Stapling Apparatus, Image Forming Apparatus, Method of Stapling Sheet Bundle, and Non-Transitory Computer Readable Data Recording Medium Having Program Stored Thereon

Abstract

A stapling apparatus includes a sheet insertion portion that receives insertion of a sheet bundle, a stapler that staples the sheet bundle, a drive apparatus that drives the stapler, and a controller that controls the drive apparatus. The controller has the drive apparatus driven with first electric power when the drive apparatus operates in an on-line stapling mode in which the sheet bundle ejected from an image forming apparatus is stapled and has the drive apparatus driven with second electric power lower than maximum electric power that can be set as first electric power when the drive apparatus operates in a manual stapling mode in which the sheet bundle inserted through the sheet insertion portion is stapled.

Description

This application claims priority to Japanese Patent Application No. 2018-213861, which was filed on Nov. 14, 2018. The entire disclosure of Japanese Patent Application No. 2018-213861 is incorporated herein by reference.

BACKGROUND

Technological Field

The present disclosure relates to a stapling apparatus and more particularly to control of a stapling apparatus.

Description of the Related Art

A stapling apparatus (which is also called a finisher) built in or annexed to an image forming apparatus capable of printing a number of sheets may recently be used. For such a stapling apparatus, for the purpose of improving operability of a user, for example, a stapling apparatus capable of automatically stapling, by insertion into a slit in the apparatus by a user, a sheet bundle in making copies of stapled documents with staples being removed or a sheet bundle output without being stapled has been proposed.

A function of the stapling apparatus includes an on-line stapling process for stapling a sheet bundle ejected from an image forming apparatus and a manual stapling process in which a user inserts sheets through a sheet bundle insertion port for stapling of the sheets. The stapling apparatus generally includes a stapler in common, without including an individual stapler for each application.

In connection with a stapling apparatus, for example, Japanese Laid-Open Patent Publication No. 2016-16596 discloses a binding device that “includes a sheet-bundle forming unit configured to form a sheet bundle by receiving and stacking a plurality of sheets, a stapler that includes a DC motor and that is configured to execute a series of operations including inserting a wire into the sheet bundle by utilizing a driving force from the DC motor, and bending the wire, a power supply unit configured to adjust electric power and supply the adjusted electric power to the motor, a sensor configured to detect, based on a rotational amount of the motor, a timing to change supplied electric power to the DC motor after start of the operations, and a supply power controller configured to cause the power supply unit to change the electric power supplied to the motor at the timing of change detected by the sensor” (see [Abstract]).

SUMMARY

The technique disclosed in Japanese Laid-Open Patent Publication No. 2016-16596 does not take into account noise in a manual stapling process. Therefore, a technique allowing a quiet and stable manual stapling process is required.

To achieve at least one of the abovementioned objects, according to an aspect of the present invention, a stapling apparatus reflecting one aspect of the present invention comprises a sheet insertion portion that receives insertion of a sheet bundle, a stapler that staples the sheet bundle, a drive apparatus that drives the stapler, and a controller that controls the drive apparatus. The controller has the drive apparatus driven with first electric power when the drive apparatus operates in an on-line stapling mode in which the sheet bundle ejected from an image forming apparatus is stapled and has the drive apparatus driven with second electric power lower than maximum electric power that can be set as the first electric power, when the drive apparatus operates in a manual stapling mode in which the sheet bundle inserted through the sheet insertion portion is stapled.

To achieve at least one of the abovementioned objects, according to an aspect of the present invention, an image forming apparatus reflecting one aspect of the present invention comprises a mechanism of the stapling apparatus described above.

To achieve at least one of the abovementioned objects, according to another aspect of the present invention, a method of performing a stapling process reflecting another aspect of the present invention comprises performing a stapling process with first electric power in an on-line stapling mode in which a sheet bundle ejected from an image forming apparatus is stapled and performing the stapling process with second electric power lower than maximum electric power that can be set as the first electric power in a manual stapling mode in which the sheet bundle inserted by a user is stapled.

To achieve at least one of the abovementioned objects, according to yet another aspect of the present invention, a computer readable data recording medium reflecting yet another aspect of the present invention has a program to be executed by the computer stored thereon, and the program causes the computer to perform a stapling process with first electric power in an on-line stapling mode in which a sheet bundle ejected from an image forming apparatus is stapled and perform the stapling process with second electric power lower than maximum electric power that can be set as the first electric power in a manual stapling mode in which the sheet bundle inserted by a user is stapled.

BRIEF DESCRIPTION OF THE DRAWINGS

The advantages and features provided by one or more embodiments of the invention will become more fully understood from the detailed description given hereinbelow and the appended drawings which are given by way of illustration only, and thus are not intended as a definition of the limits of the present invention.

FIG. 1 is a diagram showing an exemplary construction of a stapling apparatus 100 according to the present embodiment.

FIG. 2 is a diagram showing an exemplary circuit configuration of stapling apparatus 100 according to the present embodiment.

FIG. 3 is a diagram showing exemplary arrangement of a stapler 102 in stapling apparatus 100 when viewed from above.

FIG. 4A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power (electric power for driving the stapler).

FIG. 4B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period.

FIG. 5A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power in manual stapling in stapling apparatus 100 according to the present embodiment.

FIG. 5B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period in manual stapling in stapling apparatus 100 according to the present embodiment.

FIG. 6 is a diagram showing exemplary relation between stapling electric power and the number of stapled sheets in stapling apparatus 100 according to the present embodiment.

FIG. 7 is a diagram showing an exemplary lateral cross-section of a sheet bundle insertion port 105 of stapling apparatus 100 according to the present embodiment.

FIG. 8A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power in stapling apparatus 100 according to the present embodiment.

FIG. 8B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period in stapling apparatus 100 according to the present embodiment.

FIG. 9 is a diagram showing exemplary electric power control based on a type of a medium in stapling apparatus 100 according to the present embodiment.

FIG. 10 is a diagram showing an exemplary detailed construction of stapler 102 according to the present embodiment.

FIG. 11 is a diagram showing another exemplary detailed construction of stapler 102 according to the present embodiment.

