This application claims the benefit of U.S. provisional patent application Ser. No. 60/987,020, filed on Nov. 9, 2007, entitled “PRINT HEAD SERVICE SHUTTLE”. The present application is related to co-pending U.S. patent application Ser. No. 12/251,985 filed on the same day herewith by Paul Ray and entitled “MOVABLE FLUID RECEIVER”, the full disclosure of which is hereby incorporated by reference. The present application is related to co-pending U.S. patent application Ser. No. 12/251,968 filed on the same day herewith by Paul Ray, Neil Doherty, Mun Yew Lee and Thomas J. Tarnacki and entitled “WEB FLOW PATH”, the full disclosure of which is hereby incorporated by reference. The present application is related to co-pending U.S. patent application Ser. No. 11/402,425 filed on Apr. 12, 2006 by Kevin T. Kersey and Timothy J. Carlin and entitled “WEB”, the full disclosure of which is hereby incorporated by reference.
Servicing of print heads in a printer is sometimes performed to maintain performance of the print heads. Existing methods and devices for servicing the print heads may increase the footprint of the printer and may result in misalignment of the print heads with the media being printed upon.
Printing system 20 includes a print unit or print module 22, media supply 23 and media collector or media rewind 24. Print module 22 selectively deposits printing material upon web 30 to form an image, pattern, layout or arrangement of printing material upon web 30. In one embodiment, web 30 may comprise a web of printing material such as a cellulose-based media. In another embodiment, web 30 may comprise a web of polymeric material. In yet another embodiment, web 30 may comprise one or more other materials. In one embodiment, the printing material comprises a fluid such as one or more inks. In yet other embodiments, the printing material may comprise other types of fluid.
Print module 22 receives the web 30 of media from web supply 23, prints upon web 30 and discharges the printed upon web 30 to media rewind 24 which rewinds the web 30 of media. Although web 30 is illustrated as continuously extending from supply 23, across print module 22, to rewind 24, in other embodiments, media rewind 24 may be omitted where the printed upon web 30 of media is severed or processed in other fashions.
Print module 22 includes printer 34, actuator 35, media support 37 and print head servicing system 40. Printer 34 comprises a device or mechanism configured to selectively deposit printing material. Printer 34 includes main support 42, print head supports 43 and one or more pens or cartridges 44. Main support 42 comprises a frame or structure configured to support and unite individual print head supports 43 and their cartridges 44 opposite to web 30. In the particular example illustrated, main support 42 is configured to support print head supports 43 and cartridges 44 along an arc opposite to web 30. In one embodiment, support 42 is movable towards and away from web 30. In yet another embodiment, support 42 is stationary opposite to web 30.
Print head supports 43 comprise structures axially extending across the arc provided by main support 42, parallel to the centerline of the semi-cylindrical arc. Print head supports 43, sometimes referred to as print bars, extend across a width of media support 37 and support the one or more print cartridges 44. Supports 43 facilitate removal of cartridges 44 from main support 42 for repair or replacement of individual print cartridges 44 without removal of all of the print cartridges 44 from main support 42. In other embodiments where print cartridges 44 are directly supported by support 42, supports 43 may be omitted.
Cartridges 44 (also known as pens) comprise mechanisms configured to eject fluid onto web 30. In the particular example illustrated, cartridges 44 each include one or more print heads 46 (schematically shown on cartridges 44). In one embodiment, print heads 46 each comprise thermal resistive drop-on-demand inkjet print heads. In yet other embodiments, print heads 46 may comprise piezo resistive inkjet print heads. In still other embodiments, print heads 46 may comprise other mechanisms configured to eject fluid in a controlled manner.
According to one embodiment, cartridges 44 each include a self-contained reservoir of fluid which is applied to the associated print heads 46. In yet another embodiment, cartridges 44 each include a reservoir which is further supplied with fluid or ink via an offer-axis ink supply system using one or more pumps or other mechanisms to supply a fluid to each of cartridges 44. In one embodiment, cartridges 44 of printer 34 are configured to apply multiple colors of ink. In the embodiment illustrated, cartridges 44 configured to deposit black (K), cyan (C), magenta (M) and yellow (Y) colored inks. In the example illustrated, printer 34 is additionally configured to apply a fixer (F) to web 30 prior to application of the colored inks. In other embodiments, printer 34 may include a fewer or greater of such cartridges configured to apply a fewer or greater of such different types of fluid.
