Information
-
Patent Grant
-
6324360
-
Patent Number
6,324,360
-
Date Filed
Friday, January 28, 200024 years ago
-
Date Issued
Tuesday, November 27, 200122 years ago
-
Inventors
-
Original Assignees
-
Examiners
Agents
- Nixon Peabody LLP
- Studebaker; Donald R.
-
CPC
-
US Classifications
Field of Search
US
- 399 82
- 399 85
- 399 403
- 399 407
- 399 410
- 270 5802
-
International Classifications
-
Abstract
An image forming system including an image forming apparatus, one or more sorters for after-processing image-formed sheets discharged from the image forming apparatus, mode selector for selecting a sheet after-processing mode, detector for detecting the presence of sheets stored in the sheet after-processing apparatus, and controller responsive to detection by the sheet detector of presence in the sheet after-processing apparatus of sheets stored in a certain mode for disabling operation of the image forming apparatus when an operating mode using the sheet after-processing apparatus that is different from the certain mode is selected by the mode sector.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an image forming system, particularly to an image forming system including a stencil printer or other such image forming apparatus and any of various sheet after-processing apparatuses connected to the image forming apparatus.
2. Description of the Related Art
Sheet after-processing apparatuses that are combined with an image forming apparatus such as a stencil printer to constitute an image forming system include, for example, sorters for collating and stapling the printed sheets after printing. Among the operating modes using a sorter are included:
(1) Sort mode in which printed sheets are successively sorted by page into multiple sorter bins to produce printed documents, pamphlets, books or the like.
(2) Group mode in which multiple documents are sorted into groups and stored in bins to carry out multiple sorting by document of (sheets×groups).
(3) Dry mode in which printed sheets are sequentially distributed into multiple bins one by one to reduce the amount of transfer printing to the backs of the overlaid sheets.
Operation is also possible in a non-sort mode in which printed sheets are discharged directly onto a sheet output tray without being collated. As the sheet output tray is attached to the image forming apparatus, the non-sort mode can be used to conduct image forming operation even when the sorter is inoperable. Stapling is an operation ordinarily conducted in sort mode.
One problem with such a sorter is that after a first batch of printed sheets has been sorted in one mode, a second batch may be sorted on top of the first in another mode. For instance, printed sheets may be sorted in group mode on top of printed sheets collated in sort mode. This makes the collated printed sheets useless and also causes them to get mixed in with the printed sheets sorted on top of them and the operator has to go to considerable extra work to separate the printed sheets manually.
When an error arises in the sorter, such as when the sorter door is not properly closed, the sorter remains inoperable even after sort mode is selected. To conduct printing, therefore, it is necessary to change the selected mode to one that does not use the sorter, i.e., to non-sort mode.
SUMMARY OF THE INVENTION
In light of the foregoing circumstances, an object of the present invention is to provide an image forming system that disables operation of the image forming apparatus or issues a warning in response to the selection of an operating mode using the sheet after-processing apparatus that is different from the operating mode used to store sheets already present in the sheet after-processing apparatus, thereby eliminating the inconvenience caused when sheets processed in a later selected operating mode are deposited on top of sheets processed in an earlier selected operating mode.
An image forming system according to a first aspect of the present invention comprises:
an image forming apparatus for forming desired images on sheets and discharging the image-formed sheets,
a sheet after-processing apparatus connected to the image forming apparatus and capable of after-processing the image-formed sheets discharged from the image forming apparatus in any of multiple operating modes,
mode selection means for selecting a sheet after-processing operating mode of the sheet after-processing apparatus,
detection means for detecting presence of sheets stored in the sheet after-processing apparatus, and
control means responsive to detection by the sheet detection means of presence in the sheet after-processing apparatus of sheets stored in a certain mode for disabling operation of the image forming apparatus when an operating mode using the sheet after-processing apparatus that is different from the certain mode is selected by the mode selection means.
An image forming system according to a second aspect of the present invention comprises:
an image forming apparatus for forming desired images on sheets and discharging the image-formed sheets,
a sheet after-processing apparatus connected to the image forming apparatus and capable of after-processing the image-formed sheets discharged from the image forming apparatus in any of multiple operating modes,
mode selection means for selecting a sheet after-processing operating mode of the sheet after-processing apparatus,
detection means for detecting presence of sheets stored in the sheet after-processing apparatus, and
notification means responsive to detection by the sheet detection means of presence in the sheet after-processing apparatus of sheets stored in a certain mode for issuing an error notice when an operating mode using the sheet after-processing apparatus that is different from the certain mode is selected by the mode selection means.
The error notice can be effected by an alarm or an error display.
A third aspect of the invention provides an image forming system according to the first or second aspect, which further comprises an abnormality detection means for detecting abnormality of the sheet after-processing apparatus and wherein automatic selection of an operating mode not using the sheet after-processing apparatus is effected when the abnormality detection means detects abnormality of the sheet after-processing apparatus at a time when an operating mode using the sheet after-processing apparatus has been selected by the mode selection means.
The image forming system according to the first aspect of the present invention prevents sheets processed in a later selected operating mode from being deposited on top of sheets processed in an earlier selected operating mode.
The image forming system according to the second aspect of the present invention prevents sheets processed in a later selected operating mode from being deposited on top of sheets processed in an earlier selected operating mode unnoticed by the operator.