FIG. 12 is a diagram showing one example of a former part of detailed operations of stapler 102.

FIG. 13 is a diagram showing one example of a latter part of the detailed operations of stapler 102.

FIG. 14 is a diagram showing an exemplary construction of an internal mechanism of stapler 102.

FIG. 15 is a diagram showing an exemplary operation of the internal mechanism of stapler 102.

FIG. 16 is a diagram showing another exemplary operation of the internal mechanism of stapler 102.

FIG. 17 is a diagram showing one example before and after an operation to staple a thin sheet bundle by stapler 102 according to the present embodiment.

FIG. 18 is a diagram showing a first example of signal information received or transmitted by a CPU 201.

FIG. 19 is a diagram showing one example before and after an operation to staple a thick sheet bundle by stapler 102 according to the present embodiment.

FIG. 20 is a diagram showing a second example of signal information received or transmitted by CPU 201.

FIG. 21A is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thin sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100.

FIG. 21B is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thick sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100.

FIG. 22A is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thin sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100.

FIG. 22B is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thick sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100.

DETAILED DESCRIPTION OF EMBODIMENTS

Hereinafter, one or more embodiments of the present invention will be described with reference to the drawings. However, the scope of the invention is not limited to the disclosed embodiments.

An embodiment of a technical concept according to the present disclosure will be described below with reference to the drawings. In the description below, the same elements have the same reference characters allotted and their labels and functions are also identical. Therefore, detailed description thereof will not be repeated.

First Embodiment

FIG. 1 is a diagram showing an exemplary construction of a stapling apparatus 100 according to the present embodiment. An apparatus construction of stapling apparatus 100 according to the present embodiment will be described with reference to FIG. 1. Stapling apparatus 100 includes a stapler 102, an ejection tray 103, an insertion sensing unit 104, and a sheet bundle insertion port 105. In one aspect, stapling apparatus 100 may be annexed to an image forming apparatus 101 and may staple a sheet bundle ejected from image forming apparatus 101 and eject the stapled sheet bundle to ejection tray 103. In another aspect, stapling apparatus 100 may be contained in image forming apparatus 101.

Stapler 102 staples a sheet bundle. The sheet bundle sent from image forming apparatus 101 to stapling apparatus 100 is stapled by stapler 102 and ejected to ejection tray 103. Sheet bundle insertion port 105 is used for a user to insert a sheet bundle when the user performs manual stapling. Insertion sensing unit 104 senses the sheet bundle inserted through sheet bundle insertion port 105.

FIG. 2 is a diagram showing an exemplary circuit configuration of stapling apparatus 100 according to the present embodiment. A circuit configuration of stapling apparatus 100 according to the present embodiment will be described with reference to FIG. 2. Stapling apparatus 100 includes a central processing unit (CPU) 201, an insertion sensing circuit 202, a motor driver 203, a current measurement circuit 204, and a medium detector 205. In one aspect, image forming apparatus 101 may include a CPU 206 and a medium detector 207.

CPU 201 controls stapling apparatus 100 as a whole. CPU 201 may communicate data with CPU 206 of image forming apparatus 101. In one aspect, CPU 206 may execute a program for performing a process for stapling a sheet bundle which will be described in an embodiment hereafter. Insertion sensing circuit 202 converts a thickness of a sheet bundle inserted through sheet bundle insertion port 105 into a voltage, a current, or a signal and sends the voltage, the current, or the signal to CPU 201. In one aspect, a potentiometer or a photosensor is employed as insertion sensing unit 104 and an output from insertion sensing circuit 202 is varied by an operation of insertion sensing unit 104.

Motor driver 203 drives stapler 102 based on a signal from CPU 201. In one aspect, a dedicated integrated circuit (IC) or an H bridge circuit is employed as motor driver 203.

Current measurement circuit 204 measures an amount of current used for driving stapler 102. In one aspect, a circuit including a dedicated IC or an operational amplifier is employed as current measurement circuit 204. In another aspect, motor driver 203 may contain current measurement circuit 204.

Medium detector 205 detects a type of a sheet bundle to be stapled by stapler 102. In one aspect, a reflective sensor is employed as medium detector 205. Image forming apparatus 101 may individually include medium detector 207.

FIG. 3 is a diagram showing exemplary arrangement of stapler 102 in stapling apparatus 100 when viewed from above. Arrangement of stapler 102 according to the present embodiment will be described with reference to FIG. 3. When stapling apparatus 100 is viewed from above, ejection tray 103 is arranged in the center of stapling apparatus 100 and sheet bundle insertion port 105 is arranged in a side surface of stapling apparatus 100. Stapler 102 moves to an appropriate position along a rail 302 for movement, depending on an on-line stapling process and a manual stapling process.

FIG. 4A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power (electric power for driving the stapler). FIG. 4B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period. An operation of a conventional stapling apparatus will be described with reference to FIGS. 4A and 4B.

In FIG. 4A, stapling electric power in an example where the number of stapled sheets is not greater than ten is 70%. Similarly, stapling electric power in an example where the number of stapled sheets is from ten to fifty is 80%. Stapling electric power in an example where the number of stapled sheets is from fifty to one hundred is 100%. Any stapling electric power is set to sufficiently be higher than a stapling electric power lower limit 401A.

Stapling electric power lower limit 401A is defined as minimum electric power necessary for stapling by stapler 102 and determined by the number of sheets in a sheet bundle and a type of the sheet bundle as well as a minimum necessary amount of electric power for operating a mechanism of stapler 102 for punching, cutting, and bending of a staple.

It can be seen in FIG. 4B that a stapling time period in the example where the number of stapled sheets is not greater than ten gradually increases with increase in number of stapled sheets. It is seen in FIG. 4A that stapling electric power at this time is 70%. It can be seen that a stapling time period in the example where the number of stapled sheets is from ten to fifty once decreases owing to increase in stapling electric power and thereafter gradually increases with increase in number of stapled sheets. It is seen in FIG. 4A that stapling electric power at this time is 80%. Similarly, it can be seen that a stapling time period in the example where the number of stapled sheets is from fifty to one hundred once decreases owing to increase in stapling electric power and thereafter gradually increases with increase in number of stapled sheets. It is seen in FIG. 4A that stapling electric power at this time is 100%.

