Method and apparatus to control waste toner collection in an image forming apparatus

1. A device to move toner within a waste toner container comprising:

a member movably positioned within the container and having a raking section and a floating section, the member moveable in a reciprocating manner with the raking section oriented to distribute the toner within the container and the floating section oriented to keep the member towards a surface of the toner;

a driving device operatively connected to the member to move the member in the reciprocating manner; and

an extension where movement of the member creates interference between the member and the container when the amount of toner in the container reaches a predetermined quantity.

2. The device of claim 1 wherein the member pivots to allow the floating surface to remain towards the surface of the toner.

3. The device of claim 1 wherein the member is adapted to reciprocate in a first direction to distribute the toner within the container, the member further adapted to move in a second direction to accommodate a rising waste toner level and maintain the floating surface towards the surface of the toner.

4. The device of claim 3 wherein the first direction is substantially horizontal.

5. The device of claim 3 wherein the second direction is substantially vertical.

6. The device of claim 1 wherein the interference occurs at least once per reciprocating cycle of the member.

7. A device to move toner within a waste toner container comprising:

a toner distributing member positioned within the container;

a driving device operatively connected to the toner distributing member to move the toner distributing member in a reciprocating motion within the container;

a control circuit configured to move the driving device at a desired operating speed;

a logic circuit configured to detect accumulation of waste toner within the waste toner container by monitoring the control circuit; and

an extension where movement of the toner distributing member creates interference between the toner distributing member and the container when the toner distributing member reaches a predetermined position, the interference detectable by the logic circuit.

8. The device of claim 7 wherein the logic circuit generates a full condition signal in response to detecting the interference between the toner distributing member and the container.

9. The device of claim 8 wherein the logic circuit detects the interference between the toner distributing member and the container by sensing that a difference between maximum and minimum values of a motor control parameter generated by the control circuit over one or more reciprocating cycles of the toner distributing member has exceeded a predetermined threshold.

10. The device of claim 7 wherein the extension is coupled to the toner distributing member, the extension configured to contact a portion of the container when the toner distributing member reaches the predetermined position.

11. The device of claim 7 wherein the extension is coupled to the container, the extension configured to contact a portion of the toner distributing member when the toner distributing member reaches the predetermined position.

12. The device of claim 7 wherein the toner distributing member comprises a first end and a second end, the first end pivotally attached to the driving device and the second end having a floating configuration oriented to cause the second end of the toner distributing member to remain towards a surface of the toner.

13. A device to move toner within a container of an image forming apparatus, the device comprising:

a member movably positioned within the container;

a driving device operatively connected to the member to move the member in a reciprocating manner;

the member being shaped to distribute the toner within the container while being maintained towards a surface of the toner when driven in the reciprocating manner; and

an extension where movement of the member creates interference between the member and the container when the member reaches a predetermined position.

14. A method of operation in an image forming apparatus that includes a waste toner system, the method comprising:

using a speed-controlled actuator to reciprocatingly drive a toner distributing member that distributes waste toner collected in a waste toner container;

detecting accumulation of waste toner based on monitoring a motor control signal that varies as needed to maintain a desired motor speed while driving the toner distributing member by comparing monitored values of the motor control signal generated over one or more raking cycles to one or more reference values corresponding to nominal accumulation conditions;

creating an interference between the toner distributing member and the waste toner container when the accumulation of waste toner reaches a predetermined value; and

detecting a near full condition based on sensing a change in the motor control signal related to the interference between the toner distributing member and the waste toner container.

15. The method of claim 14 wherein creating the interference between the toner distributing member and the waste toner container comprises coupling an extension to at least one of the toner distributing member and the waste toner container.

16. The method of claim 14 wherein the interference occurs at least once per reciprocating cycle of the toner distributing member.

17. The method of claim 14 wherein detecting a near full condition further comprises comparing monitored values of the motor control signal generated during forward and reverse movements of the toner distributing member.

18. The method of claim 14 wherein detecting a near full condition further comprises comparing maximum and minimum monitored values of the motor control signal generated during one or more raking cycles.

19. A method of operation in an image forming apparatus that includes a waste toner system, the method comprising:

driving a toner distributing member that distributes waste toner collected in a waste toner container, the driving occurring in a first direction and in a backwards and forwards manner;

lifting the toner distributing member toward a surface of the waste toner collected in the waste toner container, the lifting occurring in a second direction as the volume of waste toner in the waste toner container changes; and

detecting accumulation of waste toner based on monitoring a motor control signal that varies as needed to maintain a desired motor speed while driving the toner distributing member in the first direction by comparing monitored values of the motor control signal generated over one or more raking cycles to one or more reference values corresponding to nominal accumulation conditions.

20. The method of claim 19 further comprising:

coupling an extension to at least one of the toner distributing member and the waste toner container, the extension creating an interference between the toner distributing member and the waste toner container when the accumulation of waste toner reaches a predetermined value; and

detecting a near full condition based on sensing a change in the motor control signal related to the interference between the toner distributing member and the waste toner container.

21. The method of claim 20 wherein the interference occurs at least once per backward and forward cycle of the toner distributing member.

22. The method of claim 20 wherein detecting a near full condition further comprises comparing monitored values of the motor control signal generated during forward and backward movements of the toner distributing member.

23. The method of claim 20 wherein detecting a near full condition further comprises comparing maximum and minimum monitored values of the motor control signal generated during one or more backward and forward cycles.

24. The method of claim 19 wherein the first direction is substantially horizontal and the second direction is substantially vertical.