The image forming system according to the third aspect responds to an error arising in the sorter, such as failure of the sorter door to close properly, by automatically setting a mode not using the sheet after-processing apparatus even if a mode using the sheet after-processing apparatus is selected. This saves the operator from the trouble of resetting the operating mode of the sheet after-processing apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a diagram showing the overall configuration of an image forming system that is an embodiment of the present invention,
FIG. 2
is a diagram showing the structure of the printer unit of
FIG. 1
,
FIG. 3
a
is a plan view of the sheet feeder tray of
FIG. 2
,
FIG. 3
b
is a side view of the sheet feeder tray of
FIG. 2
,
FIG. 4
is diagram showing the structure of the sorter of
FIG. 1
,
FIG. 5
is sectional view taken along line V—V in
FIG. 4
,
FIG. 6
is a diagram showing the operation panel section of the printer unit,
FIG. 7
is a block diagram of a control circuit,
FIG. 8
is a flowchart showing the flow of processing between standby and the completion of print/sort operation,
FIG. 9
is a flowchart showing the flow of processing for setting sorter mode,
FIG. 10
is a flowchart showing the flow of processing for sorter tower selection
FIG. 11
is a diagram showing a sorter tower selection screen.
FIG. 12
is a diagram showing a sorter tower use/nonuse selection screen,
FIG. 13
is a flowchart showing the flow of processing for error detection,
FIG. 14
is a flowchart showing the flow of processing for sort operation,
FIG. 15
is a flowchart showing subroutine
1
(SUB
1
) in the flowchart of
FIG. 14
,
FIG. 16
is a flowchart showing subroutine
2
(SUB
2
) in the flowchart of
FIG. 15
,
FIG. 17
is a flowchart showing subroutine
3
(SUB
3
) in the flowchart of
FIG. 15
,
FIG. 18
is a flowchart showing subroutine
4
(SUB
4
) in the flowchart of
FIG. 15
,
FIG. 19
is a flowchart showing subroutine
5
(SUB
5
) in the flowcharts of
FIGS. 16 and 17
,
FIG. 20
is a flowchart showing subroutine
6
(SUB
6
) in the flowcharts of
FIGS. 17 and 18
,
FIG. 21
is a flowchart of showing the flow of processing for stapling operation,
FIG. 22
is a flowchart showing subroutine
7
(SUB
7
) in the flowchart of
FIG. 21
, and
FIG. 23
is a flowchart showing subroutine
8
(SUB
8
) in the flowchart of FIG.
21
.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will now be described in further detail with reference to the accompanying drawings.
FIG. 1
is a diagram showing the configuration of an image forming system that is an embodiment of the present invention. As shown in
FIG. 1
, the image forming system according of this embodiment consists of a printer unit
1
as an image forming apparatus, and, as sheet after-processing apparatuses, a first sorter
2
connected to the printer unit
1
and a second sorter
3
connected to the first sorter
2
.
Printer Unit
FIG. 2
is a diagram showing the structure of the printer unit
1
serving as the image forming apparatus of the image forming system. The printer unit
1
is a stencil printer equipped with a stencil maker. The printer unit
1
is equipped with an original document reading section
411
, an automatic document feeder (hereinafter referred to as ADF or ADF unit)
413
, a stencil making section
415
, a printing section
417
, a sheet feeding section
419
, a sheet discharge section
421
, and a stencil discard section
423
.
The document reading section
411
has a line image sensor
427
supported on guide rails
425
(only one shown) to move in the direction of arrow A in
FIG. 2
, a document glass
429
for placing an original such as a book, a pressure plate
431
provided on the document glass
429
to be openable/closable, a target glass plate
433
to which an original sheet is fed by the ADF
413
, and an original sensor
434
provided on the pressure plate side for detecting the presence of an original document on the document glass
429
. When a book type original is read, an unshown drive device is operated to drive the line image sensor
427
along the guide rails
425
under the document glass
429
to effect scanning at a prescribed speed between a home position designated by the symbol A and a scan end position designated by the symbol B. When an original sheet is read using the ADF
413
, the line image sensor
427
is moved to and made stationary at a position directly under the target glass plate
433
as indicated by the symbol C.
The ADF
413
has an original input tray
435
for holding a stack of original sheets, original pickup rollers
437
for feeding the original sheets on the original input tray
435
toward the top of the target glass plate
433
one by one, an original output tray
439
for receiving original sheets after reading, original feed rollers
441
located upstream of the target glass plate
433
relative to the direction of original sheet conveyance for feeding originals from the original input tray
435
across the top of the target glass plate
433
at a prescribed scanning speed, original feed rollers
443
located downstream of the target glass plate
433
for discharging original sheets from the target glass plate
433
to the original output tray
439
, and an ADF original sensor
436
for optically detecting the presence of original sheets on the original input tray
435
.
The original sheets placed on the original input tray
435
of the ADF
413
are picked up individually by the original pickup rollers
437
and conveyed to the upper surface of the target glass plate
433
by the original feed rollers
441
. As an original sheet passes over the target glass plate
433
, it is subjected to image reading by the line image sensor
427
stationed at position C under the target glass plate
433
. After being read, the original sheet is discharged to the original output tray
439
by the original feed rollers
443
.
The stencil making section
415
has a stock roll section
447
for stocking heat-sensitive stencil paper M in the form of a web, a thermal head
449
composed of multiple dot heating elements arrayed in lines perpendicular to the conveyance direction of the stencil paper M, a platen roller
451
facing the thermal head
449
, stencil paper feed rollers
453
, stencil paper guide rollers
445
,
457
and
459
, and a stencil paper cutter
461
. Image data representing the original image read by the line image sensor
427
are input to the stencil making section
415
and the individual dot heating elements of the thermal head
449
are selectively heated in accordance with the input image data to produce a stencil by thermally perforating the heat-sensitive stencil paper M in a dot matrix pattern. The stencil paper M is cut by a cutter
461
after stencil making.
The printing section
417
has a stencil drum
463
of porous ink-permeable structure which is equipped on its outer surface with a stencil clamp section
462
for clamping the leading end of a stencil to be wound thereabout and is driven to rotate about its own center of rotation counterclockwise as seen in
FIG. 2
, an ink squeezer
469
including a squeegee roller
465
and a doctor rod
467
located inside the stencil drum
463
, and a press roller
471
for pressing cut-sheet printing paper onto the ink squeezer
469
. A stencil supplied from the stencil making section
415
is wound on the outer surface of the stencil drum
463
.
