1. Field of the Invention
The present invention relates to a sheet conveying device and more particularly to a sheet conveying device including a unique mechanism for switching a sheet conveying path, a sheet processing apparatus including the sheet conveying device, an image forming apparatus including the sheet processing apparatus, an image forming system including the sheet processing apparatus, a computer program for controlling the sheet conveying device or the sheet processing apparatus, a computer program for executing a sheet processing method with a computer, a recording medium storing such a computer program such that a computer can read it out, and a sheet processing method.
2. Description of the Background Art
Japanese Patent Laid-Open Publication Nos. 7-315668 and 2000-53302, for example, each disclose a sheet conveying device in which path selectors are positioned in parallel in a direction of sheet conveyance. This configuration minimizes the widthwise dimension of the path selectors for thereby reducing the overall size of the sheet conveying device.
Particularly, in the sheet conveying device taught in the above Laid-Open Publication No. 7-315668, two path selectors do not pivot independently of each other, but pivot at the same time as each other. Such path selectors, however, occupy a great exclusive area when pivoting and cannot pivot at the same time unless use is made of solenoids having great power.
On the other hand, the sheet conveying device taught in Laid-Open Publication No. 2000-53302 includes path selectors respectively positioned at a first and a second branch portion and interconnected by a first, a second and a third link member and solenoids that control the links to switch a sheet path. Further, a third path selector is positioned at the second branch portion and driven independently of the second path selector about its own fulcrum. This configuration has a problem that when the edge of the upper path selector contacts the upper surface of the lower path selector when selecting an upward path, the above edge and the edge of the lower path selector are apart from each other by a great distance. As a result, it is likely that the leading edge of a sheet being conveyed abuts against the upper surface of the lower path selector and is steed downward thereby instead of being steered upward by the edge portion of the upper path selector, resulting in a jam.
As stated above, arranging path selectors in parallel is one of effective implementations for reducing the overall size of a sheet processing apparatus. However, a problem with the conventional technologies is that a particular solenoid or drive source must be assigned to each of two path selectors arranged in parallel and rotatable independently of each other, increasing the cost of the sheet processing apparatus. Moreover, the solenoids each being assigned to a particular path selector obstruct the reduction of the size, particularly width, of the sheet processing apparatus.
It is an object of the present invention to provide a sheet conveying device, a sheet processing apparatus and an image forming apparatus each being small size and low cost.
It is another object of the present invention to provide a sheet conveying device, a sheet processing apparatus and an image forming apparatus each being capable of surely effecting, e.g., three-way or similar sheet conveyance control and shift control even when reduced in size and cost.
In accordance with the present invention, a sheet conveying device includes a conveying member for conveying a sheet, a switching mechanism for switching the direction of conveyance of the sheet being conveyed by the sheet conveying member, and a shifting mechanism for shifting the sheet passed through the switching mechanism and nipped by the conveying member in a direction perpendicular to the direction of conveyance. The switching mechanism and shifting mechanism share a single drive source.
A sheet processing apparatus, an image forming apparatus and an image forming system each using the above sheet conveying device are also disclosed.
Further, in accordance with the present invention, a sheet processing method capable of dealing with a shift mode, a staple mode and a proof mode begins with the step of determining which of the shift mode, staple mode and proof mode is selected. If the shift mode is selected, a motor configured to move a shift roller pair in a direction perpendicular to the direction of sheet conveyance is rotated by a preselected amount when the shift roller pair is conveying a sheet in a preselected direction. Further, if the staple mode is selected, the motor is rotated in a direction opposite to the preselected direction for thereby actuating a switching mechanism configured to switch a path selector to a position for steering a sheet to a path that extends to a staple tray. On the other hand, if the proof mode is selected, the motor is rotated in the direction opposite to the preselected direction for thereby actuating the switching mechanism configured to switch the path selector to a position for steering a sheet to a path that extends to a proof tray.