Any stapling time period is set to be shorter than a stapling time period upper limit 401B. Stapling time period upper limit 401B indicates a productivity limit and an assumed value of a stapling time period below which the stapling time period should be set for maintaining productivity of a system. In other words, stapling time period upper limit 401B is set in advance, and stapling electric power is determined such that stapling is completed by the time of lapse of set stapling time period upper limit 401B.

As is clear from the description above, in a normal on-line stapling process, stapling should be completed within a prescribed time period in order to maintain productivity of the entire system, and normally, maximum electric power defined by the maximum number of stapled sheets or electric power sufficient for a stapling operation is supplied. Therefore, though stapling is completed in a short period of time, operating noise or vibration caused by reaction tends to be high.

In a manual stapling process, when a user inserts a sheet bundle through the sheet bundle insertion port, stapling apparatus 100 senses the sheet bundle and thereafter automatically starts a stapling operation. Therefore, the user feels that the stapling operation has suddenly started and may be surprised at or feel uneasy by loud noise or kickback to hands by clamping of the bundle. Holding of the sheet bundle by the user may become unstable due to the kickback and the stapling process may not normally be performed. For reasons above, stapling apparatus 100 according to the present embodiment performs a stable stapling process with lower noise and without giving the user a feeling of uneasiness in the manual stapling process.

FIG. 5A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power in manual stapling in stapling apparatus 100 according to the present embodiment. FIG. 5B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period in manual stapling in stapling apparatus 100 according to the present embodiment. An operation of stapling apparatus 100 according to the present embodiment will be described with reference to FIGS. 5A and 5B.

Referring to FIG. 5A, stapling apparatus 100 supplies stapler 102 with electric power different from electric power in the on-line stapling process in FIG. 4A as manual stapling electric power when the number of stapled sheets is within a range from two to fifty sheets. In one aspect, in consideration of safety, a thickness of an insertable sheet bundle may be restricted to some extent as compared with the maximum number of stapled sheets in the on-line stapling process (a sheet bundle having a thickness equal to or greater than a thickness corresponding to fifty sheets not being insertable).

It can be seen in FIG. 5A that stapling electric power 501A is lower than the stapling electric power in FIG. 4A and set to a value close to a stapling electric power lower limit 502A. It can be seen in FIG. 5B that a stapling time period 501B is longer than the stapling time period in FIG. 4B and longer than a stapling time period upper limit 502B.

In the manual stapling process, unlike the on-line stapling process, stapling apparatus 100 does not necessarily have to complete stapling by the time of lapse of the stapling time period upper limit, because a user does not insert a sheet bundle into stapling apparatus 100 as fast as image forming apparatus 101, and stapling at a high speed may cause noise and vibrations and make the user feel uneasy to the contrary. Electric power supplied to stapler 102 should only be higher than a stapling electric power lower limit for an assumed largest-thickness sheet bundle. When a slit width of sheet bundle insertion port 105 is restricted not to accept insertion of a sheet bundle having a thickness equal to or greater than a thickness corresponding to fifty sheets, the “largest-thickness sheet bundle” is set to contain “fifty sheets.” In one aspect, stapling apparatus 100 may fix stapling electric power in performing the manual stapling process in accordance with the process for stapling the “largest-thickness sheet bundle” assumed in the manual stapling process and set stapling electric power to be lower than stapling electric power in stapling a bundle of the same number of sheets in the on-line stapling process.

As shown in FIGS. 5A and 5B, in performing the manual stapling process, stapling apparatus 100 expressly performs the stapling process with stapling electric power being suppressed and with a time period longer than the stapling time period upper limit being spent. In one aspect, stapling apparatus 100 may set a stapling time period in the manual stapling process to be longer than a stapling time period in stapling a bundle of the same number of sheets in the on-line stapling process. Then, stapling apparatus 100 can lower noise or kickback caused by stapling and prevent the user from feeling uneasy.

FIG. 6 is a diagram showing another exemplary relation between stapling electric power and the number of stapled sheets in stapling apparatus 100 according to the present embodiment. Stapling electric power in the manual stapling process does not necessarily have to be lower than minimum electric power in the on-line stapling process but may be set within a range allowing quietness and low vibration such as a range in which noise is lower than a certain volume while an appropriate operation margin is secured. Stapling apparatus 100 may set an operation margin of stapling electric power in the manual stapling process in accordance with the stapling electric power lower limit for the maximum number of sheets insertable in manual stapling.

FIG. 7 is a diagram showing an exemplary lateral cross-section of sheet bundle insertion port 105 of stapling apparatus 100 according to the present embodiment. Control of electric power by using insertion sensing unit 104 will be described with reference to FIG. 7. In performing the on-line stapling process, stapling apparatus 100 can obtain information on the number of sheets in a sheet bundle and a type of the sheet from a counting function of image forming apparatus 101 or stapling apparatus 100, so that CPU 201 can determine appropriate stapling electric power.

In performing the manual stapling process, on the other hand, stapling apparatus 100 is unable to obtain the number of sheets in a sheet bundle and a type of the sheet, because a user inserts a sheet bundle which the user is directly holding in his/her hand into sheet bundle insertion port 105 in the manual stapling process and hence stapling apparatus 100 is unable to count the number of sheets or detect a type of a medium.

Therefore, stapling apparatus 100 according to the present embodiment is provided with insertion sensing unit 104 along a sheet bundle insertion path of sheet bundle insertion port 105. Insertion sensing unit 104 senses insertion of a sheet bundle through sheet bundle insertion port 105 and measures a thickness of the inserted sheet bundle. Stapling apparatus 100 determines electric power to be supplied in the manual stapling process based on a result of sensing by insertion sensing unit 104. At this time, stapling apparatus 100 may set stapling electric power in the manual stapling process to be lower than stapling electric power in stapling a bundle of the same number of sheets in the on-line stapling process. In one aspect, insertion sensing unit 104 may detect whether or not a thickness of a sheet bundle exceeds a prescribed thickness by using a variable resistor, a load cell, an encoder, a photosensor, and a switch. In another aspect, insertion sensing unit 104 may measure a thickness of a sheet bundle by using such an optical sensor as a transmissive photosensor or a range sensor.