Actuator 35 comprise a mechanism configured to selectively raise and lower support 42 to raise and lower cartridges 44 relative to web flow path 36 and web 30. As a result, support 42 may be moved to facilitate enhanced access to cartridges 44 for inspection, repair or replacement. In some embodiment, movement of support 42 and cartridges 44 may further facilitate servicing of print heads 46.
In one embodiment, actuator 35 comprises one or more hydraulic or pneumatic cylinder assemblies. In another embodiment, actuator 35 comprises one or more electric solenoids. In yet another embodiment, actuator 35 may comprise one or more cams driven by one or more motors. In other embodiments, ball screw mechanisms are used. In such embodiments, movement of support 42 by actuator 35 may be guided by one or more guide rods, tracks or other guide structures 48. In still other embodiments, the one or more guides 48 may be omitted.
Media support 37 comprises one or more structures configured to support and guide movement of web 30 across an opposite to print heads 46 of cartridges 44. In the particular embodiment illustrated, media support 37 supports web 30 in an arc opposite to print heads 46. As a result, print module 22 may be more compact and enhanced control over print head to media spacing is achieved. According the one embodiment, media support 37 comprises a series of arcuately arranged rollers. In another embodiment, media support 37 may comprise an arcuate plate or platen. In other embodiments, media support 37 may have other configurations.
Print head servicing system 40 comprises an arrangement of devices or components configured to facilitate and perform one or more servicing operations upon print heads 46. Examples of servicing operations include, but are not limited to, wiping, spitting and capping. As will be described hereafter, print head servicing system 40 facilitates such servicing operations with reduced or no movement or print heads 46. As a result, the risk of print heads 46 becoming misaligned with web 30 is reduced. Printed services system 40 further provides that servicing operations while not largely increasing a footprint of module 22.
Print head servicing system 40 includes guides 50 and print head service shuttles 52. Guides 50 comprise one or more structures configured to died, support and direct movement of service shuttles 52 across media support 37 to positions opposite to print heads 46 for servicing of print heads 46. Guides 50 are each dedicated to an associated with particular print head supports 43 and their associated cartridges 44. In the example illustrated, guides 50 are coupled to and provided as part of print head supports 43. As a result, print head supports 43 and the associated guides 50 may be assembled an inventory as individual units. In addition, such individual units may be more easily separated and removed from main support 42 for repair or replacement. According to one example embodiment, guides 50 comprise C-shaped tracks or channels in and along which rollers or other low friction bearing structures associated with service shuttles 52 rotate, slide or otherwise translate. In other embodiments, guides 50 may comprise other structures for guiding movement of service shuttles 52 across media support 37 to positions opposite to print heads 46. Although guides 50 are illustrated as being provided on opposite sides of each of print head supports 43, in other embodiments, guides 50 may alternatively extend along a single side of each of print head supports 43 or at a single intermediate location between opposite sides of print head support 43.
Service shuttles 52 comprise devices configured to move along guides 50 between a servicing positioned and a withdrawn position for printing. Servicing shuttles 52 are configured to perform one or more servicing operations, such as wiping, spitting and capping, upon print heads 46. As schematically shown in
In one embodiment, each actuator 54 may be supported and carried by its associated service shuttle 52. In another embodiment, portions of the actuator 54 may be stationary and operably coupled to service shuttles 52. According to one embodiment, actuator 54 comprises a rack gear extending along each of guides 50 and a pinion gear carried by service shuttle 52 in engagement with the rack gear, wherein rotation of the pinion gear, such as by a motor carried by service shuttle 52, moves the individual service shuttle 52 along the rack gear and along the associated guide 50. In another embodiment, actuator 54 may have other configurations.
Input 26 comprises one or more mechanism by which instructions are commands may be provided to controller 28. Example of input 26, include, but are not limited to, a keyboard, a keypad, a touchpad, a touch screen, a microphone with speech recognition software, one or more buttons, switches and the like. Although input 26 is illustrated as being associated with print model 22, input 26 may alternatively be associated with dryer module 24 or may be an external source of commands which transmits control signals via the internet, a network or other wired or wireless communication medium.
Controller 28 comprises one or more processing units and associated memories configured to generate control signals directing the operation of print module 22. In particular, in response to or based upon commands received via input 26 or instructions contained in the memory of controller 28, controller 28 generates control signals directing operation of actuator 35 to selectively raise and lower support 42 and cartridges 44, control signals directing the application or deposition of printing material by cartridges 44 and print heads 46, control signals directing supply 23 and/or rewind 24 to control the tension of web 30 end the rate at which web 30 is moved across media support 37, and control signals directing actuators 54 to move service shuttles 52 along guides 50 between the servicing position and the withdrawn position.
