Note: Descriptions are shown in the official language in which they were submitted.
3~
VERY HIGH SPEEI:S ~UPLICATOE~ WITH FINISHING FUNCTION
This invention relates to an improved reproduction system having
an improved finishing station for use in such system.
With the advent of higher speed and more sophisticated copy
producing machines, printing presses, and the like, considerations as to how
the mass of copies generated can best and most effectively be handled has
assumed increasing importance. One way has been to prov;de a reproduction
system with an input device in ~he form of a recirculating document handling
apparatus. In this system, a document sheet is removed from a collated set of
document sheets, placed on an exposure platen for exposure a~ the rate of one
exposure for each document sheet, and returned to the top of the set in the
document handling apparatus until the set of document sheets has been com-
pletely circulated through the apparatus, and a copy set has been produced.
The set of document sheets is then recycled for the reproduction of a second
copy set, and so on. After each copy set is produced and collected at a collec-
tion statlon9 a finishing device such as a stitcher or stapler is activated to bind
the set. These systems are of the precollation type wherein the document
sheets are precollated in the document handling apparatus prior to commence-
ment of a reproduction run. The output for the reproduc~ion machine will
likewise be precollated in sets corresponding to the sequenced numbered doc-
ument set in the document handling apparatus. The copy sheets are collected
in collated sets as they are sequentially procluced so that binding may be
effected without the interacton of additonal devices. Such systems are
described in U.S. patent No. 4,134,67~.
One of the disadvantages in these systems having continuous
document recirculation to produce each bound copy set is that for compilation
o~ each copy set and eventual stapling or stitching, many moving parts have
been required and have added to the risks of unschecluled maintenance. In
addition, generally, in providing for the stapling or stitching step, one or more
machine pitches are lost thereby reducing throughput for the system.
In order to achieve still higher rates of production of finished copy
sets, the present invention contemplates the concept of utili2ing a compilation
station which includes the stapler or stitcher heads in order to avoid the use of
copy set transport devices and permit continuous compilation of successive
s
copy sets.
Present day machines on the market, such as the
Xerox duplication machine labeled ~he 9400 Duplicator
marketed by Xerox Corporation of Starnford, Connecticut,
utilizes a document handler as an input device which
exposes as many copies of a single document sheet at a
time as is appropriate before starting on the next docu~
ment sheet. The present invention, however, contemplates
utilizing a recirculating type of document handling
apparatus such as of the general type disclosed in the
abo~e referred to U. S. Pa~ent No. 4~134r672. Any other
suitable recirculating type of document handler may also
be used in conjunction with the processor for the 9400
Duplicator.
It is therefore an object of an aspect of the
present invention to produca bound sets or stac~s of
copies of a multi-page document at the highest speed
possible for a reproduction machineO
It is an object of an aspect of the present
.invention to maintain ~ull productivity in a reproduction~
finishing system by eliminating those machine copy cycle
pitches which are wasted during some machine operating
steps.
It is an object of an aspect of the present
invention to minimize the number of moving paxts in a
finishing station for a very high speed copying machine
and thereby minimi~e service calls and down time for
the machine~
* trade mar~s
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An aspect of the invention is as followso
In a reproduction system having a document hand-
ling apparatus adapted to transport individual document
sheets from a supply stack to an exposure statlon and
effecting an exposure s~ation and effecting an exposure
of each of the document sheets before returning the same
to -the supply stack, and a processor for reproducing
copy sheets of the e~posed sheets, the combination of
a finishing apparatus adapted to receive collated sets
~ of copy sheets of a set of document shee-ts and to bind
the same, said apparatus including a binding device
having a binding position whereat binding of a set of
copy sheets is effected during a binding opera-tion, said
finishing apparatus including a compiling station where-
at collated copy sheets are collected and having amovable member upon which sheets are supported during
collection in a set prior to bindingJ means for regis-
teri.ng the copy shee~s being collected along the leading
edge thereof to provide an ali~ned edge for the set
2~ being collected, said aligned edge being within said
binding position of said device whereby binding of -the
set may be enacted along said edge without further
movemen-t of said set~ and means for moving said member
out of its supporting position during the binding
operation to e~fect removal of the set from said compi~
ling station.
