Patent Application
20090194927
The subject matter of the present disclosure broadly relates to the art of sheet compiling systems and, more particularly, to a variable-speed compiling system, such as may be used as a post-processing collator or in association with a finishing unit of a printing system, for example, as well as a method of compiling sheet media using the same.
Sheet handling systems of many types and kinds are known to utilize sheet compiling systems to collect and organize sheets of media into one or more packets or stacks thereof. For example, printing systems are known to use finishing units of a variety of types and kinds to receive sheets of media output by a marking engine or other section of the printing system. Typically, such known finishing units operate to organize the sheets of media into one or more packets or groups of sheets, such as into collated or uncollated stacks, for example. In many cases, known finishing units are also adapted to perform one or more further operations on these one or more groups of sheets, such as stapling or hole punching operations, for example.
Typically, it is desirable for known finishing units to at least approximately align one or more edges of the sheets of media in each group so that any further operations will produce uniform output. For example, it is often desirable to approximately align two adjacent edges of the sheets of media prior to a stapling operation such so that the resulting stapled packets of media will have a uniform appearance. As another example, it is normally desirable to approximately align two adjacent edges of the sheet of media prior to a hole punching operation so that all of the sheets of media will be hole punched in approximately the same locations, which will permit the sheets of media to be inserted, such as in an associated binder, in a uniform manner.
Known finishing units and other sheet handling systems commonly include a compiler or compiling system to assist in approximately aligning the sheets of media with one another. Typically, such compilers will include at least one collection tray for receiving the sheets of media. The collection tray normally includes a bottom wall for supporting the sheets of media and at least one registration wall that projects in an approximately transverse direction from the bottom wall. The at least one registration wall can then be used for approximately aligning edges of the sheets of media.
One example of such an arrangement, which is often referred to in the art as an “uphill” compiler, includes a collection tray that has bottom wall with a proximal end and a distal end. Typically, the distal end extends above the proximal end so that the bottom wall is disposed in an “uphill” orientation with respect to the sheet media being received at the finishing unit. The registration wall of the collection tray projects from the bottom wall along the proximal end thereof. Sheets of media enter the collection tray from along the proximal end such that the leading edge of the sheets of media is disposed toward the distal end of the collection tray and the trailing edge is disposed toward the proximal end of the collection tray. During use, the sheets of media are delivered into the collection tray with sufficient speed for the sheets of media to settle onto the bottom wall with the trailing edge of the sheets being spaced a short distance from the registration wall. The sheets of media then slide back toward the proximal end under the influence of gravity until the trailing edge of the sheets of media is at least approximately aligned with the registration wall.
Due to certain operational characteristics of uphill compilers, the same tend to be better suited for use in association with systems having lower output rates, such as less than 100 pages per minute (ppm), for example. This may be due, at least in part, to the time required for gravity to accelerate each sheet downhill and into approximate alignment with a registration wall. As such, the use of such uphill compilers is often avoided in sheet handling and/or printing systems that operate at higher output rates.
Other compilers or compiling systems have been developed to provide improved performance, such as the ability to handle higher printing system output rates, for example. Such compiling systems are often referred to in the art as “friction” compiling systems due to the use of an element that frictionally engages each sheet of media to urge the same toward the one or more registration walls. However, certain undesirable characteristics are often associated with known friction compiling systems.
For example, friction compilers typically include a frictional element that engages each individual sheet of media as the same is being received at or along the collection tray. The frictional element drives each sheet of media toward at least one registration wall such that at least the leading edge of successive sheets of media will be aligned with one another. One difficulty with such arrangements, however, is that causing the leading edge of the sheets of media to impact the registration wall with too much force can occasionally result in the sheet being undesirably deformed (e.g., wrinkled or folded). In other cases, such levels of impact force may result in the sheets of media bouncing back or otherwise away from the one or more registration walls. Oppositely, imparting insufficient drive force on the sheets of media can result in some of the sheets of media failing to reach the registration wall.
Accordingly, it is believed desirable to develop a compiling system for a finishing unit of a printing system and method of operating the same that overcomes the foregoing and/or other issues.