FIG. 8A is a diagram showing exemplary correlation between the number of stapled sheets and stapling electric power in stapling apparatus 100 according to the present embodiment. In FIG. 8A, CPU 201 varies on-line stapling electric power 801A and manual stapling electric power 802A based on a result of detection by insertion sensing unit 104.

FIG. 8B is a diagram showing exemplary correlation between the number of stapled sheets and a stapling time period in stapling apparatus 100 according to the present embodiment. In FIG. 8B, though an on-line stapling time period 801B is always shorter than a stapling time period upper limit 803B, a manual stapling time period 802B is significantly longer than stapling time period upper limit 803B.

Manual stapling electric power 802A should only be higher than stapling electric power lower limit 803A as described previously, without stapling time period upper limit 803B being taken into account. Therefore, CPU 201 can suppress noise and kickback in the manual stapling process by expressly lowering manual stapling electric power 802A to a value around stapling electric power lower limit 803A.

FIG. 9 is a diagram showing exemplary electric power control based on a type of a medium in stapling apparatus 100 according to the present embodiment. Stapling apparatus 100 identifies a type of a sheet inserted through sheet bundle insertion port 105 by providing medium detector 205 along the sheet bundle insertion path of sheet bundle insertion port 105. A sheet composition A is a bundle of thin sheets. A sheet composition B is a bundle of thick sheets. A stapling electric power lower limit 902 for sheet composition A which is the bundle of thin sheets is lower than a stapling electric power lower limit 904 for sheet composition B which is the bundle of thick sheets.

When CPU 201 identifies the composition of the inserted sheet bundle (a thickness and a type of the sheet) as sheet composition A by means of insertion sensing unit 104 and medium detector 205, it sets electric power to supply stapler 102 with manual stapling electric power 901 with a prescribed safety margin as compared with stapling electric power lower limit 902 for sheet composition A.

When CPU 201 identifies the composition of the inserted sheet bundle as sheet composition B by means of insertion sensing unit 104 and medium detector 205, it sets electric power to supply stapler 102 with manual stapling electric power 903 with a prescribed safety margin as compared with stapling electric power lower limit 904 for sheet composition B. Thus, CPU 201 can set electric power for supplying electric power appropriate for the manual stapling process to stapler 102 based on the thickness of the sheet bundle and the type of the sheet. Alternatively, CPU 201 may receive the number of sheets or a type of a medium input by a user through an operation panel of image forming apparatus 101 from CPU 206 of image forming apparatus 101 and may use the number of sheets or the type of the medium for setting manual stapling electric power. Alternatively, CPU 201 may receive information on a type of a sheet detected by medium detector 207 from CPU 206 of image forming apparatus 101 and may use the information for setting manual stapling electric power. Alternatively, CPU 201 may set an operation margin of stapling electric power in the manual stapling process based on combination of the stapling electric power lower limit for the maximum number of sheets insertable in manual stapling and information on the type of the sheet.

CPU 201 may selectively use the number of sheets obtained from CPU 206 of image forming apparatus 101 and a result of measurement by insertion sensing unit 104. In one aspect, when CPU 201 receives the number of sheets from CPU 206 of image forming apparatus 101, it may set manual stapling electric power based on the received number of sheets, and when CPU 201 does not receive the number of sheets from CPU 206 of image forming apparatus 101, it may set manual stapling electric power based on a result of measurement by insertion sensing unit 104.

As described above in detail, stapling apparatus 100 according to the present embodiment can perform a stable stapling process with low noise and without giving a user a feeling of uneasiness in the manual stapling process. By detecting a thickness and a type of a sheet bundle, electric power to be supplied to stapler 102 can appropriately be set.

Second Embodiment

A second embodiment will be described below. A hardware configuration the same as in stapling apparatus 100 according to the first embodiment has the same reference character allotted and description thereof will not be repeated.

FIG. 10 is a diagram showing one exemplary detailed construction of stapler 102 according to the present embodiment. Referring to FIG. 10, stapler 102 includes an anvil 1001, a clincher 1002, a one-turn cam 1003, a cam home position sensor 1004, a staple sheet cartridge 1005, a driver 1006, a wedge mechanism 1007, and a wedge home position sensor 1008.

Anvil 1001 is a mechanism for clamping to a main body of stapler 102, a sheet bundle inserted through sheet bundle insertion port 105. Clincher 1002 is provided in anvil 1001 and bends a staple of a stapler punched into the sheet bundle. By rotating, one-turn cam 1003 can operate various mechanisms of stapler 102 in coordination. Cam home position sensor 1004 detects whether or not the one-turn cam is located at a home position. In one aspect, a photointerrupter may be employed as cam home position sensor 1004.

Staple sheet cartridge 1005 contains a staple sheet and the staple sheet is pushed out in a direction where driver 1006 is located by rotation of one-turn cam 1003. Driver 1006 bends a staple at the top position in the pushed-out staple sheet into a bracket shape and pushes out the bent staple toward the sheet bundle.

When anvil 1001 presses a sheet with force stronger than a certain level, wedge mechanism 1007 is unlocked and slides. Wedge home position sensor 1008 senses slide of wedge mechanism 1007. In one aspect, a photoreflector may be employed as wedge home position sensor 1008.

FIG. 11 is a diagram showing another exemplary detailed construction of stapler 102 according to the present embodiment. Referring to FIG. 11, stapler 102 includes a clamp sensing mechanism 1101. Clamp sensing mechanism 1101 senses clamping of a sheet bundle by anvil 1001. Clamp sensing mechanism 1101 can be used in place of wedge home position sensor 1008 in FIG. 10. Though the embodiment will be described hereafter with reference to the construction in FIG. 10, the embodiment can be implemented similarly also in FIG. 11.

FIG. 12 is a diagram showing one example of a former part of detailed operations of stapler 102. FIG. 13 is a diagram showing one example of a latter part of the detailed operations of stapler 102. A series of procedures for stapler 102 to staple a sheet bundle will be described with reference to FIGS. 12 and 13.

