The presently disclosed subject matter relates to media handling systems and related methods of use and manufacture, and more particularly to a media transition unit for altering the orientation of media.
Media outputted from an imaging apparatus, such as a printer, may be subjected to a media processing machine, such as an auto-mailer device, that performs one or more operations on the media. Examples of such operations include, but not limited to, collation, folding, embossment, perforation, staple, binding, mailing, etc. Usually, the media has short edges and long edges, along which it is outputted from the imaging apparatus at high speed and volume.
In one approach, when the output media is fed along the long edge directly to the media processing machine, the machine may get jammed due to high speed and volume of the media. However, when the imaging apparatus is adapted to reduce the speed of output media and match that with the media input speed of the machine, the efficiency of the imaging apparatus and that of the machine is significantly reduced. Moreover, consumables such as toners and ribbons are expended at a higher rate in the imaging apparatus operating at low speeds.
In another approach, the speed of output media is intermediately reduced before feeding it to the media processing machine for altering the orientation of media from a long-edge-first to a short-edge-first. As a result, the efficiency of the media processing machine is significantly reduced due to the reduction in speed of the received media. Moreover, the output media may suffer a skew during re-orientation and block the input path to the media processing machine.
Therefore, there exists a need for a reliable solution that alters the orientation of the media without compromising on the efficiency of the imaging apparatus or the media processing machine.
The present disclosure discloses a media transition unit for altering orientation and/or direction of travel of media that defines a first edge and a second edge that is shorter than the first edge. In an embodiment, the media transition unit includes a first module and a second module. The first module includes a first sensor and a first conveyor belt. The first module is configured to accept the media traveling along a first direction substantially perpendicular to the first edge. The first sensor upon detecting presence of the media at the first module prompts the first conveyor belt to transport the media at a first speed in a second direction, which is substantially perpendicular to the second edge.
The second module includes a second sensor and a second conveyor belt. The second module is configured to accept the media from the first module. The second sensor upon detecting presence of the media adjacent to the second module prompts the second conveyor belt to transport the media at a second speed along the second direction. The second speed exceeds the first speed.
Other and further aspects and features of the disclosure will be evident from reading the following detailed description of the embodiments, which are intended to illustrate, not limit, the present disclosure.
The following detailed description is made with reference to the figures. Exemplary embodiments are described to illustrate the disclosure, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations in the description that follows.
In various embodiments of the present disclosure, definitions of one or more terms that will be used in the document are described below. The disclosure includes a media feeding device or media feeder that is configured to output “media” or “medium” referring to physical sheets of paper, plastic, cardboard, or other suitable physical substrates that can pass through media paths of the media feeding device. The media may include a number of edges, for example, at least two edges substantially longer than at least one of their respective adjacent edges. Further, the “long edge” of the media refers to longer edge of the media that is output from the media feeding device. Similarly, the “short edge” of the media refers to shorter edge of the media relative to the long edge of the media. For example, for a standard sheet of paper having rectangular shape and dimensions of 8.5 inches by 11 inches, the “long edge” of sheet refers to the edge of the sheet that is 11 inches in length while the “short edge” refers to the edge of the sheet that is 8.5 inches long.
Further the disclosure includes a media processing machine configured to perform operations, such as collation, folding, embossment, perforation, staple, binding, mailing, etc. on the media. The media processing machine may include a variety of existing, related art, or later developed devices that are configured to perform one or more of such operations.
The numerous references in the disclosure to the media feeding device and the media processing machine are intended to cover any and/or all devices capable of performing respective operations on the media relevant to the applicable context, regardless of whether or not the same are specifically provided.
The media handling system 100 further includes a media transition unit 106 and a media processing machine 107 in communication with the media transition unit 106. In some embodiments, the media transition unit 106 receives the media 104 along its long edge from the media feeder 102 in a first direction. The media transition unit 106 is configured to deliver the media 104 to the media processing machine 107 along the short edge of the media 104. In other words, the media processing machine 107 receives the media 104 with the leading short edge of the media 104. Thus, in the case of an 8.5 by 11 sheet of paper, the media processing machine 107 receives the sheet in a manner so that an 8.5 inch side or edge is first received.