The objects and features of the present invention will become more apparent from consideration of the following detailed description taken in conjunction with the accompanying drawings in which:
Referring to
The image reading section 51, implemented as a conventional scanner, optically scans a document in the main scanning direction while being moved in the subscanning direction to thereby read the document. The sheet feeding section, or ADF (Automatic Document Feeder) as often referred to, 54 conveys the above document to a glass platen included in the image reading section 51. The image writing section 52 is constituted by conventional optics including a laser diode, a polygonal mirror and an f θ lens and optically writes a latent image representative of the document on the surface of a photoconductive element. The latent image thus formed on the photoconductive element is developed by toner and then transferred to a sheet or recording medium as a toner image. Subsequently, the toner image is fixed on the sheet by a fixing unit and then transferred to the sheet finisher FR by an outlet roller pair 55.
In the illustrative embodiment, the sheet feeding section 53 includes four sheet cassettes arranged one above the other. A vertical sheet path 56 adjoins the right side of the sheet cassettes, as viewed in
The sheet, carrying the toner image thereon, is transferred from the printer PR to the sheet finisher FR in a direction indicated by an arrow M in
A conveying unit 5 is arranged beneath the punch unit 4 perpendicularly to the direction of sheet conveyance in order to convey chad produced from the sheet by the punch unit 4 to a hopper 3. More specifically, the conveying unit 5 conveys the chad toward an operation side OP, see
A first and a second path selector 20 and 21, respectively, are located downstream of the roller pair 6 and cooperate to steer the sheet punched by the punch unit 4 toward a shift tray 9 via a sorting, stapling or similar processing station or simply steer it toward a proof tray 22.
More specifically, in the illustrative embodiment, a particular path is assigned to each of a sort mode, a staple mode and a proof mode. In the sort mode, the first and second path selectors 20 and 21 are respectively so positioned as to block a path terminating at the proof tray 22 and a path including a roller pair 10 while unblocking a path including a roller pair 7. As a result, the sheet is driven out to the shift tray 9, which has a shifting function, by an outlet roller pair 8 via the roller pair 7. The shifting function is assigned to the roller pair 7 capable of moving back and forth in the direction perpendicular to the direction of sheet conveyance volume by volume to thereby sort consecutive volumes on the shift tray 9. In this sense, the roller pair 7 will be referred to as a shift roller pair hereinafter.
In the staple mode, the second path selector 21 unblocks the path including the roller pair 10 and blocks the path terminating at the shift tray 9. At the same time, the first path selector 20 blocks the path terminating at the proof tray 22. In this condition, the sheet is routed through a staple roller pair 11 to a staple tray 12. Every time such a sheet is driven out to the staple tray 12 by the staple roller pair 11, a knock roller knocks down the sheet toward an end fence. Subsequently, jogger fences jog the edges of the sheet in the direction perpendicular to the direction of sheet conveyance. As soon as a preselected number of sheets, constituting a single volume, are sequentially stacked on the staple tray 12 in the manner described above, a stapler 13 staples the end portion of the sheet stack, i.e., the trailing end in the illustrative embodiment in the direction of sheet conveyance. Thereafter, a belt conveyor lifts the sheet stack thus stapled toward the outlet roller pair 8. As a result, the sheet stack is driven out to the shift tray 9 by the outlet roller pair 8.
Further, in the proof mode, the first path selector 20 is pivoted to unblock the path terminating at the proof tray 22, while blocking the path terminating at the shift tray 9. At the same time, the second path selector 21 blocks the path including the roller pair 10. As a result, the sheet being driven by the roller pair 6 is steered toward the proof tray 22.
As stated above, in the illustrative embodiment, the punch unit 4 and hopper 3 are positioned upstream of all sheet finishing stations. Basically, therefore, the punch unit 4 can punch any sheet introduced into the sheet finisher FR. Sheets thus punched may be simply stacked on the proof tray 22 or driven out to and sorted on the shift tray 9 or driven out to the shift tray 9 via the stapler 13.