Initially, in an operation procedure 12A, one-turn cam 1003 starts rotation so that anvil 1001 starts to lower. At the time point of movement of one-turn cam 1003 from the home position, cam home position sensor 1004 senses start of movement of one-turn cam 1003.

Then, in an operation procedure 12B, one-turn cam 1003 further rotates so that anvil 1001 comes in contact with a sheet bundle. Then, in an operation procedure 12C, while anvil 1001 is in contact with the sheet bundle, one-turn cam 1003 further rotates so that wedge mechanism 1007 is unlocked and starts to slide. Wedge home position sensor 1008 senses a slide operation of wedge mechanism 1007 at this time point.

Then, in an operation procedure 12D, one-turn cam 1003 further rotates so that driver 1006 bends a staple at the top position in a fed staple sheet into a bracket shape and lifts the staple toward the sheet bundle. Then, in an operation procedure 12E, one-turn cam 1003 further rotates so that driver 1006 punches the staple bent in the bracket shape into the sheet bundle and presses the punched staple toward the sheet bundle.

Then, in an operation procedure 12F, one-turn cam 1003 further rotates so that clincher 1002 bends a tip end of the staple pressed by driver 1006 from an opposite side by pressing. Then, in an operation procedure 12G, one-turn cam 1003 further rotates so that clincher 1002 and driver 1006 move away from the sheet bundle.

Then, in an operation procedure 12H, one-turn cam 1003 further rotates and returns to the home position so that anvil 1001 moves away from the sheet bundle and simultaneously wedge mechanism 1007 also returns to the home position. Driver 1006 also returns to the original position and the staple sheet in staple sheet cartridge 1005 is pushed out for a next stapling process. Cam home position sensor 1004 senses return of one-turn cam 1003 to the home position. Wedge home position sensor 1008 also senses return of wedge mechanism 1007 to the home position.

FIG. 14 is a diagram showing an exemplary construction of an internal mechanism of stapler 102. Referring to FIG. 14, stapler 102 includes a link drive cam 1401, an anvil lift link 1402, an anvil lift pin 1403, a wedge stopper locking mechanism 1404, and a wedge stopper 1405.

Link drive cam 1401 rotates with rotation of one-turn cam 1003. Anvil lift link 1402 is connected to link drive cam 1401 and operates around a fulcrum X with rotation of one-turn cam 1003. Anvil lift link 1402 vertically moves anvil 1001 by coming in contact with anvil lift pin 1403.

Wedge stopper locking mechanism 1404 locks wedge stopper 1405 provided coaxially with a rotation shaft of the anvil. When anvil lift link 1402 and anvil lift pin 1403 move away from each other by at least a certain distance, wedge stopper locking mechanism 1404 unlocks wedge stopper 1405. Wedge stopper 1405 presses and locks wedge mechanism 1007. When locking of wedge stopper 1405 by wedge stopper locking mechanism 1404 is released, wedge stopper 1405 unlocks wedge mechanism 1007.

FIG. 15 is a diagram showing an exemplary operation of the internal mechanism of stapler 102. A series of operations of the internal mechanism in the process for stapling a thin sheet bundle by stapler 102 will be described with reference to FIG. 15. In an operation procedure 15A, stapler 102 is resting and one-turn cam 1003 is also located at the home position. It is assumed that a thin sheet bundle is inserted through sheet bundle insertion port 105 in this state.

In an operation procedure 15B, one-turn cam 1003 starts rotation so that link drive cam 1401 also starts rotation. Anvil lift link 1402 is driven with rotation of link drive cam 1401 and a position of contact with anvil lift pin 1403 is varied. Anvil 1001 is thus lowered.

In an operation procedure 15C, one-turn cam 1003 further rotates so that a position of contact between anvil lift link 1402 and anvil lift pin 1403 is varied and anvil 1001 comes in contact with the thin sheet bundle.

In an operation procedure 15D, one-turn cam 1003 further rotates while anvil 1001 is in contact with the thin sheet bundle and immobile so that a gap is produced between anvil lift link 1402 and anvil lift pin 1403. Wedge stopper locking mechanism 1404 thus unlocks wedge stopper 1405. With this unlocking acting as a trigger, wedge stopper 1405 unlocks wedge mechanism 1007. As wedge mechanism 1007 is unlocked, it slides.

FIG. 16 is a diagram showing another exemplary operation of the internal mechanism of stapler 102. A series of operations of the internal mechanism in stapling of a thick sheet bundle by stapler 102 will be described with reference to FIG. 16. In an operation procedure 16A, stapler 102 is resting and one-turn cam 1003 is also located at the home position. It is assumed that a thick sheet bundle is inserted through sheet bundle insertion port 105 in this state.

In an operation procedure 16B, one-turn cam 1003 starts rotation so that link drive cam 1401 also starts rotation. Anvil lift link 1402 is driven with rotation of link drive cam 1401 and a position of contact with anvil lift pin 1403 is varied. Anvil 1001 is thus lowered. Anvil 1001 comes in contact with the thick sheet bundle at this time point.

In an operation procedure 16C, anvil 1001 has already been in contact with the thick sheet bundle and immobile. Therefore, when one-turn cam 1003 further rotates, a gap is produced between anvil lift link 1402 and anvil lift pin 1403. Wedge stopper locking mechanism 1404 thus unlocks wedge stopper 1405. With this unlocking acting as a trigger, wedge stopper 1405 unlocks wedge mechanism 1007. As wedge mechanism 1007 is unlocked, it slides. In an operation procedure 16D, wedge mechanism 1007 is in a slid state until one-turn cam 1003 further rotates and returns to the home position.

It can be seen based on comparison between FIGS. 15 and 16 that wedge mechanism 1007 slides at different timing depending on a thickness of a sheet bundle. CPU 201 obtains time of start of rotation of one-turn cam 1003 by means of cam home position sensor 1004 and obtains time of slide of the wedge mechanism by means of wedge home position sensor 1008. CPU 201 can then estimate a thickness of a sheet bundle based on a difference between the time of start of rotation of one-turn cam 1003 and the time of slide of the wedge mechanism.

