Patent Application
20110292437
This invention pertains to the field of printing.
Printers generally form images by delivering patternwise applications of a donor material to a receiver or by altering the receiver so that visible contrast patterns appear thereon. Receiver that used in printing is generally supplied either in cut sheet form or in continuous web form such as a fan folded or roll form. As is well known in the art, the web form has the advantage of being able to be cut to a desired length to allow greater flexibility in the printing and/or finishing processes.
Typically in the prior art, the cut length of a web for of receiver is either set to one of a predetermined conventional cut length sizes such as the A0, A1 , A2, A3 or A4 size or 8.5″×11″, 11″×14″ or other well known sizes. A wide variety of cutters are known that can cut roll of receiver to such sizes including, but not limited to those that are described in U.S. Pat. Nos. 5, 216,471 and 5,375,494, both entitled “Image forming Apparatus and Roll Paper Cutting Machine” and issued on Jun. 1, 1993 and Dec. 27, 1994 respectively and in U.S. Pat. No. 5,751,298, entitled “System and Method for Directly Feeding Paper to Printing Devices” issued on May 12, 1998.
Alternatively it has been known in the copying arts to attempt to size a receiver on which a copy will be printed to a size of an original as is described generally in U.S. Pat. No. 4,265,153 entitled “Copy Machine with Automatic Roll Supplied Copy Paper Feeding and Cutting Apparatus and Control Circuitry”, U.S. Pat. No. 5,708,345 entitled “Compact Sheet Cutter for A Document Reproduction Machine” issued on Jan. 13, 1998.
In digital printing, it is of course possible to adjust the orientation of or other characteristics images to be printed so as to provide prints that can be printed more quickly and with less use of receiver. For example, U.S. Pat. 5,151,717, entitled “Imaging Method and Apparatus Using Discrete Receiving Sheets” describes the use an electrophotographic imaging system that can render images on a receiving sheet that is large enough to receive one image of a largest size or an array of smaller sized images. The receiving sheet with smaller images is cut to size after transfer. Similarly, U.S. Pat. No. 4,706,099 describes a laser printer that determines when the size of an image to be printed is no greater than one half of the width of the maximum print size a plurality of images are printed within the maximum print size. Such prints are then separated in a finishing operation that is performed subsequent to printing. However, it will be appreciated that the decision to print in such a manner impacts not only the printing process, but also the finishing processes and can also impact post finishing operations by increasing post printing labor required to sort or organize images. The decision to print in such a manner can also directly impact the size of a receiver to be used in printing.
For these reasons an operator of a printer must consider many factors in determining how to execute the printing of a set of digital images. It can be burdensome for an operator to make this number of decisions for each print job.
Accordingly what is needed in the art is a new approach to operating a printer to allow the printer to make automatic decisions that allow the flexibility of digital printing and configurable finishing systems to be used and to inform the operation of a receiver supply that supplies a variable length of receiver for printing.
Methods for operating a printer are provided. In one aspect, a method has the steps of receiving image data and production data for printing a set of images with each image having a defined size and shape, determining a finishing configuration of a finishing system; and determining a priority setting between an output rate priority and an efficiency priority. The images are organized for printing on the receiver in the defined sizes and shapes based upon the determined priority and the finishing configuration and the images are printed on the receiver as organized. The receiver is finished to provide prints of the images each having the defined size and shape for that image.
Toner 24 is a material or mixture that contains toner particles, and that can form an image, pattern, or coating when electrostatically deposited on an imaging member including a photoreceptor, photoconductor, electrostatically-charged, or magnetic surface. As used herein, “toner particles” are the marking particles used in an electrophotographic print engine 22 to convert an electrostatic latent image into a visible image. Toner particles can also include clear particles that can provide for example a protective layer on an image or that impart a tactile feel to the printed image.
Toner particles can have a range of diameters, e.g. less than 8 μm, on the order of 10-15 μm, up to approximately 30 μm, or larger. When referring to particles of toner 24, the toner size or diameter is defined in terms of the median volume weighted diameter as measured by conventional diameter measuring devices such as a Coulter Multisizer, sold by Coulter, Inc. The volume weighted diameter is the sum of the mass of each toner particle multiplied by the diameter of a spherical particle of equal mass and density, divided by the total particle mass. Toner 24 is also referred to in the art as marking particles or dry ink.