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By way of added explanation, the present
invention in one aspect includes a finishing apparatus
for binding copy sheets received in succession at a
sheet compilation station. The compilation station is
defined by a movable, horizontally arranged plate upon
which sheets are collected, and the stapling heads for
two or more s-tapling apparat-usO When the last sheet
of a set to be bound is collected, the plate is quickly
retracted from the set in timed sequence with the
clamping of the stapling heads whereupon the rear edge
of -the set lowers to carry the set downwardly upon
a set collecting, vertically movable tray. A set
kicker may be employed to facilitate quic~ removal of
~he stapled edge out of -the stapling heads. As the
stapled set is lowered~ the compiling plate is reposi-
tioned into its compilation position to catch the
first sheet of ~he succeeding copy set. The collect-
ing plate reciprocates, that is, moves from a collect-
inc3 position to a retracted position and back to its
collection position at a cycle rate approximately
equal to the rate of production of the processor
for the c~pying machine so that t~ere is no loss
of productivity. In other words, the time during
which the plate 102 reciprocates is approximately
e~ua]. to the pitch time for the machine or that
time for a copy sheet to move a distance fxom
the leading edge of one copy sheet to the leading edge of a succeeding sheet
regardless of where the sheets are in the system.
In the U.S. Patent No. 4,134,672, a system is disclosed wherein copy
sheets are collected in an inclined tray and requires a set transport device for5 remo~al to a set collecting point after a stitching operation. Many moving
parts are employed for the finishing step and related timing is critical for allof these parts. In the UOS. Patent No. 3,719,266, copy sheets are collected in avertically arranged tray for copy set separation. Another arrangement which
collects copy sheets in a vertically inclined collecting ~ray is disclosed in U.S.
Patent No. 4,029,30g. After collection in the tray, a set of copy sheets is
clamped and moved to a stapling position.
Other objects and advantages will be apparent frorn the ensuing
description and drawings in which:
Figure 1 is a schematic illustration of a configuration of an
15 electrostatographic printing/finishing system employing the present invention;
Figure 2 is an isometric view of the finishing station u-tilized in the
systern of Figure l;
For a general understanding of a reproduction machine with which
the present invention may be incorporated, reference is made to Figure 1
20 wherein components of a typical electrostatic prin~ing system are illustratedo
The printing system is preferably of the xerographic type as one including a
xerographic processor 11~ and a recirculating type document handling apparatus
'A 12. Preferably, the processor 11 is the same as the processor in the commercial
embodiment of the Xerox duplicator 9400~, which utilizes flash, full Erame
exposure for very high speed production. Document sheet exposure, image
processing and copy sheet transport/handling are under control by a machine
programmer and are effected in timed seqence, and in accordance with the
pro~ram an operator has preset in the machine. Further details in this regard
are not necessary since the Xerox 9400~Duplicator operates in this manner
and is well known Details of the timing relationships and related structure
and events are described in U.S. Patent Nos. 3,790,270; 31796,486; and
3,917,396, commonly assigned ~ It will
be understood that most any other type of xerographic processor and document
handling apparatus may be utilized. Operating in conjunction with the
processor 11 and apparatus 12 is a finishing station 13 and thereby for-ns the
reproduction system shown in Fig-lre lo
:.
The system comprising the processor 11 and the document handling
apparatus 12 is under control of a programmer P which permits an operator
various options: to turn the entire system ON or OFF; to program the
reproduction system for a desired number of reproductions to be made of each
5 original document sheet or set; to selec~ whether simplex or duplex copies areto be made; to select a desired outpu-~ arrangement9 that is, sets mode or
stacks mode, stapled or unstapled; to select one of a plurality of paper trays;
to condition the machine for the type of document, that is3 whether one sided
or two sided, to select a copy size reduction mode, and other desirable
10 fur~ctions. The programmer P also includes a controller which provides all
operational timing and synchronization between the processor 11 and all of its
( ~; xerographic processing functions, and system control functions, the automatic
events to be described hereinafter. The controller may include any suitable
microprocessor having a CPU and the appropria-te machine clock, but prefer-
ably the microprocessor is one similar to the Intel 8080 Microprocessor
manufactured by the Intel Corpora tion, Santa Clara9 California, and having
sufficient ROM's and RAM's for all of the necessary functions in the
reproduction systemO
The clocument handling apparatus 12 serves to feed one document
sheet at a time from a supply of document sheets of a document D into
copying position on the platen 14 where a single exposure of each document
sheet is made per document set and during sequential operation. Following
exposure, each document sheet is automatically returned to the document
supply and the next document sheet, if any, is brought in~o the exposure
position on platen 14. Document sheets returned to the supply stack may be
recycled by the apparatus 12 in the event additional copy se ts are to be
produced, or simp.Iy removed by ~he user when the copying program is
completed.
While the apparatus 12 has been described as being of the recircula-
ting type, it will be understood that dual mode apparatus may also be utilized,
that is7 those which circulate documents to effect collated and noncollated
copy sets, such as of the type disclosed in IJoS~ Patent No. 4,078,787. Further
details of ~he document handling apparatus are not necess~Lry to understand
the principles of the present invention.