FIG. 17 is a diagram showing one example before and after an operation to staple a thin sheet bundle by stapler 102 according to the present embodiment. In the example in FIG. 17, stapler 102 is arranged downstream from insertion sensing unit 104.

A state 17A represents a state that one-turn cam 1003 of stapler 102 is located at the home position. In contrast, a state 17B represents a state that one-turn cam 1003 of stapler 102 has rotated, anvil 1001 has clamped a sheet bundle, and wedge mechanism 1007 also has slid. State 17B can be concluded to represent a state that stapler 102 is ready to staple the sheet bundle. Signal information obtained by CPU 201 in each state will now be described.

FIG. 18 is a diagram showing a first example of signal information received or transmitted by CPU 201. A wedge home position signal indicates whether or not wedge mechanism 1007 is located at the home position. The example in FIG. 18 means that wedge mechanism 1007 is located at the home position when the wedge home position signal is “High” and wedge mechanism 1007 is not located at the home position when the wedge home position signal is “Low”. CPU 201 receives the wedge home position signal from wedge home position sensor 1008.

A home position signal indicates whether or not one-turn cam 1003 is located at the home position. The example in FIG. 18 means that one-turn cam 1003 is located at the home position when the home position signal is “High” and one-turn cam 1003 is not located at the home position when the home position signal is “Low”. CPU 201 receives the home position signal from cam home position sensor 1004.

A thickness sensing output signal indicates a thickness of a sheet bundle inserted through sheet bundle insertion port 105. It can be seen in the example in FIG. 18 that the thickness sensing output signal does not initially react and thereafter greatly reacts, and slightly thereafter a level of the signal is lowered (details of which will be described later). CPU 201 receives the thickness sensing output signal from insertion sensing unit 104.

Stapling electric power refers to electric power supplied to a drive apparatus (not shown) of stapler 102. CPU 201 transmits to motor driver 203, a signal or a pulse indicating a level to be supplied to the drive apparatus of stapler 102. Motor driver 203 supplies electric power to the drive apparatus of stapler 102 in accordance with an instruction from CPU 201.

A position 17A points to various signals in state 17A in FIG. 17. Since wedge mechanism 1007 is located at the home position at this time point, the wedge home position signal is “High”. Since one-turn cam 1003 is also located at the home position, the home position signal is also “High”. Since a sheet bundle has been inserted in stapler 102 and insertion sensing unit 104 has been turned as being lifted by the sheet bundle, a level of the thickness sensing output signal is high. Since the level of the thickness sensing output signal has become higher, CPU 201 has raised a signal level for driving stapler 102.

A position 17B points to various signals in state 17B in FIG. 17. Since wedge mechanism 1007 has slid and is displaced from the home position at this time point, the wedge home position signal is switched to “Low”. Since one-turn cam 1003 has also rotated, it has been displaced from the home position and the home position signal is also “Low”. A level of the thickness sensing output signal is slightly lower than the level at position 17A. This is because gaps between sheets in the sheet bundle are collapsed by pressing of the sheet bundle by anvil 1001 at a pressure equal to or higher than a certain level.

When CPU 201 recognizes the wedge home position signal being “Low”, the home position signal being maintained at “Low”, and lowering in level of the thickness sensing output signal, it determines that stapling is ready. Then, CPU 201 increases electric power supplied to a drive unit of stapler 102. CPU 201 estimates a thickness of the sheet bundle by counting a time period 1801 for transition from position 17A to position 17B. CPU 201 then adjusts electric power to be supplied to the drive apparatus of stapler 102 based on the estimated thickness. CPU 201 adjusts electric power as in FIGS. 5A, 5B, 8A, 8B, and 9 in the first embodiment.

FIG. 19 is a diagram showing one example before and after an operation to staple a thick sheet bundle by stapler 102 according to the present embodiment. In the example in FIG. 19, stapler 102 is arranged downstream from insertion sensing unit 104.

A state 19A represents a state that one-turn cam 1003 of stapler 102 is located at the home position. In contrast, a state 19B represents a state that one-turn cam 1003 of stapler 102 has rotated, anvil 1001 has clamped a sheet bundle, and wedge mechanism 1007 also has slid. State 19B can be concluded to represent a state that stapler 102 is ready to staple the sheet bundle. Signal information obtained by CPU 201 in each state will now be described.

FIG. 20 is a diagram showing a second example of a signal received or transmitted by CPU 201. Since the meaning of each signal is the same as in FIG. 18, description of the signal will not be repeated. A position 19A points to various signals in state 19A in FIG. 19. A position 19B points to various signals in state 19B in FIG. 19. As in FIG. 18, CPU 201 estimates a thickness of a sheet bundle by counting a time period 2001 for transition from position 19A to position 19B. It can be seen that time period 2001 is shorter than time period 1801 in FIG. 18. This is because, when anvil 1001 clamps a thick sheet bundle, wedge mechanism 1007 immediately starts sliding.

In the example in FIG. 20, CPU 201 sets electric power higher than in FIG. 18 to be supplied to the drive apparatus of stapler 102. In the present embodiment, CPU 201 may use information from medium detector 205 in setting electric power to be supplied to the drive apparatus of stapler 102.

As described above in detail, stapling apparatus 100 according to the present embodiment can more appropriately set electric power to be supplied to the stapler by firmly fixing a sheet bundle inserted through sheet bundle insertion port 105 and accurately measuring a thickness of the sheet bundle.

Third Embodiment

A third embodiment will be described below. Since a hardware configuration is in common to the embodiment described previously, description of hardware will not be repeated.

FIG. 21A is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thin sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100. FIG. 21B is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thick sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100. In the example in FIGS. 21A and 21B, CPU 201 sets electric power to be supplied to the drive apparatus of stapler 102 without using a signal from insertion sensing unit 104.

Each of positions 2101A and 2101B points to signals when one-turn cam 1003 of stapler 102 is located at the home position. Each of positions 2102A and 2102B points to a state that one-turn cam 1003 of stapler 102 has rotated, anvil 1001 has clamped a sheet bundle, and wedge mechanism 1007 has also slid.