While the printer PR of the illustrative embodiment is assumed to form an image corresponding to an image optically read by the image reading unit 51, the printer PR can, of course, form an image in accordance with image data directly received from a data processing apparatus or indirectly received via a network or even facsimile data. In the illustrative embodiment, the operation timing of the punch unit 4 and the operation timings of the first and second path selectors 20 and 21 are set in accordance with the timing at which an inlet sensor 2 senses the leading edge or the trailing edge of a sheet.
The paths included in the sheet finisher FR will be described more specifically with reference to
Sheets that do not have to be finished are simply stacked on the proof gray 22. On the other hand, sheets, sorted by being shifted in the direction perpendicular to the direction of sheet conveyance volume by volume, are stacked on the shift tray 9. The shift tray 9 is moved up and down by a motor under the control of a control mechanism, although shown or described specifically.
The shift roller pair 7 and outlet roller pair 8 mentioned earlier are sequentially arranged on the straight path PS2 and configured to convey a sheet introduced into the path PS2 to the shift tray 9. The roller pair 10, staple roller pair 11 and staple unit 12 also mentioned earlier are sequentially arranged on the downstream path PS3.
The first path selector 20 selectively steers a sheet toward the proof tray 22 in the proof mode or steers it toward the shift tray 9 via the shift roller pair 7 in the shift mode. The second path selector 21 selectively steers the sheet toward the shift tray 9 via the shift roller pair 7 or steers it toward the staple tray 12 via the roller pair 11 in the staple mode.
More specifically, as shown in
As shown in
Further, as shown in
By contrast, as shown in
On the other hand, as shown in
As stated above, in the illustrative embodiment, the first and second path selectors 20 and 21 share a single fulcrum or axis of rotation 23 positioned between them. This reduces positional deviation between the edges 20-B and 21-B of the path selectors 20 and 21, respectively, when the path selector 20 or 21 is pivoted on the shared fulcrum 23.
Hereinafter will be described a drive mechanism for operating the path selectors 20 and 21 and a slide mechanism for causing, by using the force of the drive mechanism, the shift roller pair 7 to slide in the direction perpendicular to the direction of sheet conveyance.
As shown in
The link 26 is integrally mounted on the slide shaft 7-A having a D-shaped cross-section mentioned earlier. Therefore, when the link 26 is linearly moved back and forth in accordance with the rotation of the cam 27, it causes the shift roller pair 7 to slide back and forth via the slide shaft 7-A in the direction indicated by the arrow in
In the illustrative embodiment, the sliding movement of the shift roller pair 7 stated above is implemented by the rotation of the stepping motor 29 effected in one direction. More specifically, the cam 27 geared to the stepping motor 29 causes the shift roller pair 7 to slide when rotated by 180° and then returns it when rotated by another 180°. Such control over the 180°—or half-rotation of the cam 27 is controlled on the basis of the number of drive pulses input to the stepping motor 29.
An HP (Home Position) sensor 28 is responsive to the home position of the cam 27, so that the angular position of the cam 27 is determined in accordance with the output of the HP sensor 28. More specifically, the cam 27 is determined to have reached its home position when an interrupter, protruding radially outward from the cam 27, interrupts the optical path of the HP sensor 28.
The shifting operation described above is effected volume by volume so as to sort consecutive sheets on the shift tray 9 while conveying the sheets. As for a volume, assume that ten volumes of identical booklets, for example, should be produced by copying or printing by a single job. Then, a single volume refers to each of ten volumes to be sequentially sorted on the shift tray 9.
Reference will be made to
A worm 32 is fixedly mounted on a drive shaft that drives the gear 30. A worm wheel 33 is held in mesh with the worm 32 while a pivot cam 33-A is rotatable integrally, coaxially with the worm wheel 33. A spring, not shown, constantly biases the worm 32 toward the gear 30 in order to maintain the worm 32 in mesh with the worm wheel 33. As shown in
In the general configuration of the drive mechanism described above, when the stepping motor 29 is rotated in the opposite direction mentioned earlier, the output torque of the stepping motor 29 is transferred to the gear 30 via the cam 27, causing the gear 30 to rotate together with the one-way clutch 31. At this instant, because the one-way clutch 31 is configured to act on a shaft over which it is coupled in a locking direction, the worm 32 rotates together with the shaft 30-A of the gear 30 to thereby cause the worm wheel 33 to rotate. As a result, the pivot cam 33-A rotatable integrally with the worm wheel 33 and the cam surface 20-A or 21-A of the path selector 20 or 21, respectively, contact each other, switching the position of the path selector 20 or 21, as will be described more specifically later.
