus as recited in claim 1, further comprising a shift register circuit that receives parallel electrical signals that represent slices of a particular pel of print data, said shift register circuit also receiving a "Subpel" Clock signal;

said shift register circuit outputting said first electrical signal as serial data that is clocked out at the Subpel Clock rate, said shift register circuit also outputting another set of parallel electrical signals to an OR-gate, said OR-gate including an output that produces a fifth electrical signal that is directed to a Count Enable input of said counter circuit, and said counter circuit also receiving a "Pel" Clock signal.

4. The printing apparatus as recited in claim 3, wherein said OR-gate sets its output to a Logic 1 state in the event that any of the slices of a particular pel are set to a Logic 1 state, and the Count Enable input will increment the count output of said counter circuit so long as at least one slice of a particular pel is set to Logic 1 upon the transition of said Pel Clock input signal.

5. The printing apparatus as recited in claim 1, wherein said Toner Tally is accumulated page-by-page for an entire print job, and the resultant Toner Tally is transmitted to a host computer connected to said printing apparatus by way of a communications link.

6. The printing apparatus as recited in claim 5, wherein said resultant Toner Tally is modified by a resolution factor that depends upon the print job'"'"'s resolution in dots per inch.

7. The printing apparatus as recited in claim 5, wherein said resultant Toner Tally is stored in a "job statistics" file in a non-volatile memory at said host computer.

8. The printing apparatus as recited in claim 5, wherein said resultant Toner Tally for a first print job is compared at said host computer to a corresponding resultant Toner Tally for a second print job.

9. In a printing system having a processing circuit, a memory circuit that stores information, and a print engine, a method for determining the number of pels of a print job that are being printed upon a page of print media as a "Toner Tally", said method comprising the steps of:

(a) communicating print data as a first electrical signal to said print engine;

(b) communicating a second electrical signal to a counter circuit, said counter circuit having a most significant bit ("MSB") output that produces a third electrical signal that is directed to said processing circuit;

(c) receiving, at a "Clear MSB" input of said counter circuit, a fourth electrical signal that is sourced at said processing circuit;

(d) holding said MSB output third electrical signal at a first logic state until said counter has accumulated enough counts to set said MSB output to a second logic state;

(e) modifying the value of a predetermined memory element and then outputting a transition in said fourth electrical signal directed to said Clear MSB input at said counter circuit, thereby clearing said MSB output to said first logic state; and

(f) continuing to accumulate a count value at said counter'"'"'s other count outputs.

10. The method as recited in claim 9, further comprising the step of temporarily storing said number of pels of a print job'"'"'s page in said memory circuit as a "Toner Tally".

11. The method as recited in claim 9, wherein said first logic state is equal to Logic 0, and said second logic state is equal to Logic 1.

12. The method as recited in claim 9, further comprising the steps of:

(a) receiving parallel electrical signals that represent slices of a particular pel of print data at a shift register circuit;

(b) receiving a "Subpel" Clock signal at said shift register circuit;

(c) outputting from said shift register circuit said first electrical signal as serial data that is clocked out at the Subpel Clock rate;

(d) outputting from said shift register circuit another set of parallel electrical signals to an OR-gate;

(e) creating a fifth electrical signal at an output of said OR-gate and directing said fifth electrical signal to a Count Enable input of said counter circuit; and

(f) receiving a "Pel" Clock signal at said counter circuit.

13. The method as recited in claim 12, wherein said OR-gate sets its output to a Logic 1 state in the event that any of the slices of a particular pel are set to a Logic 1 state, and the Count Enable input will increment the count output of said counter circuit so long as at least one slice of a particular pel is set to Logic 1 upon the transition of said Pel Clock input signal.

14. The method as recited in claim 9, further comprising the steps of accumulating said Toner Tally page-by-page for an entire print job, and transmitting the resultant Toner Tally to a host computer connected to said printing apparatus by way of a communications link.

15. The method as recited in claim 14, further comprising the step of modifying said resultant Toner Tally by a resolution factor that depends upon the print job'"'"'s resolution in dots per inch.

16. The method as recited in claim 14, further comprising the step of storing said resultant Toner Tally in a "job statistics" file in a non-volatile memory at said host computer.

17. The method as recited in claim 14, further comprising the step of comparing said resultant Toner Tally for a first print job to a corresponding resultant Toner Tally for a second print job.