For purposes of this application, the term “processing unit” shall mean a presently developed or future developed processing unit that executes sequences of instructions contained in a memory. Execution of the sequences of instructions causes the processing unit to perform steps such as generating control signals. The instructions may be loaded in a random access memory (RAM) for execution by the processing unit from a read only memory (ROM), a mass storage device, or some other persistent storage. In other embodiments, hard wired circuitry may be used in place of or in combination with software instructions to implement the functions described. For example, controller 28 may be embodied as part of one or more application-specific integrated circuits (ASICs). Unless otherwise specifically noted, the controller is not limited to any specific combination of hardware circuitry and software, nor to any particular source for the instructions executed by the processing unit.
At the same time, service shuttles 52 is moved by actuator 54 to a withdrawn position as shown in which service shuttles 52 is withdrawn from or not opposite to either web 30 or print heads 46. In one embodiment, each service shuttle 52 has a height H greater than the distance of gap G, enabling printing without interference from service shuttles 52.
As shown in
Once print head support 34 has been moved to the raised position shown in
Upon completion of the servicing operations, controller 28 generates control signals directing actuator 54 to retract service shuttle 52 to the withdrawn position shown in
Because printing system 20 raises and lowers one or more of print head supports 43 between the lowered printing position shown in
As shown by
Print module 122 includes a printer 134, actuator 135, web flow path 136, including media support 137, web drive 138 and print head servicing system 140. Printer 134 comprises a device or mechanism configured to selectively deposit printing material. Printer 134 includes main support 142, print head supports 143 and one or more pens or cartridges 144. Support 142 comprises a structure configured to support cartridges 144 opposite to web 130. In the particular example illustrated, support 142 is configured to support cartridges 144 along an arc opposite to web 130. In the embodiment illustrated, support 142 is movable towards and away from web 130. In yet another embodiment, support 142 is stationary opposite to web 30.
Print head supports 143 comprise structures axially extending across the arc provided by main support 142, parallel to the centerline of the semi-cylindrical arc. Print head supports 143, sometimes referred to as print bars, extend across a width of media support 137 and support the one or more print cartridges 144. Supports 143 facilitate removal of cartridges 144 from main support 142 for repair or replacement of individual print cartridges 144 without removal of all of the print cartridges 144 from main support 142. In other embodiments where print cartridges 144 are directly supported by support 42, supports 143 may be omitted.
Cartridges 144 comprise mechanisms configured to eject fluid onto web 130. In the particular example illustrated, cartridges 144 each include one or more print heads 146 (schematically shown on one of cartridges 144). In one embodiment, print heads 146 each comprise thermal resistive drop-on-demand inkjet print heads. In yet other embodiments, print heads 146 may comprise piezo resistive inkjet print heads. In still other embodiments, print heads 146 may comprise other mechanisms configured to eject fluid in a controlled manner.
According to one embodiment, cartridges 144 each include a self-contained reservoir of fluid which is applied to the associated print heads 146. In yet another embodiment, cartridges 144 each include a reservoir which is further supplied with fluid or ink via an offer-axis ink supply system using one or more pumps or other mechanisms to supply a fluid to each of cartridges 144. In one embodiment, cartridges 144 of printer 134 are configured to apply multiple colors of ink. In the embodiment illustrated, cartridges 44 configured to deposit black (K), cyan (C), magenta (M) and yellow (Y) colored inks. In the example illustrated, printer 34 is additionally configured to apply a fixer (F) to web 130 prior to application of the colored inks. In other embodiments, printer 134 may include a fewer or greater of such cartridges configured to apply a fewer or greater of such different types of fluid.
Actuator 135 comprise a mechanism configured to selectively raise and lower support 142 to raise and lower cartridges 144 relative to web flow path 136 and web 130. As a result, support 142 may be moved to facilitate enhanced access to cartridges 144 for inspection, repair or replacement. In some embodiments, movement of support 142 and cartridges 144 may further facilitate servicing of print heads 146.
In the embodiment illustrated, actuator 135 comprises one or more hydraulic or pneumatic cylinder assemblies 147. In another embodiment, actuator 135 comprises one or more electric solenoids. In the yet another embodiment, actuator 135 may comprise one or more cams driven by one or more motors. In such an embodiment, support 142 may be guided by one or more guide rods or other guide structures. In still other embodiments, actuator 135 may be omitted.