The sheet feeding section
419
has a sheet feeder tray
473
for stacking sheets of printing paper P′, sheet feed rollers
477
for feeding out sheets of printing paper P′ one at a time, and timing rollers
479
for feeding sheets of printing paper P′ between the stencil drum
463
and the press roller
471
.
FIGS.
3
(
a
) and
3
(
b
) show plan and side views of the sheet feeder tray
473
structure. As shown, guide plates
538
are provided in facing relationship one on either side of the sheet feeder tray
473
to retain and guide the cut-sheet printing paper P′ by maintaining contact with the opposite side edges thereof. A rack
540
is attached to each guide plate
538
. The racks
540
are provided inside the sheet feeder tray
473
to project along the surface of the sheet feeder tray
473
perpendicularly to the direction in which the sheets of printing paper P′ are fed. The racks
540
are fixed with their toothed sides
540
a
facing each other across a prescribed interval in the direction of the printing paper P′ feed.
The toothed side
540
a
of each rack
540
engages with a pinion
542
provided at the middle portion of the sheet feeder tray
473
near its feed-out end. A potentiometer
544
linked with the shaft of the pinion
542
under the sheet feeder tray
473
produces an output voltage that varies with the rotational position of the pinion
542
. When the spacing between the guide plates
538
is changed to match the size of the printing paper P′, the racks
540
move simultaneously in opposite directions and rotate the pinion
542
, whereby the output of the potentiometer
544
on the shaft of the pinion
542
changes. The width of the printing paper P′ in the scanning direction is determined from the magnitude of the output.
A paper sensor
546
for detecting presence/absence of printing paper P′ in the sheet feeder tray
473
is provided at the rear center of the sheet feeder tray
473
. The paper sensor
546
detects whether or not the length of the printing paper P′ in the sub-scanning direction is greater than a prescribed value. The potentiometer
544
and the paper sensor
546
are members of a paper size detector that discriminates the size of the printing paper P′ and provides paper size information, such as whether the paper is of standard or nonstandard size. In the present embodiment, the main scanning direction lies perpendicular to the conveyance direction of the printing paper P′ and the sub-scanning direction lies in the conveyance direction of the printing paper P′.
The sheet discharge section
421
has a stripping claw
481
for stripping printed sheets P off the stencil drum
463
, a non-sort output tray
483
for stacking the printed sheets P, and a belt-type discharge conveyor
485
for conveying printed sheets P stripped off the stencil drum
463
by the stripping claw
481
to the non-sort output tray
483
.
The stencil discard section
423
has a stencil detacher claw
487
for peeling stencil papers (stencils) M wound on the outer surface of the stencil drum
463
off the stencil drum
463
, a box support
491
for detachably supporting a discarded stencil box
489
for depositing discarded stencils M, and rollers
492
for delivering the discarded stencils M peeled off the stencil drum
463
by the stencil detacher claw
487
into the discarded stencil box
489
. A discarded stencil sensor
493
of photoelectric type is provided at the entrance to the discarded stencil box
489
to detect delivery of the discarded stencils M into the discarded stencil box
489
. The stencil discard section
423
is further equipped with a box-actuated switch
495
for detecting whether the discarded stencil box
489
is attached to the box support
491
.
When stencil printing is conducted with this stencil printer, the stencil drum
463
is driven by an unshown drive unit to rotate about its own center of rotation counterclockwise as seen in FIG.
2
and the timing rollers
479
operate at the proper timing relative to the rotation of the stencil drum
463
to feed a sheet of the printing paper P′ from the sheet feeder tray
473
to between the stencil drum
463
and the press roller
471
. The press roller
471
presses the printing paper P′ onto the stencil M on the outer surface of the stencil drum
463
to effect press-wise stencil printing.
The printed sheet P is stripped from the stencil drum
463
by the stripping claw
481
, conveyed to the non-sort output tray
483
by the discharge conveyor
485
, and stacked on the non-sort output tray
483
with its image-printed side facing up. When the stencil M has served its purpose, it is detached from the stencil drum
463
by the stencil detacher claw
487
and delivered to the discarded stencil box
489
by the rollers
492
.
Sorters
The sorters
2
and
3
serving as sheet after-processing apparatuses in this embodiment will now be explained.
FIG. 4
shows the structure of the first sorter
2
of this embodiment of the present invention. As shown, the sorter
2
is equipped with a vertical row of bins
21
for holding printed sheets P, an indexer
22
for inserting printed sheets P into the bins
21
, an indexer sensor
23
for detecting whether the printed sheets P are reliably inserted into the bins
21
, and conveyor belts
24
and
25
for conveying printed sheets P discharged from the printer unit
1
to the bins
21
.
The indexer
22
is driven vertically by an unshown DC servo motor. As it moves, it sequentially inserts printed sheets P into the bins
21
in proper order while the indexer sensor
23
checks that each insertion is properly executed. The indexer
22
is equipped with a pair of rollers
26
a
and
26
b
that pinch the printed sheet P from opposite sides. When the upper roller
26
a
moves down into pressure contact with the lower roller
26
b
, the rollers
26
a
,
26
b
pinch the printed sheet P conveyed therebetween and impart it with force to convey it into a bin. Even a printed sheet P or the like that is limp and hard to convey can therefore be reliably conveyed without failure owing to the fact that it is caught between the two rollers. Soiling of the printed surface of the printed sheet P conveyed as pinched between the rollers
26
a
,
26
b
can be minimized by forming the surface of the upper roller
26
a
that contacts the printed surface with sharp, needle-like protrusions. Soiling of the printed surface can also be prevented by separating the upper roller
26
a
from the lower roller
26
b
to release the printed sheet P from the pinched state.