Typically, receiver 26 takes the form of paper, film, fabric, metallicized or metallic sheets or webs. However, receiver 26 can take any number of forms and can comprise, in general, any article or structure that can be moved relative to print engine 22 and processed as described herein.
Returning again to
For example, in a four toner image, four toners having subtractive primary colors, cyan, magenta, yellow, and black, can be combined to form a representative spectrum of colors. Similarly, in a five toner image various combinations of any of five differently colored toners can be combined to form other colors on receiver 26 at various locations on receiver 26. That is, any of the five colors of toner 24 can be combined with toner 24 of one or more of the other colors at a particular location on receiver 26 to form a color different than the colors of the toners 24 applied at that location.
In the embodiment that is illustrated, a primary imaging member (not shown) such as a photoreceptor is initially charged. An electrostatic latent image is formed by image-wise exposing the primary imaging member using known methods such as optical exposure, an LED array, or a laser scanner. The electrostatic latent image is developed into a visible image by bringing the primary imaging member into close proximity to a development station that contains toner 24. The toner image 25 on the primary imaging member is then transferred to receiver 26, generally by pressing receiver 26 against the primary imaging member while subjecting the toner to an electrostatic field that urges the toner to receiver 26. The toner image 25 is then fixed to receiver 26 by fusing to become a print 70.
In
Electrophotographic printer 20 is operated by a controller 82 that controls the operation of print engine 22 including but not limited to each of the respective printing modules 40, 42, 44, 46, and 48, receiver transport system 28, receiver supply 32, transfer subsystem 50, to form a toner image 25 on receiver 26 and to cause fuser 60 to fuse toner images 25 on receiver 26 to form prints 70 as described herein.
Controller 82 operates electrophotographic printer 20 based upon input signals from a user input system 84, sensors 86, a memory 88 and a communication system 90. User input system 84 can comprise any form of transducer or other device capable of receiving an input from a user and converting this input into a form that can be used by controller 82. For example, user input system 84 can comprise a touch screen input, a touch pad input, a 4-way switch, a 6-way switch, an 8-way switch, a stylus system, a trackball system, a joystick system, a voice recognition system, a gesture recognition system or other such systems. Sensors 86 can include contact, proximity, magnetic, or optical sensors and other sensors known in the art that can be used to detect conditions in electrophotographic printer 20 or in the environment-surrounding electrophotographic printer 20 and to convert this information into a form that can be used by controller 82 in governing printing and fusing. Memory 88 can comprise any form of conventionally known memory devices including but not limited to optical, magnetic or other movable media as well as semiconductor or other forms of electronic memory. Memory 88 can be fixed within electrophotographic printer 20 or removable from electrophotographic printer 20 at a port, memory card slot or other known means for temporarily connecting a memory 88 to an electronic device. Memory 88 can also be connected to electrophotographic printer 20 by way of a fixed data path or by way of communication system 90.
Communication system 90 can comprise any form of circuit, system or transducer that can be used to send or receive signals to memory 88 or external devices 92 that are separate from or separable from direct connection with controller 82. Communication system 90 can connect to external devices 92 by way of a wired or wireless connection. In certain embodiments, communication system 90 can comprise a circuitry that can communicate with such separate or separable device using a wired local area network or point to point connection such as an Ethernet connection. In certain embodiments, communication system 90 can alternatively or in combination provide wireless communication circuits for communication with separate or separable devices using a Wi-Fi or any other known wireless communication systems. Such systems can be networked or point to point communication. External devices 92 can comprise any type of electronic system that can generate signals bearing data that may be useful to controller 82 in operating electrophotographic printer 20. For example and without limitation, an external device 92 can comprise what is known in the art as a digital front end (DFE), which is a computing device that can be used to provide a source of image data and, optionally, production data including printing information from which the manner in which the images are to be printed can be determined. Optionally the production data can include finishing information that defines how the images that are provided are to be processed after printing. Similarly, image and production data can be obtained from any other source that can provide such data to printer 20 by any other manner, including but not limited to memory 88.
Further, in certain embodiments image data and/or production data or certain aspects thereof can be generated from a source at printer 20 such as by use of user input system 84 and an output system 94, such as a display, audio signal source or tactile signal generator or any other device that can be used by controller 82 to provide human perceptible signals for feedback, informational or other purposes.