As stated above, in the illustrative embodiment, the operation for switching the path selector 20 or 21 is effected when the one-way clutch 31 press-fitted in the gear 30 acts in the locking direction. On the other hand, the operation for moving the shift roller pair 7 back and forth in the axial direction of the slide shaft 7-A is effected when the one-way clutch 31 acts in the unlocking direction. It follows that the path selector switching operation is not effected when the shift roller sliding operation is under way. In the shift mode in which consecutive sheets are conveyed via the shift roller pair 7, the path selectors 20 and 21 are held in the default condition shown in
When the one-way clutch 31 acts in the locking direction, the path selector 20 or 21 is switched in position, as stated above. At this instant, the shift roller pair 7 is caused to slide at the same time because the cam 27 rotates integrally with the driven gear 29-B. However, so long as the path selector 20 or 21 is switched to a position shown in
Further, the one-way clutch assigned to the shifting operation makes it possible to reverse the rotation of the stepping motor 29 and therefore to start switching the path selector 20 or 21 only if the shifting operation has completed, i.e., even if a sheet has not moved away from the shift roller pair 7. This successfully enhances the productivity of the apparatus.
The operation for switching the path selectors 20 and 21 will be described more specifically hereinafter.
Assume that the stepping motor 29 is rotated in the direction for switching the path selector 20 or 21 held in the default condition. Then, the pivot cam 33-A is rotated clockwise, as viewed in
Assume that the pivot cam 33-A is further rotated clockwise from the condition of
Subsequently, when the pivot cam 33-A is further rotated until it leaves the cam surface 20-A, the force of the pivot cam 20-A, acting on the first path selector 20, is canceled. As a result, the first and second path selectors 20 and 21 both are returned to their default positions by the action of the springs 34 and 35, respectively. Further, as soon as the interrupter 33-B of the pivot cam 33-A, rotating in the above direction, interrupts the optical path of the HP sensor 36, the stepping motor 29 is deenergized so as to restore the default condition shown in
In the illustrative embodiment, the pivot cam 33-A is driven via the one-way clutch 31 and therefore rotatable in only one direction, as stated previously. It follows that to define the transition from the default condition of
A control system included in the illustrative embodiment will be described with reference to
The CPU 360 controls, in accordance with the outputs of the above switches and sensors, various operations including the up-and-down movement of a punch included in the punch unit 4, the operation of the conveying unit 5, the jogging or positioning operation effected on the staple tray 12 perpendicularly to the direction of sheet conveyance, the stapling operation of the staple unit 13, the discharge of a stapled sheet stack, the up-and-down movement and shift of the shift tray 9, and the operation of the knock roller that knocks down a sheet toward the rear fence mentioned earlier. Further, the CPU 360 counts drive pulses input to a staple conveyance motor, not shown, for driving the staple roller pair 11 and controls the knock roller and jogging operation in accordance with the count of the drive pulses.
It is to be noted that the CPU 360 controls the sheet finisher FR by executing a program stored in a ROM (Read Only Memory), not shown, while using a RAM (Random Access Memory), not shown, as a work area.