The conveyor belts
24
,
25
are driven by unshown DC motors. Suction fans
28
and
29
are provided near the conveyor belts
24
,
25
to supply negative pressure for sucking the printed sheets P onto the conveyor belts
24
,
25
. The suction produced by the suction fans
28
,
29
enables the printed sheets P discharged from the printer unit
1
to be conveyed to the bins
21
under suction attachment. The conveyor belt
24
and the suction fan
28
constitute a conveyance path
31
for mode switching. The conveyance path
31
can be selectively driven by an unshown drive mechanism to either of the positions indicated by the solid and broken lines in FIG.
4
. When the mode-switching conveyance path
31
is raised (broken line in FIG.
4
), the printed sheets P discharged from the printer unit
1
pass under the conveyance path
31
into the non-sort output tray
483
. When the conveyance path
31
is lowered (solid line), the printed sheets P discharged from the printer unit
1
are sucked onto the conveyor belt
24
and conveyed to the first sorter
2
. The mode-switching conveyance path
31
is initially in the raised position. It is left in this position during operation in the non-sort mode, which does not use the sorting bins of the first sorter
2
. When the selected mode is one that utilizes the sorting bins of the first sorter
2
, i.e., when it is the sort mode, group mode or dry mode, the conveyance path
31
is controlled to swing to the lowered position at the start and to return to the initial state upon completion of the sorting job.
The first sorter
2
is equipped with alignment rods
51
,
52
and
53
driven by unshown pulse motors for aligning the printed sheets P inserted into the bins
21
, and with a stapler
34
driven vertically in
FIG. 4
by an unshown pulse motor for stapling the printed sheets P inserted into each bin
21
, one bin at a time starting from the topmost.
The row of bins
21
is equipped with a sheet sensor
40
capable of detecting whether printed sheets P are present in any of the bins
21
.
The second sorter
3
is also equipped with a vertical row of bins and an indexer and has the same structure as the first sorter
2
. When the first sorter
2
fills up, an unshown solenoid operates a sorter switch plate
41
of the first sorter
2
to switch the paper conveyance path to the second sorter
3
side. This causes the printed sheets P to be conveyed to the second sorter
3
by the action of a conveyor belt
42
and suction fans
43
provided above the row of bins
21
. Upon reaching the second sorter
3
, the printed sheets P are sorted into the bins of the second sorter
3
by the indexer (neither bins nor indexer shown).
Alignment Rods, Stapler
FIG. 5
is sectional view taken along line V—V in
FIG. 4
showing structure of the bins
21
, alignment rods
51
,
52
,
53
and stapler
34
of the sorter
2
in detail.
The alignment rods
51
and
52
move perpendicularly to the conveyance direction of the printed sheets P, as indicated by the arrows B and C, respectively. The alignment rod
51
operates first to center the printed sheets P in the bins and the alignment rod
52
thereafter moves perpendicularly to the conveyance direction of the printed sheets P to sandwich the printed sheets P between itself and the alignment rod
51
, thereby aligning the printed sheets P. The alignment rod
53
moves in parallel with the conveyance direction of the printed sheets P, as indicated by arrow D, and operates to align the printed sheets P by pushing them against an upright gate
21
a
at the end of each bin. The upright gates
21
a
are biased by springs or other energizing means to rotate in the direction opposite from that indicated by the arrow F in FIG.
5
. The range of their rotation is limited by an unshown member so as to stop them at the position where they contact the ends of the printed sheets P on the upstream side relative to the conveyance direction of the printed sheets P. An upright gate tilt lever
38
is fastened on each upright gate
21
a
. When a stapler unit
35
moves downward with a solenoid
37
(explained later) turned ON (with a movable portion thereof projecting toward the lever
38
), the movable portion of the solenoid
37
pushes the lever
38
down to rotate the upright gate
21
a
to its horizontal position. Home position (HP) sensors
51
A,
52
A and
53
A are provided for detecting whether the alignment rods
51
,
52
,
53
are in home position (HP).
The stapler
34
is installed in the stapler unit
35
to be movable in the direction of arrow E together with an in-pusher
36
for pushing the printed sheets P back into the bins as explained later. The solenoid
37
for tilting the upright gates
21
a
at the ends of the bins is mounted on the stapler unit
35
.
When the stapler
34
is used, stapling is begun after all of the printed sheets P have been aligned. Upon completion of the alignment, the indexer
22
retreats to the top of the conveyor section and the stapler unit
35
moves to a location above the uppermost bin by the height of one bin (hereafter called the “0th bin position”). The solenoid
37
is then turned ON to ride on the lever
38
of the 1st bin, whereafter the stapler unit
35
is lowered to the 1st bin to open its upright gate
21
a
. An out-pusher
53
a
mounted on the alignment rod
53
is then lowered to the bin at which stapling is to be started and the alignment rod
53
is moved toward the printed sheets P so that the printed sheets P in the bin concerned are pushed toward the stapler unit
35
by the pusher
53
a
. The pushed-out printed sheets P are then stapled by the stapler
34
. When the stapling is finished, the in-pusher
36
mounted at the side of the stapler
34
pushes the stapled sheets P back into the bin and solenoid
37
turns OFF to allow the upright gate
21
a
to close. The foregoing process is then repeated to effect stapling at every bin where printed sheets P are present. The foregoing explanation also applies to the stapler and alignment rods of the second sorter
3
.
Operation Panel
FIG. 6
is a diagram showing an operation panel
70
provided in the printer unit
1
. The operation panel
70
comprises a ten-digit keypad
73
, a copies LED indicator
74
, a display
77
consisting of a liquid crystal panel or the like, a sorter mode button
60
, a staple button
61
, a sorter tower select button
62
, cursor buttons
64
, an OK button
65
, a start button
71
, a stop button
72
, a stencil/print button
76
, a stencil making mode LED
78
, and a print mode LED
79
.