As shown in
The operating speed of a section of the media transition unit 106 that receives the media 104 may be adjusted to be substantially equivalent to or in accordance with the operating speed of the media feeder 102 at which the media feeder 102 outputs the media 104 in the first direction. Such adjustment to the operating speed allows the media transition unit 106 to continuously receive and transport the media 104 in the second direction without jamming a media path of the media transition unit 106.
The tray 112 further includes conveyor belts 114-1, 114-2 (collectively, conveyor belts 114) for transporting the received media 104 in the second direction perpendicular to the first direction of travel of the media 104 from the media feeder 102. The tray 112 may additionally include one or more sensors 116-1, 116-2 (sensors 116) for detecting the presence of the media 104 in close proximity. The conveyor belts 114 may be made of plastics, rubber, or any other suitable existing, related art, or later developed material. The conveyor belts 114 may be configured to provide a first media path for the received media 104. The conveyor belts 114 include a predetermined transverse separation between them. This separation extends along the entire length of the conveyor belts 114. However, the belts 114 are configured to substantially receive the media 104 from the media feeder 102. The conveyor belts 114-1 and 114-2 may extend along the longitudinal edges X, Y, respectively.
Further, over the conveyor belts 114, foam rollers 118-1 and 118-2 (collectively, foam rollers 118) may be mounted on a shaft 120, which runs transverse to the longitudinal axis of the first module 108. The shaft 120 is also located adjacent to the second transverse edge Q of the tray 112. There may be a predetermined spacing between the foam rollers 118 and the conveyor belts 114 to provide a passage for the received media 104. One of skill in the art will understand that the foam rollers 118 may be made of any existing, related art, or later developed suitable material, which is porous, and/or soft in nature.
The first sensor 116-1 may be located adjacent to the first longitudinal edge X and the second sensor 116-2 may be placed adjacent to the second transverse edge Q of the tray 112. The sensor 116-1 may be configured to operate control circuits (
The first module 108 may be in communication with the second module 110, along the transverse edge Q of the tray 112. The second module 110 may include a top tray 122 and a bottom tray (not shown) having a predetermined spacing between them. Both the top tray 122 and the bottom tray may include respective conveyor belts. For example, as shown, the top tray 122 may include conveyor belts 124-1 and 124-2 (collectively, conveyor belts 124) that are longitudinally parallel to the conveyor belts 114. Similarly, the bottom tray also includes conveyor belts (
The second module 110 includes a second set of pulleys 130-1 and 130-2 (collectively, second set of pulleys 130), which may include respective conjugate pulleys (not shown) coupled to the second pulley set 130 via at least one respective shaft (not shown). The second set of pulleys 130 is located below the bottom tray of the second module 110 for driving the respective conveyor belts, such as, conveyor belts 132. Similarly, the second module 110 includes a third set of pulleys 134-1 and 134-2 (collectively, third set of pulleys 134), which may include respective conjugate pulleys (not shown) coupled to the third set of pulleys 134 via at least one respective shaft (not shown). These third set of pulleys 134 along with their conjugate pulleys are located below the top tray 122 of the second module 110 for driving the respective conveyor belts 124. The pulley 130-2 may be driven by a motor M2 that in turn, may rotate the second set of pulleys 130 in a clockwise (or anti-clockwise) direction to drive the conveyor belts 132 on the bottom tray towards the media processing machine 107. In an embodiment, the driving motor M2 is a stepper motor 129, which is configured to provide more initial speed at its start-up and stop. This enables the second module 110, particularly the conveyor belts 132 to pick the media 104 away from the first module 108 at a faster speed relative to the operating speed of the first module 108 and deliver the picked media 104 towards the media processing machine 107. Also, the stepper motor 129 allows accelerating the media 104 on the second module 110, since the stepper motor 129 exhibits high torque at small angular velocities relative to that in the DC motor 128. Thus, the media transport speed on the second module 110 is greater than the media transport speed on the first module 108. Further, the operating speeds of the motors 128 and 129 may be adjusted independent of each other via respective control circuits (
The media transition unit 106 may optionally include a display unit 138 configured to display the count of media 104 exiting the second module 110 of the media transition unit 106. A variety of existing, related art, or later developed display units may be used for this purpose, for example a hexadecimal display unit known in the art. This display unit 138 along with a display control circuit (not shown), a counter circuit (