For either the simplex or duplex modes of operation, copy sheets
exiting through the exit slot.5t) positioned at one end of the housing for the
xerographic processor 11 are directed to the finishing station 13 which
comprises a compiling station, a stapler apparatus, and an output elevator
system. After leaving the processor 11, as shown in Figure 2, each sheet is
positioned upon a transport 92 to be further conveyed generally along the same
horizontal plane as its previous path to a fixed receiving point or station 93.
The transport includes a movable endless transport belt 94 upon which each
sheet is placed and a plurality of loosely retained rotatable balls 95 which rest
on and along the belt 94 by gravity and which coact with the belt to convey
sheets there~etween. The belt 94 is driven by a motor and suitable gearing
and pulleys (not shown) at a velocity slightly greater than the processing speedof the processor 11 in order to add more working space between the sheets and
o to ensure that the final handling of copy sheets does not impede the
throughput of the entire system as determined by the process speed of ~he
processor 11. The rate at which the sheets arrive at the station 93 neverthelessis the same as the process speed or reproduction rate of the processor.
It will be noted that the axis oE the belt 94 is at a slight angle to
the direction of the movement of the copy sheets. This arrangement drives
each sheet of copy slightly laterally against a side registration edge 97 which
is parallel to and offset from the centerline of the incoming path of sheet
movement. As viewed in Figure 2, the sheet S as can be seen through a sheet
clearance opening 98 formed in the top plate of the transport 920 In this
orientation, the sheets are positioned so that their toner image side is down,
~; ~ for the simplex mode9 or an odd numbered page is down for ~he duplex copying
mode, and the top of each sheet is along the edge 97.
At the exit slot 50, a sheet contacting switch S-l is positioned to
be actuated as each sheet enters the transport 92 of the finishing station 13.
The circuit for this switch is connected to the logic in the programmer P and
serves to reset the machine clock for the finishing function so that zero time
for the sheet commences when the sheet is at the station 93 which serves as
the system reference point.
At the receiving station 93, there is positioned a pair of contacting
transport rollers or a set oE corrugating rollers 100 which receive each copy
sheet within the nip for directing a sheet onto a compiling receiving plate 102
located at a compiling station which includes this plate~ The plate 102 is
suitably mounted for horizontal reciprocable movement between the position
showing in Figure 2 whereat copy sheets are compiled to form a set C just
S5
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prior to a stapli~g opexation to its retrac~ed position
shown in Figure 3~ A pneuma~ic cylinder 104 havlng an elect~o~
magnetic actuable valve 105 is suitably connected to ~he
plate to provide very fast reciprocable movement upo~ logic
control in the programmer P. The valve 105 is energized
by means o a ~ime siy~al rrom the programmer logic to drive
the plate to ~he co~lacting or compiling position of ~igure
1 or to retract the plate ~o the position shown i.n Figure 3.
The rate at which ~he plate 102 makes a complete
reciprocable cycle is approxlmately equal to the ra~e of
production o the processor, or i~s pitch per uni-t of .imeO
For example, if the production rate for the processor is
1.20 copies per minute, its pitch i9 one sheet plus one space
between shee~s per one -hal:E second and ~he cycle ~lme f or
recipro:::a~ion of the pla~e will be approx~ma~ely one-half
15 s~cond.
Also pO5iti.0Iled along the far edge of the compiler
station is an individually-operable~ dual stapler apparatus
.llO which provides a stapling unc~ion either with a s ~ gle
stapLe ~r with ~wo s~apl~s, both being adapted to be applied
at variable posi~ions along the long edge o a set C of
copy sheets. Stapling is achievPd by way of two iden~ical
mechanisms, ~ach of which provides the func~ions o copy
se~ clamping, s~aple driving and staple clinching~ Preferably,
the apparatu~ utilizes two commerc.ial type s~aple.r heads
~5 11~, such as the Bostitch staple h ad indicated a5 the 64-E
manufactuxed by tha Bos~i~ch Division of the Tex~ron CorpGra~ior
~:~ Pro~.idence, Rhode Island. The stapling apparatus 110 may be
iderltical to that disclosed in detail in commonl~ assigned co
pending Canadian application Serial No. 380y401, filed June 23,
1981.
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The stapling apparatus may be of a type in which
logic timed control signals are imparted to two electromag-
netic clu-tches and on~ solenoid in order to acquire copy
set clamping along the edge of the copy set to be stapled;
5 staple driving which separates a staple from a supply and
drives it through the set; and clinching wherein the staple
legs are bent to secure the copy sheets. Since further
details of the apparatus does not determine ~he presen~
invention, further description thereo is unnecessary.