The keypad
73
is composed of numerical keys
0
to
9
which are pressed to enter settings such as the number of copies to be printed.
The copies LED indicator
74
displays the number of copies to be printed entered using the ten-digit keypad
73
. The number displayed by the LED indicator
74
decreases from the set value by one synchronously with the discharge of each printed sheet P during the printing operation of the printer unit
1
.
The display
77
displays error messages when a malfunction such as a paper jam occurs and also displays the size of the printing paper P′ loaded in the sheet feeder tray
473
. The display
77
further displays selection for use of the first sorter
2
connected to the printer unit
1
, the set condition of the auto-stapler, the operating state of the first and second sorters
2
,
3
, and pertinent error messages when problems arise. Other information displayed by the display
77
includes the operating state of the printer unit
1
, the state of the sorter
2
use mode, the operating state of the stencil printer
1
, the selected sorter mode, and the staple mode. The sorter mode and the staple mode displayed in reverse video are the ones currently in effect.
The sorter mode button
60
is pressed to select one mode from among the non-sort mode for depositing the printed sheets P in the non-sort output tray
483
and the three modes for storing the printed sheets P using the sorters
2
,
3
(i.e., the sort mode, group mode and dry mode). When the sorter mode button
60
is repeatedly pressed after power-on, the selected mode circulates among the non-sort mode, sort mode, group mode, dry mode and non-sort mode in the order mentioned. In the non-sort mode, the printed sheets P discharged from the paper output port of the printer unit
1
are fed directly into the non-sort output tray
483
.
In the sort mode, the printed sheets P discharged from the paper output port of the printer unit
1
are successively sorted by page into the bins to be collated into multipage documents, pamphlets, books or the like.
In group mode, the printed sheets P discharged from the paper output port of the printer unit
1
are sorted into groups and stored in bins to carry out multiple sorting by document of (sheets×groups).
In dry mode, which is for reducing the amount of transfer printing to the backs of the overlaid sheets, the process of sequentially distributing the printed sheets P discharged from the paper output port of the printer unit
1
into the bins one by one is repeated until the total number of copies has been printed.
The staple button
61
is pressed to conduct auto-stapling. In auto-stapling, as explained further later, the stapler
34
is used to staple the printed sheets P after they have been sorted into the bins and aligned. Repeatedly pressing the staple button
61
after power-on circulates the selected mode among near-single mode, center-double mode, far-single mode, and stapling OFF mode.
The sorter tower select button
62
is used to select between use and nonuse of each of multiple sorter units.
The cursor buttons
64
are used to move the cursor in the selected screen displayed on the display
77
.
The OK button
65
is used to accept items selected using the cursor buttons
64
.
The start button
71
is pressed to start the operation of the printer unit
1
and the sorters
2
,
3
.
The stop button
72
is pressed to stop the operation of printer unit
1
and the sorters
2
,
3
.
The stencil/print button
76
is pressed to switch between stencil making operation and printing operation. The LEDs
78
and
79
are provided above the stencil/print button
76
to indicate which of the stencil making and printing modes is in effect.
The liquid crystal screen of the display
77
displays both the operating state of the printer unit
1
and numerals indicating the first sorter
2
and the second sorter
3
connected to the printer unit
1
. These numerals are displayed in reverse video to indicate that the corresponding sorter can be used. The sorter use modes and the set operation of the stapler
34
are also displayed.
Control Circuit
The control circuit of the present embodiment will now be explained.
FIG. 7
is a block diagram showing the configuration of the control circuit of the present embodiment. As shown in
FIG. 7
, the control circuit comprises a printer unit system group
93
responsive to instructions from the operation panel
70
and including a stencil drum drive system, a stencil making system, a clamp system, a stencil discard system and a paper feed system, and further comprises a controller
94
for driving the sorters
2
,
3
, a ROM
91
for storing a program and setting data, and a CPU
90
for controlling the controller
94
based on the program and setting data stored in the ROM
91
. The controller
94
of the sorter
2
is responsive to commands from the CPU
90
for driving a system group
95
of the sorters
2
,
3
that includes a feed-in conveyor system, a bin guide conveyor system, an indexer drive system, a switch system, an alignment system, a staple system, and a sorter switch system. A RAM
92
is provided in association with the CPU
90
for storing the number of copies to be printed, the sorter mode and other settings, whenever they are input through the operation panel
70
.
Control Program
The operation of the present embodiment will now be explained. To simplify the explanation, the present embodiment is defined as having a row of bins
21
consisting of
20
bins and will be explained with regard to the sort mode conducted using the first and second sorters
2
and
3
for the purpose of collation and stapling.
When the system is in the standby mode, the display
77
shown in
FIG. 6
displays the operating state of the printer unit
1
, the selected sorter mode, the staple mode, the size of the paper loaded in the sheet feeder tray
473
, and the numerals representing the connected first sorter
2
and second sorter
3
. The sorter mode and the staple mode displayed in reverse video are the ones currently in effect.
From Standby to Completion of Operation
FIG. 8
is a flowchart showing the flow of processing between standby and the completion of print/sort operation in the auto-staple mode. The operator first sets the operating mode of the sorter in step F
1
by pressing the sorter mode button
60
of the operation panel
70
(
FIG. 6
) and then sets auto-staple mode in step F
2
by pressing the staple button
61
of the operation panel
70
. Next, in step F
3
, it is checked whether the number of copies to be printed has been set by use of the ten-digit keypad
73
. When the result in step F
3
is YES, control passes to step F
4
in which it is checked whether the start button
71
was pressed. When the result in step F
4
is YES, control passes to step F
5
, in which error detection processing is started, and to steps F
6
and F
7
, in which print operation and sort operation are commenced. The print operation (F
6
) is conducted by effecting the print processing of the printer unit
1
synchronously with the after-processing of the sorters
2
and
3
.