A specific procedure for controlling the drive mechanism included in the illustrative embodiment will be described hereinafter with reference to
Briefly, as shown in
More specifically, as shown in
In the step S101, to cause the shift roller pair 7 to shift consecutive sheets volume by volume, the CPU 360 determines whether or not a volume to deal with is an odd volume, i.e., a 2(N−1) volume. If the answer of the step S101 is Y, the CPU 360 determines whether or not the trailing edge of a sheet has moved away from the roller pair 6 to see if the sheet can be shifted or not. For this purpose, in the illustrative embodiment, the CPU 360 determines whether or not a preselected period of time t1 elapses from the time when the trailing edge of the sheet moves away from the inlet sensor 2 to the time when it moves away from the roller pair 6 (step S102). If the answer of the step S102 is Y, the CPU 360 causes the stepping motor 29 to rotate in the forward direction (step S103). It is to be noted that in the illustrative embodiment the forward direction refers to the direction for shifting the shift roller pair 7. The step S103 is followed by a step S104.
As for the step S104, assume that the shift roller pair 7 is movable between a first position or initial or leftmost position, as viewed in
If the answer of the step S104 is Y, meaning that the shift roller pair 7 has reached the second position, the CPU 360 deenergizes the stepping motor 29 (step S105). Subsequently, the CPU 360 determines whether or not a preselected period of time t2 elapses from the time when the trailing edge of the sheet moves away from the inlet sensor to the time when it moves away from the shift roller pair 7 (step S106), thereby determining whether or not the sheet has moved away from the shift roller pair 7. On the elapse of the period of time t2 (Y, step S106), the CPU 360 determines whether or not the sheet thus shifted is the last sheet of the odd or 2(N−1) volume (step S107). If the answer of the step S107 is Y, the procedure is transferred to the step S4,
If the answer of the step S107 is negative (N) the CPU 360 causes the stepping motor 29 to rotate in the forward direction to thereby return the shift roller pair 7 from the second position to the first stated mentioned earlier (step S108). The CPU 360 then determines whether or not the shift roller pair 7 has reached the first position (step S109) and then deenergizes, if the answer of the step S109 is Y, the stepping motor 29 (step S110). The step S110 is also followed by the step S4,
In the step S4 following the step S107 or S110,
The distance between the first and second positions of the shift roller pair 7 is two times as great as the distance between the cam pin 27-B and the center of the cam 27. In the illustrative embodiment, this distance is selected to be 15 mm although it can be freely selected at the design stage on the basis of the distance between the cam 27-B and the center of the cam 27.
On the other hand, if the answer of the step S101 is N, meaning that the volume to deal with is an even volume, the CPU 360 determines whether or not the preselected period of time t1 has elapsed as in the step S102 (step S111), thereby determining whether or not the trailing edge of the sheet has moved away from the roller pair 6. If the answer of the step S111 is Y, the CPU 360 causes the stepping motor 29 to rotate in the forward direction (step S112). At this instant, if the sheet being conveyed is the last sheet, as determined in the step S107, the shift roller pair 7 has been located at the second position in the step S104, so that the stepping motor 29 moves the cam pin 27-B and therefore the shift roller pair 7 from the second position to the first position. Therefore, the CPU 360 determines whether or not the shift roller 7 has returned from the second position to the first position (step S113) and then deenergizes, if the answer of the step S113 is Y, the stepping motor 29 (step S114).
After the step S114, the CPU 360 determines whether or not the preselected period of time t2 has elapsed as in the step S106 (step S115), thereby determining whether or not the trailing edge of the sheet has moved away from the shift roller pair 7. As a result, the sheet is shifted from the first position to the second position. At this instant, the amount of shift is 30 mm because the distance between the first and second positions is 15 mm, as stated earlier. Consequently, consecutive volumes are sequentially stacked on the shift tray 9 while being shifted from each other by 30 mm.
If the answer of the step S115 is Y, the CPU 360 determines whether or not the sheet shifted is the last sheet of the even volume or 2N volume (step S116). If the answer of the step S116 is Y, the procedure returns to the step S4,
Referring again to
On the other hand, if the answer of the step S201 is N, meaning that the sheet being conveyed is the second or successive sheet, the CPU 360 simply waits for the entry of the sheet and the end of the job with the path selector 21 remaining in the second path selector position (step S4). On the end of the job, the CPU 360 executes the initialization (step S5) and then ends the procedure.