As is shown in
As is shown in this embodiment, receiver supply 32 comprises a frame 120 having a support structure 122 on which a web 124 of receiver 26 is positioned for supply to printer 20. In this embodiment, web 124 is supplied from a roll 126 of receiver 26 that is supported by support structure 122. In other embodiments web 124 is provided in fan fold format and is drawn as needed from as stack (not shown) that is supported by support structure 122.
Web 124 of receiver 26 is drawn through a pair of lead pinch rollers 130 and 132 and trailing pinch rollers 134 and 136. Pinch rollers 130 and 134 are positioned in opposition to pinch rollers 132 and 136 across a receiver supply transport path 138 and biased against each other by biasing members 140 and 142. A first pinch roller motor 144 drives one of lead pinch rollers 130 and 132, here shown as pinch roller 132, to cause lead pinch rollers 130 and 132 to rotate in the directions as shown, and a second pinch roller motor 146 drives one of trailing pinch roller 134 or trailing pinch roller 136, shown here as pinch roller 136, to cause trailing pinch rollers 134 and 136 to rotate in the directions shown to provide receiver 26 to receiver transport system 28.
A supply controller 150 is connected to first pinch roller motor 144 and to second pinch roller motor 146 to drive web 124, receiver 26 from roll 126 past a cutter 154 that is also controlled by supply controller 150. Cutter 154 is adapted to cut web 124 of receiver 26 at cut line 158 to separate web 124 to form a cut sheet 128 of receiver 26. Cutter 154 can comprise any known cutting or slitting technology that can cut web 124 of receiver 26 in response to electronic or other control signals. Similarly, supply controller 150 can take the form of any electronic system that can receive signals from controller 82 and that can use pinch roller motors 144 and 146 and cutter 154 and a sensor system 164 to act to cut web 124 as described herein.
In embodiments where receiver supply 32 is separate from or separable from printer 20, supply controller 150 can include any known communication circuit (not shown) that is adapted to communicate with controller 82 by way of communication system 90. In embodiments where receiver supply 32 is integral to printer 20, the functions described herein as being performed by supply controller 150 are optionally performed by controller 82.
When controller 82 sends an appropriate signal, supply controller 150 sends appropriate signals to cause receiver 26 to be advanced so that a leading edge 152 of receiver 26 is moved from lead pinch rollers 130 and 132 to receiver transport system 28. After cutting, a trailing edge 156 continues to be moved by lead pinch rollers 130 and 132 to receiver transport system 28. As shown a leading edge 160 of the remaining web 124 is supported on a surface 162 of cutter 154 and is advanced by trailing pinch rollers 134 and 136 until gripped by lead pinch rollers 130 and 132 in advance making the next sheet 128 receiver 26. The cutting of sheet 128 of receiver 26 from web 124 of receiver 26 is preferably done before or after printing is complete so that the cutting does not interrupt the printing process. However, in certain embodiments the cutting of sheet 128 can occur during printing as well.
Sensor system 164 has at least one supply sensor 166 arranged to provide signals from which supply controller 150 can determine a extent of receiver 26 supplied past cutter 154. In the embodiment that is illustrated supply sensor 166 comprises a follower wheel that rests on receiver 26 that rotates as web 124 of receiver 26 is moved past a point that is proximate to cut line 158 and that generates a signal that supply controller 150 can use to determine a length of receiver web 124 that has moved past cut line 158. This embodiment of supply sensor 166 and sensor system 164 is not limiting and there are a wide variety of other types and arrangements of sensors known to those of skill in the art that can be used for the purpose of sensing a condition from which supply controller 150 can determine an amount of receiver 26 from a web 124 that has moved past cut line 158.
In operation, supply controller 150 receives instructions from controller 82 indicating a length of receiver 26 that is to be supplied to receiver transport system 28. Alternatively, supply controller 150 cuts web 124 to form a sheet 128 having when instructed to do so by controller 82. Other variations known to those of skill in the art can be used to determine the exact information or control signals that controller 82 proves to supply controller 150 and the exact information or control signals, if any, returned by supply controller 150 to controller 82 in the process of causing a sheet 128 of receiver 26 to be supplied to receiver transport system 28.
Controller 82 then identifies a finishing configuration of finishing system 100 (step 172). In this embodiment, finishing system 100 comprises cutting system 102 and an optional automatic folding system 104. Each of these systems will have an initial finishing configuration for processing a print 70 that is made having the set of images printed on it. For example, a cutting system 102 will be configured to apply a one of a plurality of different cutting patterns to a print 70 as the print 70 is moved to finishing system 100. Often, cutting system 102 will have the configuration used for processing the last print (not shown).