A compiling system in accordance with the subject matter of the present disclosure is provided that is adapted to receive sheets of media from an associated output pathway of an associated media transport system. The compiling system includes a collection tray that is adapted to receive the sheets of media. The collection tray includes at least one registration wall suitable for use in at least approximately aligning the sheets of media with one another. The compiling system also includes a sheet-engaging element operative to engage an individual sheet of media and to urge the individual sheet of media toward the at least one registration wall. The compiling system further includes a variable-speed rotation source drivably connected to the sheet-engaging element. The variable-speed rotation source is operative to selectively generate rotational output for driving the sheet-engaging element at a first speed prior to engaging the individual sheet of media and at a second speed that is less than the first speed after engaging the individual sheet of media and prior to the individual sheet of media contacting the registration wall.
A printing system in accordance with the subject matter of the present disclosure is provided that includes a sheet media source adapted to selectively dispense sheet media and at least one printing engine in operative communication with the sheet media source for receiving sheet media therefrom. The at least one printing engine is adapted to output marked sheet media. The printing system also includes a finishing unit that is disposed in operative communication with the at least one printing engine for receiving marked sheet media therefrom. The finishing unit includes a collection tray and a variable-speed compiling system. The collection tray is adapted to receive the marked sheet media and includes at least one registration surface. The variable-speed compiling system is operative to engage a sheet of media while operating at a first speed and at least approximately align the sheet of media with the at least one registration surface of the collection tray while operating at a second speed that is less than the first speed. The printing system further includes a control system that is in communication with the sheet media source, the at least one printing engine and the finishing unit. The control system operative to determine arrival of the sheet of media at the finishing unit and operate the variable-speed compiling system at the first speed prior to engaging the sheet of media. The control system is also operative to operate the variable-speed compiling system at the second speed after engaging the sheet of media and prior to the sheet of media contacting the at least one registration surface. The control system is also operative to operate the variable-speed compiling system to at least approximately align the sheet of media with the at least one registration surface.
A method of compiling sheet media in accordance with the subject matter of the present disclosure is provided that includes providing a compiling unit that is operatively disposed along a media transport pathway, which media transport pathway is adapted to convey individual sheets of media therealong at a first sheet speed. The compiling unit includes a collection tray and a variable-speed compiling system. The collection tray includes a sheet registration wall suitable for approximately aligning the individual sheets of media with one another. The method also includes receiving at the compiling unit one sheet of media traveling at the first sheet speed and engaging the one sheet of media using the variable-speed compiling system. The method further includes reducing the speed of the one sheet of media from the first sheet speed to a second sheet speed using the variable-speed compiling system prior to the one sheet of media contacting the sheet registration wall of the collection tray. The method also includes urging the one sheet of media into approximate alignment with the sheet registration wall of the collection tray using the variable-speed compiling system.
A method of compiling printed sheet media in accordance with the subject matter of the present disclosure is provided that includes providing a printing system including a sheet media source operative to output individual sheets of media, at least one printing engine operative to selectively mark the individual sheets of media and a finishing unit adapted to receive and compile the individual sheets of media. The finishing unit includes a collection tray and a variable-speed compiling system. The collection tray includes a sheet registration wall suitable for approximately aligning the individual sheets of media with one another. The method also includes receiving at the finishing unit one of the individual sheets of media traveling at a first sheet speed and engaging the one sheet of media using the variable-speed compiling system. The method further includes reducing the speed of the one sheet of media from the first sheet speed to a second sheet speed using the variable-speed compiling system prior to the one sheet of media contacting the sheet registration wall of the collection tray. The method also includes urging the one sheet of media into approximate alignment with the sheet registration wall of the collection tray using the variable-speed compiling system.
As discussed above, it will be appreciated that the subject matter of the present disclosure is broadly applicable for use in association with sheet handling and/or transporting systems of any suitable type, kind, configuration and/or construction. As one example, the subject matter of the present disclosure will the shown and described herein with specific reference to use in association with printing systems. It is to be clearly understood, however, that such use is merely exemplary and is not intended to be limiting.
The terms “print”, “printing” and “marking” as used herein are to be broadly interpreted to encompass any action or process involving the production and/or output of sheet media having text, images, graphics and/or other indicia formed thereon by any process, such as inkjet or electrophotographic processes, for example.