When print/sort operation is initiated, the CPU
90
issues a command causing the print operation of the printer unit
1
in step F
6
and the sort operation of the first sorter
2
and the second sorter
3
in step F
7
to be effected simultaneously. When print/sort of multiple originals is conducted, the print operation and the sort operation are repeated as many times as there are originals. When these operations are completed, stapling operation is effected in step F
8
. Then, in step F
9
, the number of the sorter mode in effect when the printed sheets were discharged from the printer unit
1
is stored in a register PM. PM=0 designates no paper or non-sort mode, PM=1 designates sort mode, PM=2 designates group mode, and PM=3 designates dry mode. The default value of register PM set at power-on is zero. PM is also set to “0” if no paper is present in the sorters when sort mode is in effect, when printing is effected in non-sort mode, and when printing in sort mode, group mode or dry mode is completed and the printed sheets are removed before the subsequent sorter mode is set. Next, in step F
10
, “0” is written in a register EK. The value written in register EK is used in the error detection processing subroutine of step F
5
. Writing EK=0 terminates the error detection processing.
Setting Sorter Mode
FIG. 9
is a flowchart showing the flow of processing for setting the sorter mode when the system is idle (in standby mode).
The sorter mode in which the sorters are set is stored in a register MD. MD=0 designates non-sort mode, MD=1 designates sort mode, MD=2 designates group mode, and MD=3 designates dry mode. The default value of register MD set at power-on is zero.
First, in step F
11
, it is checked whether the sorter mode button
60
was pressed. When the result is YES, it is checked in step F
12
whether an error other than “Paper in bins” error has occurred on the sorter side. When an error other than “Paper in bins” error has occurred on the sorter side, register MD is rewritten to MD=0 (non-sort mode) in step F
14
. Thus when a sorter has experienced an error other than “Paper in bins” error, the non-sort mode is automatically selected notwithstanding that an operating mode that uses the sorters was selected. This eliminates the need to reset the sorter mode.
When the result in step F
12
is YES, i.e., when no error other than “Paper in bins” error has occurred on the sorter side, control passes to step F
13
, in which it is checked whether the value of register PM is “0” and thereby discriminate whether or not printed sheets P remain in the sorters. When the result is YES, meaning that no printed sheets P remain in the sorters, control passes to step F
15
, in which it is checked whether the value of register MD before the sorter mode button
60
was pressed was 3 (dry mode). When the result is NO, the value of register MD is incremented by 1 in F
16
to advance the mode by one. When the result in F
15
is YES, meaning that the value of register MD before the sorter mode button
60
was pressed was 3, register MD is rewritten to “0” in step F
14
to return to the non-sort mode.
On the other hand, when the result in step F
13
is NO, meaning that printed sheets remain in the sorters, control passes to step F
17
, in which it is checked whether the sorter mode before the sorter mode button
60
was pressed (register MD value) and the mode when the printed sheets were discharged from the printer unit
1
(value of register PM) are the same. When the register MD value and the register PM value are equal, control passes to step F
18
, in which it is checked whether MD=3 (dry mode). When the result is YES, control passes to step F
19
, in which a switch from dry mode to non-sort mode (MD=0) is effected. When the result in step F
18
is NO, the value of register MD is incremented by 1 in step F
20
, “Paper in bins” error is displayed in step F
21
, and operation of the printer unit
1
is disabled in step F
22
.
Step F
22
can be omitted or can be defined to display or sound an alarm rather than disable the printer unit
1
.
When the register MD value and the register PM value are found to be different in step F
17
, control passes to step F
23
, in which it is checked whether the sorter mode before the sorter mode button
60
was pressed (register MD value) is equal to the mode when the printed sheets were discharged from the printer unit
1
plus 1. A YES result in step F
23
means a “Paper in bins” error has occurred. When the sorter mode button
60
is pressed under such circumstances, therefore, MD is set to “0” in step F
24
to make the sorter mode non-sort mode, irrespective of the value of register MD, the “Paper in bins” error is cleared in step F
25
, and the printer unit
1
is re-enabled in step F
26
. A NO result in step F
23
means that the non-sort mode is set with paper present in the bins. In this case, control passes to step F
27
, in which the sorter mode is changed to the mode at the time the printed sheets P were sorted into the bins.
The control set out in the foregoing prevents printed sheets sorted in a later selected mode from getting mixed in with paper sheets already present in the bins that were sorted in another mode. At the time point when a “Paper in bins” error arises, moreover, the non-sort mode is set, skipping the other modes, because the occurrence of this error means that modes other than the non-sort mode and the mode in which the sheets in the bins were sorted cannot be used. This enables the sorter mode to be promptly switched without displaying the unusable modes.
Sorter Tower Selection
FIG. 10
is a flowchart of a subroutine for sorter tower selection.
When it is found in step F
31
that the sorter tower select button
62
was pressed, a sorter tower select screen such as shown in
FIG. 11
is displayed in step F
32
. At this point the operator selects one or more sorter tower numbers to be set by using the cursor buttons
64
and pressing the OK button
65
. Control then passes to step F
33
, in which a screen such as shown in
FIG. 12
is displayed for enabling the operator to set whether or not the selected sorter tower or towers are to be used. The operator then uses the cursor buttons
64
to select Yes or No and then presses the OK button
65
. Next, in step F
34
, it is checked whether at least one sorter tower has been selected. When the result in step F
34
is NO, control returns to step F
32
to restart sorter tower selection, and when it is YES, the subroutine is terminated.
Error Detection
FIG. 13
is a flowchart of an interrupt subroutine for error detection processing that is activated in step F
5
and terminated in step F
10
of FIG.