Similarly, an optional automatic folding system 104 can be configured at any of a plurality of different settings when a print 70 will be provided to folding system 104 for folding. For example, folding system 104 might be configured to fold parallel to a path of travel of a print 70 past folding system 104 or folding system 104 might be configured to fold across a path of travel of a print 70 past folding system 104. It will be appreciated that there are a variety of other configurations for both cutting system 102 and folding system 104 and for any other known finishing devices that may be incorporated in finishing system 100.
Controller 82 identifies the finishing configuration of the components in finishing system 100 such as cutting system 102 and folding system 104. This can be done based on stored information regarding the configuration, based on sensor sensors (not shown) in finishing system 100 that can be used to determine the configuration of finishing system or by exchanging data with a controller (not shown) in finishing system 100.
Controller 82 then determines a priority setting for printer 20 (step 174). In this embodiment, the priority setting includes an output rate priority setting and an efficiency priority setting. Typically, the priority setting will be entered at printer 20 using user input system 84 and output system 94. However the priority setting can be generated remotely and sent to printer 20 by way of communication system 90.
In general, it will be appreciated that because printer 20 is capable of rendering images on receiver 26 that have a variety of different orientations and because finishing system 100 is capable of finishing a print 70 generated using receiver 26 in a variety of different ways there is more than one way in which a set of images can be printed and finished in accordance with the production data.
Accordingly, there are many ways in which an operator of printer 20 can organize images and finishing operations to execute the printing of a set of images. Typically, it has been left to the operator of printer 20 to determine which of way to operate printer 20. As noted above, this involves making many decisions regarding the printing which may or may not result in the most effective use of printer 20 at any given time.
The use of the priority setting simplifies this problem by reducing the decision making required of an operator of printer 20 to a single decision that can be used to guide controller 82 such that controller 82 makes automatic selections from among a combination of available possible options that can result in the printing of a set of images.
Accordingly, here an operator of printer 20 is asked to make a priority setting that is here characterized as being either one of an output rate priority setting or an efficiency priority setting. The priority setting can be made by an operation of printer 20 for example, by way of user input system 84 and output system 94 or by using a separate device that is in communication with communication system 90. Once that controller 82 determines that a priority setting is made, controller 82 can take appropriate steps to optimize or otherwise adjust the printing process accordingly. These optimizations or adjustments can be implemented without further decision making on the part of the operator of printer 20. As will be described in greater detail below, these optimizations or adjustments can impact image organization and receiver length determinations.
Specifically, in this embodiment the priority setting is used to organize the set of images for printing on receiver 26 in the defined sizes and shapes. For example, where a production rate priority setting is determined, controller 82 will organize the set of images for printing so that they will be printed in a manner that can be most quickly printed and finished for delivery.
It will be appreciated that both the organization of the set of images shown in
While this may indicate that a production rate priority setting would dictate the use of the print organization shown in
It will be understood that the use of the embodiments shown in
It will further be understood the use of the organizations shown in
Such issues can be addressed by controller 82 when an efficiency priority setting is determined— As is shown in
Accordingly, once that a priority determination is made, controller 82 can automatically select from among the available organizational choices in a manner that is guided by the priority setting to make a variety of decisions automatically that are currently left to an operator's discretion.
Once that a determination is made as to the organization of the images, controller 82 and supply controller 150 can be used to identify a receiver length to allow the set of images 200, 202, 204, 206 and 208 to be printed according to the determined organization and to cause a sheet 128 of receiver 26 to be provided for printing having the identified length (step 178). It will be appreciated that, at a minimum, the length of a sheet 128 of receiver 26 that is used will be a function at least of the organization of the prints as the organization dictates the minimum necessary length of a sheet 128 of receiver 26. In this regard, it will be observed that using the different print organizations show in
In the printer 20 of
In certain embodiments, the length of a sheet 128 of receiver 26 that is provided can extend beyond such a minimum length. The extent to which the length of a sheet 128 of receiver 26 has additional length that extends beyond the minimum length can be determined based upon the determined priority. For example, it may be more efficient to provide additional length of a sheet 128 of receiver 26 to enable faster handling of a print 70 made using sheet 128 or to otherwise facilitate finishing of print 70 or any post finishing processing of a print 70. The extent to which the length of sheet 128 extends beyond such a minimum can additionally be determined based upon the processing data or upon requirements of the process used to print the images, the finishing system or any post-finishing activities.
