Note: Descriptions are shown in the official language in which they were submitted.
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A FINISHING APPARATUS WITH A ROTARY
SORTER AND AN ADHESIVE BINDER
This invention relates to improved finishing systems, and in par-
ticular, for such systems which are integrated into high speed copiers and
reproduction machines.
Companion U.S. patent applications to the above-entitled applica-
5 tion, and filed on even date herewith, are as follows: Serial No. (D/84265),entitled "Copying Machine With Rotary Sorter and Adhesive Binding Appa-
ratus"; Serial No. (D/84266), entitled "Copying Machine With Rotary Sorter
and Stapling/Stitcher Appara tus"; Serial No. (D/84267), entitled "Copying
Machine With Rotary Sorter Having Sheet Gripping Devices"; and Serial No.
10 (D/84168), entitled "Copying Apparatus with Finisher".
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 provide a reproduction
15 system with an input device in the form of a recirculating document handling
apparatus. In this systern, a document sheet is removed from a collated set of
document sheets, placed on an exposure platen for exposure at 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
20 completely 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 individually produced and
collected at a collection station, a finishing device such as a stitcher or
stapler is activated to bind the set. These systems are of the precollation type25 wherein the document sheets are precollated in the document handling
apparatus prior to commencement of a reproduction run. The output for the
reproduction machine will likewise be precollated in sets corresponding to the
sequenced numbered document set in the document handling apparatus. The
copy sheets are collected in collated sets as they are sequentially produced so
30 that binding may be effected without the interaction of additional devices.
Such systems are described in U.S. Patent No. 4,134,672.
The disadvantage in these systems having a complete document
recirculation for the production of each bound copy set is that the speed of
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production is limited to the mechanical limitations in the speed of handling
document sheets in the document handling device. It necessitates that the
input device, the document handler, be of extreme high reliability as it places
the original document sheets under the severe stress of being constantly
recirculated. In practice, for these systems, there appears to be a threshold inthe production rate of finished copy sets. The failure rate in the document
handling apparatus increases beyond acceptable limits when too high a speed
of document sheet movement in the apparatus is attempted.
In order to achieve still higher rates of production of finished copy
sets, another reproduction system has evolved which utilizes post-collation
rather than precollation. Such a system is disclosed in U.S. Patent No.
4,444,491. The arrangement disclosed in this patent utilizes a document
handling apparatus wherein a predetermined number of light images is
produced for each document sheet, say for example, of page one of a multi-
page document, before a successive document sheet, perhaps page two of the
document, is likewise imaged. This sequencing in turn is repeated many more
times when a very large number of copy sets is to be reproduced. In this
manner, the mechanical movements involved in document handling are held to
a minimum.
As the copy sheets are being produced in accordance with the
above imaging procedure, a single array of vertically oriented collecting bins
or sorter is positioned and vertically moved in either direction to receive a
copy sheet output for collating the copy sheets into collated sets. The bin
array or sorter in effect serves as a buffer in the production of finished copy
25 sets. As these sets are being produced, a finishing device such as a stitcher or
stapler is positioned and activated to apply a staple to each set as they are
completed. With this arrangement, better than previously available through-
put is achieved from the various apparatus utilized in the reproduction system
having finishing capability. However, complete and uninterrupted throughput
30 is not available with this system since there are some machine pitches or copy
cycles lost to accommodate various positionings of the sorter array. In
addition, the use of a linear array of collecting bins limits the reproduction
system to either a stapler/stitcher or to an adhesive binder, rather than
permitting the incorpora tion of both without undue costly fabrication, and
35 more important, requires the use of complicated copy set transports which
adds more sheet handling to the system.
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In the prior art, a variety of rotary sorters
have been disclosed, but these have been directed mainly
to aspects of the sorter structure per se, and not to
the arrangement with either a stapler/stitcher or an
adhesive binding device, or in combination with a copier
or printing machine to produce a system wherein ultimate
throughput is achieved with either stapling/stitching or
adhesive binding, and if in combined use, their
selectivity. In U.S. Patent No. 3,851,872, a simple
rotary sorter is disclosed as being arranged for simplex
or duplex sheet collection. There is no provision for
binding, nor permitting continuous r~tation of the
sorter during sheet collection utilizing all of the bins
continuously. In U.S. Patent No. 2,876,008, a large
rotary collating apparatus is disclosed as being tilted
at an angle so as to permit continuous use of all of the
bins at one time, and which, upon rotation of the drum,
produces agitation to jog the copy sheets into
registration along two edges. In U.S. Patent No.
4,145,038, a rotary collator-sorter is disclosed which
is devised so as to be selectively usable as either a
collator or as a sorter. A rotary sorter is disclosed in
the German Patent No. 1,436,096, dated January 30, 1969,
as being associated with a single sheet feeder and an
output feeder. In none of these prior art disclosures
is there association with a binding device.