Web flow path 136 comprises a path formed by one or more stationary or movable structures along which web 130 is guided and moved. In the particular example illustrated, web flow path 136 is formed by overhead rollers 150, 151, 152, 153, 154, 155, 156, 157 and 158, arcuately arranged rollers 160, forming media support 137, and control rollers 162, 164, 166. Rollers 150-158 guide and direct web 130 along path 36 over, around and about print support 42 and cartridges 44 generally to control roller 162. Although path 136 is illustrated as utilizing rollers 150-158 for directing web 130 over and around support 142, in other embodiment, path 136 may include a greater or fewer of such rollers for directing web 130 around support 142. In still other embodiments, other structures may be used to guide web 130 over and around support 142. For example, stationary structures such as arcuate panels or plates may be used to guide or direct web 130 around support 142.
Arcuately arranged rollers 160 form media support 137 and comprise a series of rotationally supported cylinders or rollers supported in an arc by a support 166 opposite to support 42 and cartridges 144. In one embodiment, support 166 supports rollers 160 which rotate about their individual axes. Rollers 160 facilitate relatively smooth movement of web 130 with minimal friction upon web 130. In other embodiment, rollers 160 may include a greater or fewer of such rollers or may include other structures configured to support web 130 in an arc opposite to support 142. For example, in another embodiment, rollers 160 may be replaced with one or more arcuate platens or plates.
Control rollers 162, 164 comprise independently rotationally driven rollers which define or form web flow path 136 and which move web 130 along web flow path 136. Roller 162 is located immediately upstream of cartridges 144 and their associated print heads 146. Roller 164 is located immediately downstream of cartridges 144 and their associated print heads 146 along web flow path 136. Rollers 162 and 164 form or define a printing zone across support 166 and rollers 160. Rollers 162 and 164 are configured to be driven at different speeds, facilitating adjustment of the tension of web 130 across an opposite to cartridges 144 during printing upon web 30. At the same time, rollers 162 and 164 may be driven at substantially the same speed, facilitating precise velocity control of web 130 across the printing zone formed by rollers 162, 164 and rollers 160.
Control roller 166 comprises an independently rotationally driven roller which further partially defined a farce web flow path 136. Control roller 165 engages or contacts web 130 after web 130 has left printer model 122 and has passed through dryer module 124. In operation, control roller 165 pulls web 130 partially through dryer module 124 despite being physically associated with printer model 122. Because printer module 122 includes control roller 165, the cost and complexity of dryer model 124 is reduced. Likewise, control of the velocity of control roller 165 may be more easily facilitated using controller 28 (shown and described with respect to
As further shown by
As further shown by
Web drive 138 comprises one or more mechanisms configured to rotationally drive rollers 162, 164 and 165. In the example illustrated, web drive 138 comprises stepper motors 172, 174 and 175 (with associated encoders). In other embodiments, web drive 138 may comprise other controllable sources of torque. In still other embodiments, web drive 138 may comprise a single motor configured to selectively supply distinct levels of torque or velocity to rollers 162, 164 and 165 using one or more transmissions and clutch mechanisms.
Print head servicing system 140 includes guides 150 and printed service shuttles 152. Guides 150 comprise one or more structures configured to died, support and direct movement of service shuttles 152 across media support 137 to positions opposite to print heads 146 for servicing of print heads 146. Guides 150 are each dedicated to an associated with particular print head supports 143 and their associated cartridges 144. In the example illustrated, guides 150 are coupled to and provided as part of print head supports 143. As a result, print head supports 143 and the associated guides 150 may be assembled an inventory as individual units. In addition, such individual units may be more easily separated and removed from main support 142 for repair or replacement. According to one example embodiment, guides 150 comprise C-shaped tracks or channels in and along which rulers or other low friction bearing structures associated with service shuttles 152 rotate, slide or otherwise translate. In other embodiments, guides 150 may comprise other structures for guiding movement of service shuttles 152 across media support 137 to positions opposite to print heads 146. Although guides 150 are illustrated as being provided on opposite sides of each of print head supports 143, in other embodiments, guides 150 may alternatively extend along a single side of each of print head supports 143 or at a single intermediate location between opposite sides of print head support 143.
Service shuttles 152 comprise devices configured to move along guides 150 between a servicing positioned and a withdrawn position for printing. Servicing shuttles 152 are configured to perform one or more servicing operations, such as wiping, spitting and capping, upon print heads 146. As schematically shown in
In one embodiment, each actuator 154 may be supported and carried by its associated service shuttles 152. In another embodiment, portions of the actuator 154 may be stationary and operably coupled to service shuttles 152. According to one embodiment, actuator 154 comprises a rack gear extending along each of guides 150 and pinion gear carried by service shuttles 152 in engagement with the rack gear, wherein rotation of the pinion gear, such as by a motor carried by service shuttle 152, moves the individual service shuttle 152 along the rack gear and along the associated guide 150. In another embodiment, actuator 154 may have other configurations.