The determination of the length can be fully variable or the determination can be made such as between one of set of predetermined receiver lengths.
Once that the length is determined, controller 82 can provide appropriate signals that cause supply controller 150 to provide a sheet 128 of receiver 26 having the determined length.
The set of images 200, 202, 204, 206, and 208 is then printed on the supplied sheet 128 of receiver 26 at in accordance with the determined organization (step 180) and a print 70 having the set of images 200, 202, 204, 206, and 208 is subject to a finishing operation to provide prints having the defined size and shape (step 182). These steps are generally performed in any manner known in the printing and finishing arts.
It will be appreciated that as noted above, additional post finishing processing steps may be required depending on the way in which the set of images 200, 202, 204, 206 and 208 are printed and finished. Accordingly in the embodiment of
In this regard, controller 82 can identify when a particular organization of the set of images or the use of a particular finishing configuration will require post-finishing effort to complete the job of producing prints from the images. The extent of such post finishing processing effort can be factored by controller 82 into the process of determining which organization to use for example in making a set of prints based upon images 200, 202, 204, 206 and 208. For example, where an output rate priority is selected, controller 82 will consider the overall amount of time required to deliver the finished prints from images 200, 202, 204, 206 and 208 including an estimated amount of time required to perform any post finishing steps such as sorting or collating that are required by a combination of the organization of the images during printing and finishing configurations. Information regarding such additional post finishing steps can be programmed into printer 20 and for example stored in memory 88 or made available to printer 20 by way of communication system 90 from a remote database.
Similarly, where additional post finishing efforts are associated with additional costs, such costs are factored by controller 82 into determining an organization for a set of images when an efficiency priority setting is in effect. Here too, information regarding the costs of such additional post finishing steps can be programmed into printer 20 and for example stored in memory 88 or made available to printer 20 by way of communication system 90 from a remote database and such information can include costs data associated with such post finishing operations. It will be understood that the embodiment of receiver supply 32 that is described herein for supplying receiver 26 for printing is exemplary only and that other forms of receiver supply 32 known in the art as being capable of providing variable lengths of cut sheets of a receiver 26 from a web 124 of such a receiver 26 in response to electronic signals can be used. Similarly, it will be appreciated that the methods that are described herein are equally applicable to determining which of a supply of different lengths of cut sheet receiver are to be used and that in this regard, the methods described herein can be used to select from among different sizes of cut sheets from a conventional receiver supply 32 that is capable of delivering such different sizes of cut sheet receivers to a receiver transport system.
It will be appreciated that there are circumstances where all of the images in a set of images cannot be printed using a single sheet 128 of receiver 26. This can occur, for example, where such images cannot be printed within a printable length of the receiver or printable area on a receiver.
Accordingly, in some embodiments, organizing steps such as steps 176 or 177 can include determining that the set of images cannot be organized for printing on a sheet 128 of receiver 28. In response to such a determination, the steps of organizing the images in a set of images for printing in the defined size and shapes will include organizing the images for printing in the defined sizes and shapes using a length of a sheet of receiver and using a length of at least one additional receiver. Such organizing will be performed based upon the determined priority setting and the finishing configuration and, optionally, any post-processing effort required to produce prints for each of the images in a set using the receiver and the at least one additional receiver as generally described above.
As shown in
For example, as shown in
However, as is shown in
It will be appreciated that for print engines 22 that are capable of printing from one edge of a sheet to the other, the printable length and the length of the sheet can be the same. However as is noted elsewhere above, the length of receiver 26 in a sheet 128 can be determined based on other factors that may cause a length of a sheet of receiver 26 to be larger than a printable length.
It will be understood that in the methods described herein are not limited to use with electrophotographic printers, such as the electrophotographic printer 20 described herein, and that any form of printing technology can be used. Examples of such other forms of printing technology include ink jet printing technology, thermal printing technology, laser printing technology and metal or other etching printing technology.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
This application relates to commonly assigned, copending U.S. application Ser. No. ______ (Docket No. 96330RRS), filed ______, entitled: “PRINTER WITH VARIABLE LENGTH RECEIVER SUPPLY” hereby incorporated by reference.