The terms “printer” and “printing system” as used herein are to be broadly interpreted to encompass any device, apparatus or system that is capable of performing a “printing” action. Examples of such equipment and/or systems include, without limitation, desktop printers, network printers, stand-alone copiers, multi-function printer/copier/facsimile devices, high-speed printing/publishing systems and digital printing presses.
Additionally, such exemplary embodiments of equipment, systems and/or processes can utilize sheet media of any suitable size, shape, type, kind, material, quality, weight and/or thickness (e.g., recycled paper, plain paper, bond paper, coated paper, card stock, transparencies and/or other media). Furthermore, such exemplary equipment, systems and/or processes can output indicia on such sheet media using any printing or marking substance, such as liquid ink, solid ink, toner and/or colorant, for example, in monochrome (e.g., black) or one or more colors, or any combination thereof.
Turning now to the drawings wherein the showings are for the purpose of illustrating exemplary embodiments, and not for limiting the same,
Sheet media source 102 is shown in
As shown in
With continued reference to
In the exemplary arrangement shown in
Finishing unit 106 is also shown as including an optional second collection tray 132, which is shown as being used in operative association with a compiling system 134. In one preferred embodiment, compiling system 134 will also be a variable-speed compiling system that is substantially similar to compiling system 126. However, it will be appreciated that a compiling system of any suitable type and/or kind could alternately be used in association with the second collection tray. In the exemplary embodiment shown, compiling system 134 also includes a sheet-engaging element 136 and a variable-speed drive unit 138 that is drivably connected to the sheet-engaging element. Finishing unit 106 is shown as further including an optional third collection tray 140 that is of an uphill-type configuration and, as such, is not shown as being operatively associated with a compiling system or other component.
In
Turning, now, to the general operation of a printing system in accordance with the present disclosure, such as printing system 100, for example, sheets of media are fed from a media source (e.g., sheet media source 102) to a printing engine (e.g., one of marking engines 118 of marking system 104) by way of a media pathway extending therebetween (e.g., media transport pathway 120). Once output by the marking engine or transported directly from the sheet media source, the sheet media (either marked or unmarked) is directed to a finishing unit or other sheet media receiving system (e.g., finishing unit 106). In some cases, the sheets of media may simply be output from the printing system, such through the use of collection tray 140, for example. Alternately, the sheets of media may be directed to a collection tray and compiler (e.g., collection tray 124 and compiling system 126) for one or more compiling operations (e.g., stacking, sorting and/or collating). Generally, such compiling operations will include at least approximately aligning an edge of the sheets of media with a registration surface of the corresponding collection tray. Optionally, one or more finishing operations may also be performed on the compiled sheets of media.
With more specific reference to the general operation of a variable-speed compiling system of the finishing unit, such as compiling system 126 and/or compiling system 134, for example, the sheet-engaging element (or elements) thereof is preferably operated at a first speed for accepting or otherwise initially engaging a sheet of media SHT (
Returning to the general operation of the variable-speed compiling system, once the sheet of media has been engaged by the sheet-engaging element (or elements), the speed of operation of the sheet-engaging element is reduced to a second, lower speed, which results in the sheet-engaging surface having a corresponding second, lower speed. Due to the engagement of the sheet-engaging surface with the sheet of media, the linear speed of the same is also reduced to a lower rate of travel, such as a speed approximately equal to the surface speed of the sheet-engaging element, for example. As a result of the reduced rate of travel of the sheet of media, undesirable effects, such as element wear, sheet bounce-back and edge bending, for example, can be minimized or at least reduced.
As will be discussed in greater detail hereinafter, variation of the speed of operation of the sheet-engaging element can be accomplished in any suitable manner, such as by altering the output from a corresponding variable-speed rotation source (e.g., variable-speed drive 130 or 138), for example. Additionally, it will be appreciated that any such variation in the output characteristics of the variable-speed drive or rotational output source can be accomplished in any suitable manner. For example, a variable-speed drive could simply be operated at the first speed for a first period of time and the second speed for a second period of time. As other examples, a variable-speed drive could be operated with reference to one or more triggering events and/or signals, or with respect to a combination of timing and triggering events. Additionally, the variation in the speed of operation of a variable-speed drive can, optionally, follow a predetermined speed profile over which the speed of operation is altered according to predetermined data, inputs and/or conditions, such as at predetermined rates of change and/or for predetermined durations, for example. Furthermore, the variation of the speed of operation can, optionally, be selectively varied based on any suitable factors and/or conditions, such as due to variations in printing system performance and/or variations in sheet media characteristics, for example.