During operation, the media feeder 102, such as an imaging apparatus, may be arranged to output the media 104 in a first direction whereby the long edge of the media 104 is the leading edge. In other words, the first direction in which the media is outputted by the media feeder 102 is substantially perpendicular to the long edge of the media 104. In the first direction, as the media 104 passes over the first sensor 116-1 for translation on to the media transition unit 106, the media 104 may be detected by the sensor 116-1 to activate the first module control circuit 140. The first sensor 116-1 enables the first module control circuit 140 to start or stop automatically within a first predetermined time based on the media 104 to be delivered from the media feeder 102 on to the first module 108. Upon activation, the first module control circuit 140 provides pulse-width modulation signals having a first duty cycle for controlling the power supply applied to the DC motor 128. The first module control circuit 140 initiates the DC motor 128 for the first predetermined time. The first module control circuit 140 may additionally adjust the speed of operation of the DC motor 128 based on the operating speed of the media feeder 102 so that the media 104 is received by the first module 108 without jamming the associated media path. Subsequently, the received media 104 along the long edge is registered against the wall 113 and placed over the conveyor belts 114, which are then driven by the DC motor 128. The conveyor belts 114 drive the media 104 at a first speed in a second direction that is substantially perpendicular to the first direction, i.e., the second direction is substantially perpendicular to the short edge of the media 104, towards the second module 110.
While being driven in the second direction, the media 104 is detected by the second sensor 116-2 to activate the second module control circuit 138 as the media 104 is about to enter the second module 110. The second module control circuit 138 generates pulse-width modulation signals having a second duty cycle, which is relatively lesser than the first duty cycle, to trigger the stepper motor 129 for a second predetermined time. The second module control circuit 142 may additionally adjust the speed of operation of the stepper motor 129 in accordance with the operating speed of the first module 108 for smooth operation of the media transition unit 106. Upon activation, the stepper motor 129 drives the conveyor belts 132 on the bottom tray of the second module 110 at a second speed, which is greater than the first speed. This allows the media 104 to quickly move out of the media transition unit 106 without jamming while feeding the media 104 into the processing machine 107 at a predetermined rate. The stepper motor 129 operates simultaneously with the DC motor 128 to pick-up the media 104 from the first module 108 to the second module 110. The picked-up media 104 moves in the spacing between the conveyor belts 132 and 124 on the second module 110. The conveyor belts 132 and 124 press the media 104 to smoothen any media buckling and avoid jamming of the media 104. For this, the conveyor belts 132 and 124 may rotate counter clockwise relative to each other for driving the media 104 towards the media processing machine 107. For example, if the conveyor belts 132 are rotated in a clockwise direction by the motor 129, the conveyor belts 124 correspondingly rotate in an anti-clockwise direction as the media 104 travels between the belts 132, 124.
The media 104 driven towards the media processing machine 107 is detected by the third sensor 116-3, which in turn activates the counter circuit 144. The counter circuit 144 may be configured to count the media 104 exiting from the media transition unit 106. The counter circuit 144 may determine the media count and output the media count on the display unit 140. The media 104 may then be driven towards the media processing unit 107 through the third sensor 116-3. Once the media 104 is transferred to the media processing machine 107, the first module control circuit 140 automatically stops the DC motor 128 using the pulse-width modulation signals having first duty cycle after the first predetermined time. Alongside, the second module control circuit 142 automatically stops the stepper motor 129 using the pulse-width modulation signals having second duty cycle after the second predetermined time. The first predetermined time is greater than the second predetermined time.
Although the media transition unit 106 has been explained with respect to the media feeder 102, it will be well understood by a person skilled in the art that the media transition unit 106 can be incorporated or otherwise used with other imaging apparatuses such as scanners, photocopiers, integrated imaging devices, and facsimile machines.
The above description does not provide specific details of manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the subject matter as encompassed by the following claims.