If the staple mode is not selected (N, step S2) the CPU 360 determines whether or not the proof mode is selected (step S3). If the answer of the step S3 is Y, the CPU 360 determines whether or not a sheet being conveyed is the first sheet to be dealt with in the proof mode (step S301). If the answer of the step S301 is Y, the CPU 360 causes the stepping motor 29 to rotate in the reverse direction in order to guide the sheet toward the proof tray 22 (step S302). As a result, the path selector 20 is angularly moved to the position shown in
On the other hand, if the answer of the step S301 is N, meaning that the sheet being conveyed is the second or successive sheet, the CPU 360 simply waits for the entry of the sheet and the end of the job with the path selector 20 remaining in the third path selector position (step S4). On the end of the job, the CPU 360 executes the initialization (step S5) and then ends the procedure.
It should be noted that the position of the stepping motor 29 is indefinite in a power-down condition. Therefore, when the entire system is initialized in the event of power-up, the subroutine shown in
As stated above, in the illustrative embodiment, the stepping motor 29, which is a drive source assigned to the shift mechanism, is used to move the path selectors 20 and 21, but the one way-clutch 31 prevents the path selectors 20 and 21 from moving when the shifting operation is under way. When the edges of the path selectors 20 and 21 are spaced apart from each other, a sheet conveyed to the path selectors 20 and 21 is driven out to the shift tray 9 via the shift roller pair 7 and outlet roller pair 8.
Assume that the path selector 20 or 21 is angularly moved when the sheet, passing through the shift roller pair 7, is shifted in the direction perpendicular to the direction of conveyance. Then, it is likely that the leading edge of the next sheet is caught by the path selector 20 or 21 or that the edge of the path selector 20 or 21 contacts a sheet passing through the gap between the path selectors 20 and 21, resulting in a jam. The illustrative embodiment obviates this kind of jam by preventing the path selectors 20 and 21 from moving when the shifting operation is under way, as stated above, thereby insuring stable sheet conveyance.
Although the stepping motor 29 is shared by both of the shift mechanism and path selector switching mechanism, productivity in an interrupt mode is enhanced because when one mechanism is operating, the other mechanism does not operate.
In the illustrative embodiment, when a sheet is conveyed to the shift roller pair 7, the stepping motor 29, driving the shift roller pair 7, is rotated in the reverse direction just after the shift of the sheet so as to switch the path selector 20 or 21, thereby allowing the above sheet to be steered to another path. This unique arrangement is achievable because the shift roller pair 7 and path selectors 20 and 21 are driven by the forward and reverse rotation of a single motor and because such forward and reverse rotation effect the above drive independently of each other.
Controlling the path selector positions with the number of pulses from a home position, the illustrative embodiment can recognize a plurality of positions by use of a single home position sensor. In addition, using a motor for path selector switching in place of conventional DC solenoids, the illustrative embodiment is capable of moving the path selectors slowly with a minimum of noise.
Further, when one of the two path selectors is in movement, the other path selector is surely held in a halt. This prevents the path selectors from hitting against each other for thereby maintaining the switching operation stable.
Moreover, the two path selectors are shaped symmetrically to each other with respect to the fulcrum or shaft 23 while the pivot cam 33-A is positioned between the cam surfaces 20-A and 21-A of the path selectors. More specifically, the cam surfaces 20-A and 21-A are inclined toward the pivot cam 33-A while parting from each other and move the path selectors 20 and 21, respectively, in contact with the pivot cam 33-A. The cam surfaces 20-A and 21-A thus inclined relative to the cam 33-A exert a minimum of force on the cam 33-A.
In summary, it will be seen that the present invention provides a sheet conveying device in which a switching mechanism shares a single drive source with a shifting mechanism to thereby obviate the need for solenoids. The conveying device is therefore small size and low cost. Further, the shifting operation and switching operation can be performed independently of each other by using the reversible rotation of the drive source. This not only reduces the size and cost of the device, but also realizes sure control over sheet conveyance, e.g., three-way sheet conveyance and shift.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof.
Number | Date | Country | Kind |
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2003-307580 | Aug 2003 | JP | national |
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