A suitable control system, such as control system 108, for example, can be utilized to operate the foregoing and other systems and/or components of the printing system, such as in the manner discussed above, for example. As shown in
Control system 108 can optionally include a data storage device 148, such as a non-volatile memory or hard drive, for example, that is suitable for storing print jobs, settings, attributes and any other data, values, text, graphics, information and/or content. The data storage device is shown in
Either or both of input interface 150 and communication interface 152 can be used to communicate, generate, receive, input or otherwise provide print jobs to the printing system. For example, input interface 150 can be in communication with an optional raster output scanning system 154 suitable for scanning paper documents and transmitting rasterized images of the scanned documents in the form of image data to the controller or another system or component. Scanning system 154 can optionally include an automatic document feeding device 156 or other suitable arrangement for inputting sheet media. As another example, input interface 150 could be in communication with an optional memory device reader 158 adapted to retrieve document files, image files or other data or information from portable memory devices, such as memory cards, for example, and transmit such files, data or information to controller 146 or another system or component.
As a further example, a print job could optionally be transferred or otherwise sent to the printing system through communication interface 152, such as from a standalone computer 160 and/or from a computer workstation or terminal 162, for example, by way of any suitable line of communication, such as through a computer network 164, for example. A print job, however transmitted or received, can be directly communicated to controller 146 for processing or the print job can be stored in a suitable manner, such as within data storage device 148, for example, until recalled for printing.
One or more user interface devices, such as a display, keyboard, pointing device, indicator lamp, associated computing device (e.g., a remotely connected or networked computer) or other input or output device, for example, is provided on printing system 100 and is in communication with controller 146. In one preferred embodiment, a display 166 is provided that outputs graphical programming windows for communication of text, graphics, data, values and/or information to a user or operator. Additionally, the user interface is adapted for user input of text, graphics, data, values and/or information, such as from the keyboard (not shown), pointing device (not shown) or, in one preferred embodiment, touch-screen input on display 166, for example. It will be appreciated, however, that the foregoing user interface arrangement is merely exemplary and that text, graphics, data, values and/or information can be inputted and outputted in any suitable manner.
Control system 108, as is shown in
As previously discussed, control system 108 is operative to selectively vary the operating speed of a compiling system (e.g., compiling systems 126 and 134) of printing system 100 such that the sheet-engaging element thereof (e.g., sheet-engaging element 128, 136 and/or 142) operates at a first speed prior to engaging an incoming sheet of media (e.g., sheet SHT in
Operating module 174 can utilize any suitable data, values, settings, parameters, inputs, signals, algorithms, routines and/or any other information or content for controlling the variation in operating speeds of a compiling system. For example, control system 108 could include predetermined speed data and/or values, which are collectively represented in
Control system 108 can also optionally include a selection module 180 that is capable of selecting between different first speeds, different second speeds, different rates of change, different durations and/or different ones of any other such operating characteristics. For example, it may be desirable to select different first speeds and different second speeds depending upon the sheet media data (e.g., box 172) corresponding to a given print job so that faster or slower speeds can be used depending upon the size and/or thickness of sheet media that is called for by the print job.
Control system 108 can also optionally include a timing module 182 that is capable performing any desired timing operations, such as determining the time period between two event-related signals or communicating a timing signal at a predetermined period of time after receiving an event-related signal, for example. As a more specific example, it may be desirable for operating module 174 to decelerate a sheet-engaging element (e.g., element 128) of a compiling system (e.g., compiling system 126) at a predetermined time after the arrival of a sheet of media (e.g., sheet SHT) at a predetermined location. It will be appreciated that such arrival may be monitored or otherwise determined in any suitable manner, such as by using a sheet-arrival sensor 184 that is operatively associated with a portion of the media transport pathway (e.g., pathway 120), for example. Upon receiving a sheet-arrival signal from sensor 184, timing module 182 can perform a timing operation for generating or otherwise communicating a suitable timing signal to operating module 174 after predetermined period of time, such as a time slightly greater than the expected duration for the sheet of media to arrive at and be engaged by the sheet-engaging element, for example.