It is therefore an object of an aspect of the
present invention to produce bound sets or stacks of
copies of a multi-page document at the highest speed
possible for a reproduction machine.
It is an object of an aspect of the present
invention to increase productivity in a
reproduction/finishing system by simultaneously
collecting sequenced sheets and binding the same at
their collected stations.
It is an object of an aspect of the present
invention to reposition an array of collecting bins
sequentially in a direction wherein successive bins in
the array will receive a copy sheet at a fixed point
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thereby collecting sets of collated copy sheets, and
wherein the collected sets are positioned at another
point for binding.
Various aspects of the invention are as
follows:
A finishing apparatus comprising:
a rotary sorter having radially extending bins
for containing sheets formed into booklets with the
splines thereof extending outwardly radially and
defining a peripheral line of movement during rotation
of the sorter,
means for imparting rot2tion to said sorter,
and
a binding station adjacent said rotary sorter,
said binding station having an adhesive binding device
arranged to apply adhesive material to the spline of the
booklets for binding the same as the splines of the
booklets pass said station, said binding device
including a rotary applicator, the periphery of which is
adjacent said peripheral line and arranged to apply the
adhesive material to the splines during rotation of said
rotary sorter and said applicator.
A finishing apparatus comprising:
a rotary sorter having radially extending bins
for containing sheets formed into booklets with the
splines thereof extending outwardly radially and
defining a first peripheral line of movement during
rotation of the sorter,
means for imparting rotation to said sorter,
and
a binding station adjacent said rotary sorter,
said binding station having an adhesive binding device
arranged to apply adhesive material to the spline of the
booklets for binding the same as the splines of the
booklets pass said station, said binding device
including an applicator member arranged to apply
adhesive material along a second peripheral line of
movement, the periphery is adjacent said first
peripheral line of movement and arranged to apply the
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3b
adhesive material to the splines during rotation of said
rotary sorter.
According to another aspect thereof, the
present invention includes a finishing station having an
adhesive applying device for selectively binding copy
sheets received in succession at a binding position
comprising a rotary bin array, having a series of
individual bins each with an inlet for receiving
individual sheets at a fixed sheet loading station;
means supporting the bin array for rotary movement for
disposition of a selected one of the bins at the sheet
loading station for loading of sheets therewithin; drive
means adapted when actuated to rotate the array
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during the collection of sheets in collated fashion; set retaining or clamping
means for holding collected sheets within the bins as the array rotates; an
adhesive applying means movable toward and away from the bins, and controls
for the above.
The finishing station in the form of a sorter/finisher may also be
utilized in an office environment as a stand alone system. The concept of the
finishing aspect of the present invention resides in its abili ty to register,
clamp, finish, and automatic unload of books at a very reasonable cost while
maintaining a high degree of production quality.
Other objects and advantages will be apparent from the ensuing
description and drawings in which:
Figure I is a schematic illustration of a configuration of an
electrostatographic printing/finishing system employing the present invention;
Figure 2 is an elevational view of the documen~ handling apparatus
utilized in the printing system of Figure l;
Figure 3 is a partial elevational view of the loading station showing
the sheet gripping mechanism;
Figure 4 is an isometric view of the sheet gripping mechanism;
Figure 5 is a partial elevational view of the unloading station
showing the release mechanism for the gripper mechanism;
Figure 6 is an elevational view of the adhesive binding device;
Figure 7 is a schematic of portions of the sorter and the adhesive
application roller applying material to the edges of booklets;
Figure 8 is a partial plan view of the stapler/stitcher in its two
operating positions;
Figure 9 is a block diagram of the control scheme for the printing
system of Figure l; and
Figures 10a, 10b, and 10c are flow diagrams of the control function
of the present invention.
For a general understanding of a reproduction systern with which
the present invention may be incorporated, reference is made to Figure I
wherein components of a typical electrostatic printing/finishing systern are
illustrated. The printing function of the system is preferably of the xero-
graphic type as one including a xerographic processor I, and a document
handling apparatus 2. Preferably, the processor I is the same as the processor
in the commerical embodiment of the Xerox duplicators, models 9400`3and
12~5~1~
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9500~), which utilize flash, full frame exposure, for very high speed produc-
tion. Similarly, the document handling apparatus 2 is the same as those used
in the same machines. It will be understood that most any other type of
xerographic processor and multiple exposure document handling apparatus may
be utilized. Operating in conjunction with the processor I and apparatus 2 is a
finishing module 3 and thereby forms the reproduction system shown in Figure
1.