During the compiling operation, the receiving
plate 102 is in the position shown in Figure 1 wherein its
far edge is adjacent the clamping
s~
position for ~he s~apling apparatus. As sheets are conveyed past ~he reference
point 93 by the rollers 100, they are directed upon the plate 102 and into
clamping positions relative to the stapler heads 112. As the sheets are being
directed into their prestapling position, they engage and become registered
against corner registration members 114, 115. The member 114 is positioned
between the heads 112 and in spatial arrangement so that when all sheets of a
set are against ~he member5 the now aligned edge of the set is in proper
position to be clamped and stapled by the stapling heads.
After a stapling operation, a stapled copy set is dropped onto an
elevator device 118 which is utilized lto collect into a pile stapled or unstapled
sets or stacks of copy sheets for delivery ~o an opera~or. The elevator
( J~ comprises a tray 119 mounted in cantilever fashion at the upper ends of a pair
of vertically arranged, drive screws 120 threadedly received in threaded
members 121 secured one to each side corner of the tray 119~ so that upon
rotation of the drive screws 126, ~he tray 119 is moved vertically in the up or
down directions~ A reversible motor M-l is operatively connected to the
member 121 for imparting rotation to the same in either direction. Elevator
height of piled sets or stacks is controlled by an optical sensor SR-l which
"looks" across the pile and effects the energization of the motor M-l and
lowering of the tray 119 until the pile is at or below the sensor.
A typical reproduction run will now be described in order ~o
illustrate the sequence of events which occur during operation of the system
,~, of Figure 1. For this run9 it will be assumed the operator programmed the
system to produce twenty copy sets of a five sheet document set, in the
simplex mode. 1his program is manually preset in the programmer P and the
five document sheets placed in the docurnent handler 12 in precollated
arrangement. Upon activation of the system, each page or sheet of the
clocurnent set is placed upon the plate 14 for exposure, removed therefrom and
returned to the stack of document sheets, and so on until the set of five
document sheets has been recycled in the document handling apparatus twenty
timesO
Corresponding copy sheets are produced in collated arran~ement in
the processor 11 and exited at the slot S0 in succeeding order in accordance
with ~he production rate for the processor. Since ~he present inven~ion is
arranged so that there will be no skipped pitches in the production run, the
copy sheets will be evenly spaced throughout processing, for all twenty ~imes
5~
five, or one hundred sheets set to be produced. The first five copy sheets,
corresponding to the first complete cycling of the document apparatus 12 are
transported by way of the transport 92, ~hrough the reference point 93 and
into the compiling station to be collected Eor a stapling operation. Each of
5 these sheets is conveyed to and upon the top surface of the plate 102 and intothe clamping position for the stapling heads 112~ the leading edges of the sheets
being registered by the devices 114,115. At the instant the fifth sheet is so
positioned, so as to complete the collection of the first copy set9 the clampingclutshes for stapling heads are activated ~o clamp the adjacent edge of the
10 collected se~. Simultaneous with this ac tion, the compiling plate 102 is
retracted to permit the lowering of the opposite or trailing edge of the set, asshown in Figure 3. This plate is returned immediately to its compiling position
as shown in Figure 1 so as to be in position to receive the first sheet of the
second set of five copy sheets being transported. Immediately after the
15 leading edge of the first set was clamped, the clutch for providing the force to
drive staples through this edge and the clinching solenoid are activated in
timed sequence to produce a stapled set. The forward registration device 114
may be suitably connected to a kicker driving mechanism and timed in its
actuation to kick the stapled edge out of the stapling positions of the heads 112
20 at the instant before the plate 102 is returned. With the far por~ions of thestapled set already in position below the level of the plate 102 and dropping,
the final kick of the set causes immediate lowering of the set and out of the
) return path of the plate.
The timing sequences provided in the logic for the programmer P
for the activatlons enumerated aboveo clamping by the stapling heads,
retraction of the plate 102, staple driving ancl clinching, final kicking of a
completed copy set~ and return of the plate 102. Final kicking of a completed
copy set is such that the compiling plate 102 is returning to the compiling
station as the first copy sheet of a succeeding copy se~ being produced. The
logic will determine when these actions are to occur by way of operator
rnanipulation of the programmer P during presetting of the desired reproduc
tion run. As ~he stapled sets are produced, one by one ~hey Eall upon the
elevator tray 119 which lowers in accordance with the sensed height of the
topmost set thereon.
FFOrn the foregoing it will be apparen~ that an elec~rostatographic
system with finishing station has been described which will produce stapled
g~
I
collated sets at a high production rate withou~ loss of throughput, in fact, at a
rate in accordance with the full processing speed of the copy processing
machine. Furthermore, it will be apparent that the present invention
accomplishes higil speed s~aplin~ or stitching with a minimum of parts
5 especially a minimum of moving parts thus minimizing maintenance calls and
down time.
While the im~ention has been disclosed wi th ref erence to the
structure disclosed, it is not confined to the details set forth but is intended to
cover such modifications or changes as may come within the scope of the
10 following claims.
(,
f"'"