At the same time, service shuttle 152 is moved by actuator 154 to a withdrawn position as shown in which service shuttles 152 is withdrawn from or not opposite to either web 30 or print heads 146. In one embodiment, each service shuttle 152 has a height greater than the distance of gap, enabling printing without interference from service shuttles 152.
As shown in
Once print head support 134 has been moved to the raise position shown in
Upon completion of the servicing operations, controller 28 generates control signals directing actuator 154 to retract service shuttle 152 to the withdrawn position shown in
As with printing system 20, because printing system 120 raises and lowers one or more of print and supports 143 between the lowered printing position shown in
Service station 224 securely receives and supports cartridge 230 and is movable with respect to housing 12 to position cartridge 230 in space 231 opposite to print heads 146 for servicing print heads 146. Service station 224 includes frame 244, latches 248, capper 250, actuator 252 (shown in
Latches 248 comprise a pair of mechanisms associated with frame 244 and configured to releasably secure cartridge 230 with respect to frame 244.
Capper 250 comprises a mechanism configured to cap or seal the nozzles of print heads 146 when print heads 146 are not being used. As shown by
Actuator 252 comprises a mechanism configured to pivot capper 250 between a capping position (shown in
In the example illustrated, actuator 252 is configured to further pivot service cartridge 230 between a lowered position (shown in
Torque source 254 (shown in
Actuator 154 comprises a mechanism configured to linearly move service station 224 in either of directions indicated by arrows 428 shown in
As shown by
Payout sensor 257 comprises a sensing device configured sense payout of material 304 and to detect the presence of cartridge 230 and service station 224. In one embodiment, sensor 257 comprises an optical sensor having and emitter and a corresponding detector, wherein transmission of light from the emitter, such as an optical beam, is interrupted by a portion of cartridge 230 upon its insertion. Sensor 257 communicates signals representing the presence of cartridge 230 and payout of material 304 to controller 32 to facilitate generation of status signals or warnings regarding the operational status of print system 210.
Cartridge 230 is configured to receive ink or other fluid from print heads 146 to determine the status of each the nozzles of print heads 146, to wipe the nozzles of print heads 146 and to receive ink or fluid during spitting or priming of the nozzles of print heads 220. As shown by
Housing 76 comprises one or more structures configured to support and retain the remaining components of cartridge 230. As shown by
Supply core 278 (shown in
Supports 282 comprise structures to guide and direct the web of material 304. As shown in
Support 284 comprises a structure configured to support the webbing of material 304 at an elevated position with respect to webbing 306. In other embodiments, support 284 may alternatively support 304 at a height similar to or less than that of spitting area 306. Support 284 resiliently supports webbing of material 304 during contact with print heads 146 during wiping. In the example illustrated, support 284 comprises a foam rubber roller 474 which includes a foam material about a rigid shaft that is resiliently supported by a resilient suspension 476. In one embodiment, suspension 476 comprises a preloaded shock or spring secured at one end of housing 276 or a structure fixedly secured to housing 276 and an opposite end secured to journal supports 478 which support foam roller 474. Suspension 476 allows the axis of roller 474 to conform to any macro misalignments between cartridge 30 and the face of print heads 146. As a result, material 304 may be placed into contact with print heads 146 while maintaining even pressure. In addition, spring loading of supports 478 compensates for larger misalignments between the faces of print heads 146 during wiping while maintaining even wipe pressure In other embodiments, support 284 may include other structures or materials for resiliently supporting material 304 or may omit such resilient supporting structures.
Input shaft 286 comprises a shaft configured to grip the material 304. In the embodiment illustrated, input shaft 286 comprises a knurled shaft rotatably supported by frame 276. As a result, cartridge 230 provides accurate control of the take-up and unwinding of material 304. In other words, input shaft 286 provides uniform advance per a given input shaft rotation. In the embodiment illustrated, axial ends of input shaft 286 provide outward projections which are received within detents 400 of latches 248 as shown in
Drive train 288 includes components associated with both service station 224 and cartridge 230. As shown by
Idler gears 492 are rotatably supported by housing 276 and are in meshing engagement with one another so as to transmit torque to input shaft gear 494. Input shaft 494 is rotatably supported by housing 276 and is secured to input shaft 286. In the embodiment illustrated, gear 314 is overdriven relative to the rotation of gear 494. As a result, material 304 is more tightly wound about core 280 and is more securely held against input shaft 286. Clutch 310 comprises a friction clutch configured to facilitate relative rotation between gear 314 and take-up core 280.