8
. The error detection processing begins at the time of an affirmative finding in step F
4
in
FIG. 8
, i.e., at the time the start button
71
is pressed, and initially sets the error detection register EK to “1” in step F
41
. The types of errors are written in an error register ERR. ERR=1 designates a door open error, ERR=2 designates a jam error, and ERR=3 designates a stapling error. In the following step F
42
, it is checked whether the value in error register ERR is “1.” When it is, control passes to step F
43
, in which a door open error is displayed, to step F
44
, in which sorter operation is stopped, and to step F
45
, in which it is checked whether EK=0. When the result in step F
45
is NO, control returns to step F
42
. Steps F
42
to F
45
are repeated until EK=0 is determined, at which time the error detection processing is terminated.
When the result in step F
42
is NO, control passes to step F
46
, in which it is checked whether error register ERR value is 2. When the result is YES, a jam error is displayed in step F
47
and control passes to step F
44
. When the result in step F
46
is also NO, control passes to step F
48
, in which it is checked whether the error register ERR value is 3. When the result is YES, a stapling error is displayed in step F
49
and control is passed to step F
44
. When the result in step F
48
is also NO, a normal screen is displayed in step F
50
and control is passed to step F
45
.
Flow of Sort Operation
FIG. 14
is a flowchart of a subroutine showing the flow of sort operation processing in step F
7
of FIG.
8
. Upon the commencement of sort operation, first, in step F
51
, a DC motor is operated to lower the conveyance path
31
for mode switching (FIG.
4
), thereby switching the conveyance path so as to convey the printed sheets P to the first sorter
2
and the second sorter
3
. Next, in step F
52
, conveyance of the printed sheets P to the sorters
2
,
3
is enabled by turning on the DC motors for operating the conveyor belts
24
,
25
and
42
and turning on the suction fans
28
,
29
and
43
. With the system in this state, control passes to step F
53
, in which subroutine
1
(SUB
1
) shown
FIG. 15
is executed to insert the printed sheets P into the bins. Then, when insertion of all printed sheets P has been completed, control passes to step F
54
, in which the conveyor belts
24
,
25
and
42
and the suction fans
28
,
29
,
43
are turned off, and to step F
55
, in which the conveyance path
31
for mode switching is raised. This completes the sort operation.
FIG. 15
is a flowchart of subroutine
1
(SUB
1
) executed in step F
53
of FIG.
14
. First, in step F
61
, it is checked whether the first sorter
2
is set to be usable. When it is, it is checked in step F
62
whether the second sorter
3
is set to be usable. When the first sorter
2
is usable and the second sorter
3
is unusable, subroutine
2
(SUB
2
) shown in
FIG. 16
is executed in step F
63
. When both the first sorter
2
and the second sorter
3
are usable, subroutine
3
(SUB
3
) shown in
FIG. 17
is executed in step F
64
. When the first sorter
2
is found to be unusable in step F
61
and the second sorter
3
is found to be usable in step F
65
, subroutine
4
(SUB
4
) is executed in step F
66
.
FIG. 16
is a flowchart of subroutine
2
(SUB
2
) executed in step F
63
of FIG.
15
. First, in step F
67
, the set number of copies to be printed is compared with the number of bins (20) of the first sorter
2
. When the set number is equal to or less than the number of bins, the set value is written to a register M in step F
68
. When it is greater, the number of bins (20) is written to register M in step F
69
. Following step F
68
or F
69
, subroutine
5
(SUB
5
) shown in
FIG. 19
is activated in step F
70
and subroutine
2
is terminated. The value written to register M is used in subroutine
5
.
FIG. 17
is a flowchart of subroutine
3
(SUB
3
) executed in step F
64
of FIG.
15
. First, in step F
71
, the set number of copies to be printed is compared with the number of bins (20) of the first sorter
2
. When the set number is equal to or less than the number of bins, the set value is written to register M in step F
72
and subroutine
5
(SUB
5
) shown in
FIG. 19
is activated in step F
73
, whereafter subroutine
3
is terminated. When the set number is found to be equal to or less than the number of bins in step F
71
and found to be equal to or less than the total number of bins of the first sorter
2
and the second sorter
3
in step F
74
, the number of bins (20) is written to register M in step F
75
, the difference obtained by subtracting the number of bins of the first sorter
2
from the set number is written to in step F
76
, subroutine
5
(SUB
5
) shown in
FIG. 19
is activated in step F
77
, and subroutine
6
(SUB
6
) shown in
FIG. 20
is activated in step F
78
, whereafter subroutine
3
is terminated.
When it is found in step F
74
that the set number is greater than the total number of bins of the first sorter
2
and the second sorter
3
, the number of bins of the first sorter
2
is written to register M in step F
79
, the number of bins of the second sorter
3
is written to register N in step F
80
, subroutine
5
(SUB
5
) is activated in step F
81
, and subroutine
6
(SUB
6
) is activated in step F
82
, whereafter subroutine
3
is terminated. The value written to register N is used in subroutine
6
.
FIG. 18
is a flowchart of subroutine
4
(SUB
4
) executed in step F
66
of FIG.
15
. First, in step F
83
, the set number of copies to be printed is compared with the number of bins (20) of the second sorter
3
. When the set number is equal to or less than the number of bins, the set value is written to register N in step F
84
. When it is greater, the number of bins (20) is written to register N in step F
85
. Following step F
84
or F
85
, subroutine
6
(SUB
6
) shown in
FIG. 20
is activated in step F
86
and subroutine
4
is terminated.
FIG. 19
is a flowchart of subroutine
5
(SUB
5
) for controlling the first sorter
2
. First, in step F
91
, a solenoid (not shown) is actuated to turn the sorter switch plate
41
ON so as to convey printed sheets P into the first sorter
2
. When the sorter switch plate
41
is ON, it is in the position indicated by the solid line in FIG.
4
. When it is OFF, it is in the position indicated by the broken line in FIG.