18. A printing apparatus, comprising:

a print engine that determines the number of pels of a print job that are being printed upon a page of print media, a memory circuit that stores information, and a processing circuit that is configured to receive said number of pels of a print job'"'"'s page from said print engine and to temporarily store said number of pels in said memory circuit as a "Toner Tally";

said print engine containing a counter circuit, said counter circuit comprising a hardware portion and a software portion;

wherein said hardware portion comprises an n-bit counter having a plurality of count-bit outputs, and a "Clear MSB" input, said n-bit counter incrementing its count value at every active pel to be printed; and

wherein said software portion comprises a computer program running on said processing circuit that, when the most significant of said plurality of count-bit outputs changes state, repeatedly sets said Clear MSB input of said n-bit counter and increments a memory element.

19. The printing apparatus as recited in claim 18, further comprising a shift register circuit that receives parallel electrical signals that represent slices of a particular pel of print data, said shift register circuit also receiving a "Subpel" Clock signal;

said shift register circuit outputting a first electrical signal as serial data that is clocked out at the Subpel Clock rate, said shift register circuit also outputting another set of parallel electrical signals to an OR-gate, said OR-gate including an output that produces a second electrical signal that is directed to a Count Enable input of said counter circuit, and said counter circuit also receiving a "Pel" Clock signal.

20. The printing apparatus as recited in claim 19, wherein said OR-gate sets its output to a Logic 1 state in the event that any of the slices of a particular pel are set to a Logic 1 state, and the Count Enable input will increment the count output of said counter circuit so long as at least one slice of a particular pel is set to Logic 1 upon the transition of said Pel Clock input signal.

21. The printing apparatus as recited in claim 18 wherein said Toner Tally is accumulated page-by-page for an entire print job, and the resultant Toner Tally is transmitted to a host computer connected to said printing apparatus by way of a communications link.

22. The printing apparatus as recited in claim 21, wherein said resultant Toner Tally is modified by a resolution factor that depends upon the print job'"'"'s resolution in dots per inch.

23. The printing apparatus as recited in claim 21, wherein said resultant Toner Tally is stored in a "job statistics" file in a non-volatile memory at said host computer.

24. The printing apparatus as recited in claim 21, wherein said resultant Toner Tally for a first print job is compared at said host computer to a corresponding resultant Toner Tally for a second print job.

25. A printing apparatus, comprising:

a print engine that determines the number of pels of a print job that are being printed upon a page of print media, a memory circuit that stores information, and a processing circuit that is configured to receive said number of pels of a print job'"'"'s page from said print engine and to temporarily store said number of pels in said memory circuit as a "Toner Tally";

said print engine containing a counter circuit, said counter circuit comprising a hardware portion and a software portion;

wherein said hardware portion comprises a counter integrated circuit having a plurality of count-bit outputs and at least one clear input, said counter incrementing its count value at every non-null pel to be printed; and

wherein said software portion comprises a computer program running on said processing circuit that is configured to, when at least one of said plurality of count-bit outputs changes state, repeatedly set said at least one clear input of said counter and adjust a memory element of said memory circuit.

26. The printing apparatus as recited in claim 25, wherein said counter integrated circuit comprises an n-bit counter having a plurality of count-bit outputs and a "Clear MSB" input;

and wherein said computer program configures said processing circuit to, when the most of said plurality of count-bit outputs changes state, set a Clear MSB input of said n-bit counter.

27. The printing apparatus as recited in claim 25, further comprising a shift register circuit that receives parallel electrical signals that represent slices of a particular pel of print data, said shift register circuit also receiving a "Subpel" Clock signal;

said shift register circuit outputting a first electrical signal as serial data that is clocked out at the Subpel Clock rate, said shift register circuit also outputting another set of parallel electrical signals to an OR-gate, said OR-gate including an output that produces a second electrical signal that is directed to a Count Enable input of said counter circuit, and said counter circuit also receiving a "Pel" Clock signal.

28. The printing apparatus as recited in claim 27, wherein said OR-gate sets its output to a Logic 1 state in the event that any of the slices of a particular pel are set to a Logic 1 state, and the Count Enable input will increment the count output of said counter circuit so long as at least one slice of a particular pel is set to Logic 1 upon the transition of said Pel Clock input signal.

29. The printing apparatus as recited in claim 25 wherein said Toner Tally is accumulated page-by-page for an entire print job, and the resultant Toner Tally is transmitted to a host computer connected to said printing apparatus by way of a communications link.

30. The printing apparatus as recited in claim 29, wherein said resultant Toner Tally is modified by a resolution factor that depends upon the print job'"'"'s resolution in dots per inch.

31. The printing apparatus as recited in claim 29, wherein said resultant Toner Tally is stored in a "job statistics" file in a non-volatile memory at said host computer.

32. The printing apparatus as recited in claim 29, wherein said resultant Toner Tally for a first print job is compared at said host computer to a corresponding resultant Toner Tally for a second print job.