One-way clutch mechanism 290 comprises a one-way clutching mechanism operably coupled between gear 112 and supply core 278. Like one-way clutch 90, one-way clutch 90 is configured to permit faster relative angular rotation of gear 112 with respect to the angular rotation of supply core 278 and to inhibit or prevent faster angular relative rotation of take-up core 278 with respect to data of gear 312. In other words, one-way clutch mechanism 290 allows for low back tension of supply core 278 while preventing excess material 304 from being pulled out when the wiping friction forces would otherwise do so. In the example illustrated, one-way clutch mechanism 290 includes gear 318, arm 320 and ratchet 322 which are substantially identical to gear 118, arm 120 and ratchet 122, respectively, described above with respect to one-way clutch mechanism 90. In example illustrated, arm 320 resiliently supports ratchet 322 in concurrent meshing engagement with gear 312 and gear 318, wherein arm 320 resiliently deflects during driving of gear 312 by torque source 54 to payout material 304.
In the particular example illustrated, one way clutch mechanism 290 additionally includes drag 323. Drag 323 comprises a resilient arm cantilevered from housing 276 into engagement with an outer diamer of gear 318. Drage 323 adds a drag force to inhibit rotation of gear 318 and payout of material 306 which may occur during ratcheting of gear 322. In other embodiments, drag 323 may alternatively by omitted.
Drop detect basin 292 is similar to drop detect basin 92 described above with respect to system 10. In particular, drop detection basin 92 comprises a receptacle or chamber configured to receive fluid or ink droplets ejected from nozzles of print heads 146. In the example illustrated, basin 292 spans multiple print heads such that the operation of the nozzles of each of print heads 146 may be simultaneously detected by sensors 294.
Sensors 294 extend opposite to basin 292 and detect the passing of droplets therethrough to basin 292. In the example illustrated, sensors 294 comprise optical sensors having an emitter which emist an optical beam towards an optical detector, wherein droplets passing between the emitter and the detector interrupt the beam which results in signals being transmitted to controller 32. Controller 32 uses the received signals from sensors 294 to determine which, if any, of nozzles of print heads 146 are clogged or are malfunctioning. Because basin 292 and sensors 294 are located on an opposite side of support 284 as spitting area 306, detection of nozzle malfunctioning may be performed without contamination of material 304 prior to use of material 304 to wipe print heads 146. Because waste fluid or ink from each of wiping, spitting or priming and drop detection is captured in the same removable cartridge 230, removal, recycling and replacement of such waste ink is facilitated.
Payout indicator 295 comprises a device configured to be sensed by payout sensor 257 associated with service station 224 so as to indicate the presence of cartridge 230 in station 224 and the payout of material 304. In the example illustrated, indicator 295 comprises an interrupter wheel rotatably supported by housing 276 and operably coupled to gear 318 so as to rotate in proportion to rotation of gear 318 and supply core 278. During rotation of supply core 78 during the payout of material 304, indicator 295 also rotates such that notches, windows or other openings in indicator 295 and intermediate blocking portions of indicator 295 alternately interrupt optical beams of sensor 257 to create pulses which are transmitted to controller 32 to enable controller 32 to sense rotation of indicator 295. In the example illustrated, indicator 295 is located at an insertion end 520 of cartridge 230 such that indicator 295 is sensed by sensor 257 upon full or substantially complete insertion of cartridge 30 into service station 24, wherein sensor 257 is able to detect the presence or absence of indicator 295. Because indicator 295 is operably coupled to supply core 278 and because indicator 295 is located at end 520 of cartridge 230, indicator 295 cooperates with sensor 257 to provide several benefits: (1) the indication of when cartridge 230 is fully inserted into service station 224 or is present, (2) the indication of whether material 304 is properly being advanced or whether the supply roll of material 304 is empty or jammed by the lack pulses or (3) the provision of signals which may be used by controller 32 to determine or estimate the expenditure of material 304 from supply core 278 or the remaining amount of material 304 about supply core 278. All of such benefits are provided by a single indicator-sensor mechanism.
Although the present disclosure has been described with reference to example embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the claimed subject matter. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example embodiments and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements.
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