As in all xerographic systems, a light image of an origin`al to be
reproduced is projected onto the sensitized surface of a xerographic ph~oto-
10 sensitive surface to form an electrostatic latent image thereon. Thereafter,the latent image is developed with toner material to form a xerographic
powder image corresponding to the latent image on the photosensitive surface.
The powder image is then electrostatically transferred to a record material
such as a sheet of paper or the like to which it may be fused by a fusing device15 whereby the powder image is caused to adhere permanently to the surface of
the record material.
The xerographic processor I is arranged as a self-contained unit
having all of its processing stations located in a unitary enclosure or cabinet.The processor includes an exposure station at which an original to be
20 reproduced is positioned on a glass exposure platen 4 for projection onto a
photosensitive surface in the form of a xerographic belt 5. The original or set
of individual document sheets are selectively transported by the document
feed apparatus 2 one document sheet at a time to the platen 4 for exposure.
After a predetermined number of exposures of each document sheet is made,
25 the same is returned to the top of the set until the entire set has been copied.
A suitable document handling apparatus of this type is described in U.S. Patent
No. 3,944,794, commonly assigned.
Imaging light rays from each of the document sheets, which is flash
illuminated by an illumination system 6 having suitable lamps 7, are projected
30 by means of a lens system and mirrors, onto the xerographic belt 5. The lamps7 are connected to a suitable flashing circuit (not shown) which is controlled
by the programmer for the processor in timed sequence, and in accordance
with the program the operator has preset in the machine. Further details in
this regard are not necessary since the Xerox 9400(~)reproduction machine
35 operates in this manner and is well known. The xerographic belt 5 is mounted
for movement around three parallel arranged rollers 8, 9, 10, suitably mounted
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in the processor 1. The belt is continuously driven by a suitable motor (not
shown) and at an appropriate speed. The exposure of the belt to the imaging
light rays from a document discharges the photoconductive layer in the area
struck by light whereby there remains on the belt an electrostatic latent
image corresponding to the light image projected from the document. As the
belt continues its movement, the electrostatic latent image passes a develop-
ing station at which there is positioned a developer apparatus 11 for
developing the electrostatic latent image.
After development, the powdered image is moved to an image
10 transfer station 12 where the developed image is transferred to a support
surface, normally a sheet of copy paper, brought from a main or auxiliary
paper tray 13, 14, respectively, as will appear.
Each sheet is conveyed to the transfer station by a conveyor 15,
which cooperates with sheet registration fingers 16 (only one shown). These
15 fingers rotate in a counterclockwise direction, and engage the leading edge of
a sheet, being adapted to effect the accurate timing and positioning of a sheet
relative to the movement of a developed image on the belt 5 and the other
timed events in reproduction processing. Further details of the timing
relationships and related structure and events are described in U.S. Patent
20 Nos. 3,790,270; 3,796,486; and 3,917,396, commonly assigned.
The sheet is moved in synchronism with the movement of the belt
5, and passes between a transfer roller 17 and the belt 5 at the transfer
station. Af-ter transfer, the sheet of paper is stripped off the belt 5 and
transported by a vacuum conveyor 18 in an inverted condition to a fusing
25 station where a fuser device 19 is positioned to receive the sheet of paper for
fusing the powder thereon. After fusing, the sheet is eventually transported to
a finisher station to be described hereinafter either to be stapled/stitched, orbound by adhesive material into copy sets or merely to be separated into sets
without binding.
The system comprising the processor 1, the document handling
apparatus 2, and the finishing module 3 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 reproduc-
tions to be made of each original document sheet or set; to select whether
35 simple:c or duplex copies are to be made; to select a desired output arrange-
~t
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ment, that is, sets mode or stacks mode, stapled, or unstapled; to select one ofa plurality of paper trays, to condition the machine for the type of document,
that is, whether one-sided or two-sided; to select a copy size reduction mode,
and other desirable functions. The programmer P also includes a controller
which provides all operational timing and synchronization between the proces-
sor I 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 appropriate
machine clock, but preferably the processor is one similar to the Intel 8080
microprocessor manufactured by the Intel Corporation, Santa Clara,
California, and having sufficient ROM's and RAM's for all of the necessary
functions in the reproduction system.
As previously stated, copy sheets are supplied from either the main
paper tray 13 or the auxiliary paper tray 14. Main paper tray 13 includes a
15 suitable elevator type base 20 on which a supply of sheets rest, base 20 being
supported for automatic up and down movement by suitable means (not shown)
designated to maintain paper feed belt 21 in operative contact with the
topmost one of the sheets on the elevator 20. The belt 21 is operated
intermittently in timed relationship to spacing of images on the photoreceptor
20 belt 5 and serves to advance the topmost sheet from the supply stack 13 to the
main paper supply transport 15.