A control system, such as control system 108, for example, will include a processing device, which can be of any suitable type, kind and/or configuration, such as a microprocessor, for example, for processing data, executing software routines/programs, and other functions relating to the performance and/or operation of the printing system (e.g., printing system 100). Additionally, the control system (e.g., control system 108) will include a storage device or memory, which can be of any suitable type, kind and/or configuration that can be used to store data, values, settings, parameters, inputs, software, algorithms, routines, programs and/or other information or content for any associated use or function, such as use in association with the performance and/or operation of the printing system or communication with a user or operator, for example.
In the embodiment shown in
Printing systems commonly include one or more sheet media sensors capable of generating a signal indicative of the presence or absence of a sheet of media within a predetermined proximity of the sensor. For purposes of clarity and ease of illustration, only sheet media sensor 184 is shown and specifically referred to herein. It is to be understood, however, that any suitable number and/or arrangement of sheet media sensors can be used, Additionally, printing systems commonly include a plurality of nips, rollers and other elements disposed along the media transport pathway for urging the sheets of media therealong. However, for purposes of clarity and ease of understanding, only nip rollers 186 and 188 are shown and specifically referred to herein. Nip rollers 186 and 188 are shown as being operatively disposed along transport pathway 120 adjacent compiling systems 126 and 134, respectively, and operate to deliver sheets of media (e.g., sheet SHT) into a corresponding one of the collection trays for engagement by the sheet-engaging element (e.g., 128, 136 and/or 142) operatively associated therewith.
Collection tray 124 is shown in
Compiling system 208 differs from the previously described compiling systems (e.g., compilers 126 and 134) in that compiling system 208 includes a friction disk 216, which may also be referred to in the art as a disk stacker, as the sheet-engaging element, rather than a roller or belt type sheet-engaging element, such as is illustrated in
Friction disk 216 differs from other known friction disk compiling systems in that friction disk 216 is driven by a variable-speed drive unit (not shown). As such, the friction disk can be operated to rotate at a first angular speed for engaging the incoming sheet of media and then operate at a second, lower angular speed for at least approximately aligning the sheet of media with the associated registration wall or surface, such as, for example, in one of the manners described herein. It will be appreciated that any suitable variable-speed drive unit can be used and that such a variable-speed drive unit can be drivably interconnected with the friction disk in any suitable manner.
With reference, now, to
In
It will be recognized that, in
In
Additionally, it will be appreciated that such deceleration can occur at any suitable point in time. For example, it will be appreciated that at a time prior to the arrival of the incoming sheet of media at the collection tray, the position of incoming sheet of media may be sensed by a suitable sheet sensing device (e.g., sheet media sensor 184), as is represented by sheet arrival event SAE in
Furthermore, it will be appreciated that such deceleration can be completed at any suitable point in time. For example, the deceleration of the sheet-engaging surface of the sheet-engaging element from first surface speed FSP to second surface speed SSP can occur over a predetermined period of time PT2, as illustrated in
In whichever manner achieved, the sheet-engaging surface of the sheet-engaging element can, in one exemplary embodiment, be reduced to at least approximately second surface speed SSP prior to an edge (e.g., a leading edge LEE or a longitudinal edge LOE in
It will be appreciated that the sheet-engaging element can be accelerated back to a greater speed of operation, such as first surface speed FSP, for example, at any suitable point in time prior to contact thereof with a second incoming sheet of media SHT2, as is illustrated in
Turning, now, to
Method 300 also includes engaging the incoming sheet of media using the variable-speed compiling system while the sheet of media is traveling at the first sheet speed and the compiling system is operating at the first speed of operation, as is indicated by box 308. Method 300 further includes reducing the speed of travel of the incoming sheet of media to a second, lower sheet speed, as is represented by box 310 in
It will be appreciated that a method of operation in accordance with the subject matter of the present disclosure, such as method 300, for example, can be repeated for any desired number of incoming sheets of media, as indicated by arrow 316. Additionally, it will be appreciated that any other actions, operations and/or steps can optionally be included, such as an action decelerating the sheet-engaging element to a third surface speed (e.g., speed TSP in
Furthermore, it will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