A time period 2103A represents a time period for transition from position 2101A to position 2102A and a time period 2103B represents a time period for transition from position 2101B to position 2102B. Time period 2103A in an example of insertion of a thin sheet bundle is longer than time period 2103B in an example of insertion of a thick sheet bundle, and CPU 201 can appropriately set electric power to be supplied to the drive apparatus of stapler 102 by checking the time period.

Fourth Embodiment

A fourth embodiment will be described below. Since a hardware configuration is in common to the embodiment described previously, description of hardware will not be repeated.

FIG. 22A is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thin sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100. FIG. 22B is a diagram showing an exemplary signal received or transmitted by CPU 201 when a thick sheet bundle is inserted through sheet bundle insertion port 105 into stapling apparatus 100. In the example in FIGS. 22A and 22B, CPU 201 sets electric power to be supplied to the drive apparatus of stapler 102 based on an output signal from current measurement circuit 204 without using a signal from insertion sensing unit 104 and a wedge home position signal.

When wedge mechanism 1007 slides, anvil 1001 has clamped a sheet bundle at a certain pressure. Therefore, load applied to the drive apparatus is high and electric power supplied to the drive apparatus increases. Therefore, CPU 201 performs processing as in FIGS. 20, 21A, and 21B by measuring a time period for transition from a state that the output signal from current measurement circuit 204 is low to a state that the output signal is high.

Each of positions 2201A and 2201B points to signals when one-turn cam 1003 of stapler 102 is located at the home position. Each of positions 2202A and 2202B represents a state that one-turn cam 1003 of stapler 102 has rotated, anvil 1001 has clamped a sheet bundle, and wedge mechanism 1007 has also slid.

A time period 2203A represents a time period for transition from position 2201A to position 2202A and a time period 2203B represents a time period for transition from position 2201B to position 2202B. Time period 2203A in an example of insertion of a thin sheet bundle is longer than time period 2203B in an example of insertion of a thick sheet bundle and CPU 201 can appropriately set electric power to be supplied to the drive apparatus of stapler 102 by checking the time period.

Although embodiments of the present invention have been described and illustrated in detail, the disclosed embodiments are made for the purposes of illustration and example only and not limitation. The scope of the present invention should be interpreted by terms of the appended claims.

Claims

1. A stapling apparatus comprising: a sheet insertion portion that receives insertion of a sheet bundle;a stapler that staples the sheet bundle;a drive apparatus that drives the stapler; anda controller that controls the drive apparatus,the controller having the drive apparatus driven with first electric power when the drive apparatus operates in an on-line stapling mode in which the sheet bundle ejected from an image forming apparatus is stapled,the controller having the drive apparatus driven with second electric power lower than maximum electric power that can be set as the first electric power, when the drive apparatus operates in a manual stapling mode in which the sheet bundle inserted through the sheet insertion portion is stapled.

2. The stapling apparatus according to claim 1, wherein minimum electric power that should be supplied to the stapler for stapling the sheet bundle having a thickness A is defined as electric power X, andthe first electric power and the second electric power in stapling of the sheet bundle having the thickness A are each higher than the electric power X by predetermined electric power.

3. The stapling apparatus according to claim 1, wherein the controller sets the second electric power to lower noise in the stapler in stapling of the sheet bundle to a volume not higher than a predetermined volume.

4. The stapling apparatus according to claim 1, wherein the second electric power is constant in the manual stapling mode regardless of the number of sheets in the sheet bundle inserted through the sheet insertion portion.

5. The stapling apparatus according to claim 1, wherein a maximum number of sheets in the sheet bundle that can be inserted through the sheet insertion portion is smaller than a maximum number of stapled sheets in the on-line stapling mode.

6. The stapling apparatus according to claim 5, wherein minimum electric power that should be supplied to the stapler for stapling the maximum number of sheets in the sheet bundle that can be inserted through the sheet insertion portion is defined as electric power Y, andthe second electric power is higher than the electric power Y by predetermined electric power.

7. The stapling apparatus according to claim 6, wherein the electric power Y is different for each type of the sheet bundle inserted through the sheet insertion portion.

8. The stapling apparatus according to claim 1, wherein a largest thickness of a sheet bundle that can be stapled in the manual stapling mode is defined as a thickness A, andthe controller sets the second electric power in stapling of the sheet bundle having the thickness A to be lower than the first electric power in stapling of the sheet bundle having the thickness A.

9. The stapling apparatus according to claim 1, further comprising a thickness sensing unit that senses a thickness of the sheet bundle inserted through the sheet insertion portion, wherein the controller sets the second electric power based on the thickness of the sheet bundle sensed by the thickness sensing unit, andthe second electric power is lower than the first electric power supplied to the drive apparatus in stapling of the sheet bundle having the sensed thickness in the on-line stapling mode.

10. The stapling apparatus according to claim 9, further comprising a medium type information identification unit that identifies a type of the sheet bundle inserted through the sheet insertion portion, wherein the controller sets the second electric power based on the sensed thickness of the sheet bundle and a result of identification by the medium type information identification unit.

11. The stapling apparatus according to claim 10, further comprising a sheet count information obtaining unit that obtains sheet count input information from the image forming apparatus, wherein the controller sets the second electric power based on the sheet count input information when the controller obtains the sheet count input information from the sheet count information obtaining unit, andthe controller sets the second electric power based on the sensed thickness of the sheet bundle when the controller does not obtain the sheet count input information from the sheet count information obtaining unit.

12. The stapling apparatus according to claim 1, further comprising: a clamping mechanism that clamps the sheet bundle inserted through the sheet insertion portion, the clamping mechanism being provided in the stapler;a reference position sensor that detects whether the clamping mechanism is located at a reference position; anda clamp sensing unit that reacts when the clamping mechanism clamps the sheet bundle at a certain pressure, whereinthe controller obtains, by the reference position sensor, first time when the clamping mechanism starts to move from the reference position,the controller obtains, by the clamp sensing unit, second time when the clamping mechanism clamps the sheet bundle at the certain pressure, andthe controller estimates a thickness of the sheet bundle based on a difference between the first time and the second time.