4
. When the sorter switch plate
41
is OFF, sheets conveyed on the conveyor belt
25
are sent from the bend region onto the conveyor belt
42
. Next, in step F
92
, the value of a register B is set to “1.” Then, in step F
93
, a DC servo motor is operated to move the indexer
22
to the Bth bin. Since B=1 at this time, the indexer
22
goes to the
1
st bin. Next, in step F
94
, the indexer sensor
23
is used to check whether a printed sheet P is present. When a printed sheet P is found, the value of register B is compared with the value of register M in step F
95
. When the value of register B is less than the value of register M, control passes to step F
96
, in which the value of register B is incremented by 1 and control is returned to step F
93
. When the value of register B becomes equal to the value of register M, control passes to step F
97
, in which alignment is effected. Next, in step F
98
, the indexer
22
is moved to the 1st bin. The sorter switch plate
41
is then turned off by the solenoid in step F
99
and subroutine
5
is terminated.
FIG. 20
is a flowchart of subroutine
6
(SUB
6
) for controlling the second sorter
3
. First, in step F
101
, the value of a register C is set to “1.” Then, in step F
102
, a DC servo motor is operated to move the indexer of the second sorter
3
to the Cth bin. Since C=1 at this time, the indexer goes to the 1st bin. Next, in step F
103
, the indexer sensor of the second sorter
3
is used to check whether a printed sheet P is present. When a printed sheet P is found, the value of register C is compared with the value of register N in step F
95
. When the value of register C is less than the value of register N, control passes to step F
105
, in which the value of register C is incremented by 1 and control is returned to step F
103
. When the value of register C becomes equal to the value of register N, control passes to step F
106
, in which alignment is effected. Next, in step F
107
, the indexer is moved to the 1st bin and subroutine
6
is terminated.
Stapling Operation
FIG. 21
is a flowchart showing the flow of stapling operation processing executed in step F
8
of FIG.
8
. First, when it is found in step F
111
that the sort operation has been completed, control passes to steps F
112
and F
114
, in which stapling operation is simultaneously effected by the staplers of all usable sorter towers. The stapling operation is effected by subroutine
7
(SUB
7
) in step F
113
and subroutine
8
(SUB
8
) in step F
115
.
FIG. 22
is a flowchart showing subroutine
7
(SUB
7
) for conducting stapling in the first sorter
2
. First, in step F
121
, the value of a register S
1
is set to “1.” The value of register S
1
designates the number of bins at which stapling was effected. Next, the stapler
34
is moved to the 0th bin position in step F
122
, the upright-gate-tilting solenoid
37
(
FIG. 5
) is turned ON in step F
123
, and the stapler
34
is moved to the 1st bin with the solenoid
37
kept ON in step F
124
. This operation pushes down the lever
38
and opens the upright gate
21
a
of the 1st bin. It also moves the out-pusher
53
a
of the alignment rod
53
to the 1st bin. Then, in step F
125
, the out-pusher
53
a
is operated to push the printed sheets P in the 1st bin toward the conveyor system side. Then, in step F
126
, the stapler
34
moves laterally to the stapling position and conducts stapling. The stapled printed sheets P projecting toward the conveyor system side are then pushed back into the bin by the in-pusher
36
in step F
127
. Next, in step F
128
, the value of register S
1
and the value of register M are compared. When S
1
<M, control passes to step F
129
, in which the value of register S
1
is incremented by 1 to effect stapling at the next bin and control is returned to step F
123
. When S
1
=M, meaning that the printed sheets P in all bins have been stapled, control passes to step F
130
, in which the stapler
34
and the out-pusher
53
a
are restored to their standby positions, and the stapling operation is terminated.
FIG. 23
is a flowchart showing subroutine
8
(SUB
8
) for conducting stapling in the second sorter
3
. Subroutine
8
is the same as subroutine
7
except that register registers S
1
and M are changed to registers S
2
and N. It will therefore not be explained in detail.
Claims
- 1. An image forming system comprising:an image forming apparatus for forming desired images on sheets and discharging the image-formed sheets, a sheet after-processing apparatus connected to the image forming apparatus and capable of after-processing the image-formed sheets discharged from the image forming apparatus in any of multiple operating modes, mode selection means for selecting a sheet after-processing operating mode of the sheet after-processing apparatus, detection means for detecting presence of sheets stored in the sheet after-processing apparatus, and control means responsive to detection by the sheet detection means of presence in the sheet after-processing apparatus of sheets stored in a certain mode for disabling operation of the image forming apparatus when an operating mode using the sheet after-processing apparatus that is different from the certain mode is selected by the mode selection means.
- 2. An image forming system comprising:an image forming apparatus for forming desired images on sheets and discharging the image-formed sheets, a sheet after-processing apparatus connected to the image forming apparatus and capable of after-processing the image-formed sheets discharged from the image forming apparatus in any of multiple operating modes, mode selection means for selecting a sheet after-processing operating mode of the sheet after-processing apparatus, detection means for detecting presence of sheets stored in the sheet after-processing apparatus, and notification means responsive to detection by the sheet detection means of presence in the sheet after-processing apparatus of sheets stored in a certain mode for issuing an error notice when an operating mode using the sheet after-processing apparatus that is different from the certain mode is selected by the mode selection means.
- 3. An image forming system according to claim 1 or 2, further comprising an abnormality detection means for detecting abnormality of the sheet after-processing apparatus and wherein automatic selection of an operating mode not using the sheet after-processing apparatus is effected when the abnormality detection means detects abnormality of the sheet after-processing apparatus at a time when an operating mode using the sheet after-processing apparatus has been selected by the mode selection means.
Priority Claims (1)
Number |
Date |
Country |
Kind |
11-021703 |
Jan 1999 |
JP |
|
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Number |
Name |
Date |
Kind |
5060922 |
Shibusawa et al. |
Oct 1991 |
|
5568247 |
Murata et al. |
Oct 1996 |
|
5758251 |
Takahashi et al. |
May 1998 |
|
5835839 |
Kaneda |
Nov 1998 |
|