13. The stapling apparatus according to claim 1, further comprising: a clamping mechanism that clamps the sheet bundle inserted through the sheet insertion portion, the clamping mechanism being provided in the stapler;a reference position sensor that detects whether the clamping mechanism is located at a reference position; anda pressure sensing unit provided in a surface of the clamping mechanism where the sheet bundle is clamped, the pressure sensing unit reacting when a pressure not lower than a certain pressure is applied to the surface of the clamping mechanism where the sheet bundle is clamped, whereinthe controller obtains, by the reference position sensor, first time when the clamping mechanism starts to move from the reference position,the controller obtains, by the pressure sensing unit, second time when the pressure not lower than the certain pressure is applied to the surface of the clamping mechanism where the sheet bundle is clamped, andthe controller estimates a thickness of the sheet bundle based on a difference between the first time and the second time.

14. The stapling apparatus according to claim 1, further comprising: a clamping mechanism that clamps the sheet bundle inserted through the sheet insertion portion, the clamping mechanism being provided in the stapler;a reference position sensor that detects whether the clamping mechanism is located at a reference position; andan electric power measurement unit that measures an amount of electric power supplied to the drive apparatus, whereinthe controller obtains, by the reference position sensor, first time when the clamping mechanism starts to move from the reference position,the controller obtains, by the electric power measurement unit, second time of sensing of supply of electric power not smaller than a predetermined amount of electric power to the drive apparatus, andthe controller estimates a thickness of the sheet bundle based on a difference between the first time and the second time.

15. The stapling apparatus according to claim 1, wherein a time period for stapling the sheet bundle having a thickness A in the manual stapling mode is defined as a time period X,a time period for stapling the sheet bundle having the thickness A in the on-line stapling mode is defined as a time period Y, andthe controller sets the second electric power to set the time period X to be longer than the time period Y.

16. An image forming apparatus comprising the stapling apparatus according to claim 1.

17. A method of stapling a sheet bundle comprising: performing a stapling process with first electric power in an on-line stapling mode in which a sheet bundle ejected from an image forming apparatus is stapled; andperforming the stapling process with second electric power lower than maximum electric power that can be set as the first electric power in a manual stapling mode in which the sheet bundle inserted by a user is stapled.

18. The method according to claim 17, wherein minimum electric power necessary for stapling the sheet bundle having a thickness A is defined as electric power X, andthe first electric power and the second electric power in stapling of the sheet bundle having the thickness A are each higher than the electric power X by predetermined electric power.

19. The method according to claim 17, further comprising setting the second electric power to lower noise in stapling of the sheet bundle to a volume not higher than a predetermined volume.

20. The method according to claim 17, wherein the second electric power is constant in the manual stapling mode.

21. The method according to claim 17, wherein a maximum number of sheets in the sheet bundle that can be inserted in the manual stapling mode is smaller than a maximum number of stapled sheets in the on-line stapling mode.

22. The method according to claim 21, wherein minimum electric power necessary for stapling the maximum number of sheets in the sheet bundle that can be inserted in the manual stapling mode is defined as electric power Y, andthe second electric power is higher than the electric power Y by predetermined electric power.

23. The method according to claim 22, wherein the electric power Y is different for each type of the sheet bundle.

24. The method according to claim 17, wherein a largest thickness of a sheet bundle that can be stapled in the manual stapling mode is defined as a thickness A, andthe method further comprises setting the second electric power in stapling of the sheet bundle having the thickness A to be lower than the first electric power in stapling of the sheet bundle having the thickness A.

25. The method according to claim 17, further comprising: sensing a thickness of an inserted sheet bundle; andsetting the second electric power based on the sensed thickness of the sheet bundle, whereinthe second electric power is lower than the first electric power in stapling of the sheet bundle having the sensed thickness in the on-line stapling mode.

26. The method according to claim 25, further comprising: identifying a type of the inserted sheet bundle; andsetting the second electric power based on the sensed thickness of the sheet bundle and the identified type of the sheet bundle.

27. The method according to claim 26, further comprising: setting, when sheet count input information is obtained from the image forming apparatus, the second electric power based on the sheet count input information; andsetting, when the sheet count input information is not obtained from the image forming apparatus, the second electric power based on the sensed thickness of the sheet bundle.

28. The method according to claim 17, further comprising: clamping the inserted sheet bundle by a clamping mechanism;obtaining first time when the clamping mechanism starts to move from a reference position where the clamping mechanism does not clamp the sheet bundle;obtaining second time when the clamping mechanism clamps the sheet bundle at a certain pressure; andestimating a thickness of the sheet bundle based on a difference between the first time and the second time.

29. The method according to claim 17, further comprising: clamping the inserted sheet bundle by a clamping mechanism;obtaining first time when the clamping mechanism starts to move from a reference position where the clamping mechanism does not clamp the sheet bundle;obtaining second time when a pressure not lower than a certain pressure is applied to a surface of the clamping mechanism where the sheet bundle is clamped; andestimating a thickness of the sheet bundle based on a difference between the first time and the second time.

30. The method according to claim 17, further comprising: clamping the inserted sheet bundle by a clamping mechanism;obtaining first time when the clamping mechanism starts to move from a reference position where the clamping mechanism does not clamp the sheet bundle;obtaining second time when electric power not smaller than a predetermined amount of electric power is supplied for driving the clamping mechanism; andestimating a thickness of the sheet bundle based on a difference between the first time and the second time.

31. The method according to claim 17, wherein a time period for stapling the sheet bundle having a thickness A in the manual stapling mode is defined as a time period X,a time period for stapling the sheet bundle having the thickness A in the on-line stapling mode is defined as a time period Y, andthe method further comprises setting the second electric power to set the time period X to be longer than the time period Y.

32. A computer readable data storage medium having a program stored thereon, the program causing the computer to perform: performing a stapling process with first electric power in an on-line stapling mode in which a sheet bundle ejected from an image forming apparatus is stapled; andperforming the stapling process with second electric power lower than maximum electric power that can be set as the first electric power in a manual stapling mode in which the sheet bundle inserted by a user is stapled.