The auxiliary tray 14 in the exemplary arrangement shown, is
arranged above main tray 13 and includes a suitable elevator type base 22 on
which a supply of sheets may be provided. As with the main supply tray 13,
25 suitable means (not shown) are provided to raise base 22 of auxiliary tray 14 as
the supply of sheets thereon is used up so as to maintain the paper feed belt 23in operative contact with the topmost sheet. The paper feed belt 23, which is
intermittently driven in the same manner as main tray feed belt 21, advances
one sheet at a time to an auxiliary paper supply transport 24. Thc transport 24
30 is suitably driven by a drive system not shown and is disposed to discharge
sheets drawn from auxiliary tray 14 onto the operating run of main supply
transport 15. The sheets from auxiliary tray 14 are thereafter fed to the
transfer station. Guides 25 serve to maintain the sheets in driving contact
with the auxiliary paper supply transport 24 during movement therealong.
During use, copy sheets leaving the processor 11 after exiting the
fuser apparatus 19 are conveyed to an exit slot 26 by way of transports 27, 28
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if the reproduction system is set for the simplex or one-sided copying. If the
system has been programmed for duplex or two-sided copying, copy sheets will
be directed to the auxiliary tray 14. If the latter mode of operation is
selected, copy sheets conveyed by the transport 27 are intercepted by a
5 deflector 29 which is adapted for movement into the sheet path. When the
deflector 29 is in the interrupt function, the copy sheets are carried around a
roller 30 and through the nip formed by this roller and a cooperating roller 31.The sheet is advanced by rollers 30, 31 between an upper sheet guide baffle 32
and a lower sheet guide baffle 33 to a second roller pair 34, 35 which further
10 advances the sheet to a transport mechanism 36 which carried the sheet to theauxiliary paper tray 14. When the desired number of one-sided copies have
been produced and delivered to the tray 14, the paper handling mechanism for
the main tray 13 may be inactivated and the paper handling mechanism for the
auxiliary tray 14 activated. It should be understood that in following the paper15 path around roller 30 and between roller pair 34, 35, the copy sheets are
turned over, i.e. the printed material is on the top of the sheets in the tray 14.
Upon reenergization of the system, the sheets from the tray 14 are
fed through the reproduction machine by means of the feed belt 23 and the
transport 24 for copying on the blank side of the sheet in the same manner as
20 described heretofore. With the reproduction system being programmed for the
duplex mode, and after completion of the correspondingly programmed number
of one-sided sheets, reenergization of the system also produces the raising of asheet stop 37 into the paper path between the upper guide baffle 32 and the
lower guide baffle 33. The feed roller 34 is mounted on the upper baffle 32 to
25 be raised therewith during the phase of duplex copying. In this manner, the
feed roller 34 will be displaced away from lower feed roller 35 so that papers
fed therebetween are not forwarded thereby.
The sheet stop 37 is formed of a ring-shaped resilient material
being compliant enough to resume its circular shape and thereby effect the
30 insertion of a sheet into the nip formed between roll 31 and a cooperating roll
38, the trailing edge of the sheet being carried by roll 31 into the nip. The
rolls 31 and 38 are formed of a high friction material such as polyurethane
foam to assure positive feeding of a sheet traveling toward stop 37 and
positive feeding of the sheet traveling away from stop against drag force
35 generated between two sheets which may be in the inverter area at ~he sarne
time traveling in opposite directions. The purpose of the stop 37 and the
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cooperating action of the rollers 31, 38 is to invert each copy sheet, while
production is in the duplex mode, so that the odd numbered page on a copy
sheet reaching the exit slot 26 is on the bottom of the sheet.
As shown in Figure 2, the document handling apparatus 2 serves to
feed one document sheet at a time from a supply of document sheets D into
copying position on the platen 4 where a single exposure if only one copy set isprogrammed, or a plurality of exposures may be made. Following exposure one
or more times, each document sheet is automatically returned to the docu-
ment supply and the next document sheet, if any, is brought into the exposure
position on plate 4. As will appear, document sheets returned to the supply
stack may be recycled by the apparatus 2 or simply removed by the user when
the copying program is completed.
The document handling apparatus 2 includes base section 40, the
lower end of which swingably supports, by means of a shaft 41, matching left
and right hand tray members 42. The tray members 42 are substantially U-
shaped when seen in cross section, each having a base 43, which are shown cut
away at the upper ends thereof to accommodate a document separator/feed
roll 44. The trays are adjustable along the shaft 41 to accommodate various
size documents.
The document separator roller 44 is rotatably supported on a drive
shaft 45 under the base section 40 such that a portion of the periphery of the
roller projects into the document tray area, the base 40 being suitably
apertured to accommodate the separator roller. The shaft 45 is supported for
rotation and driven by a continuously driven motor M through suitable pulleys
and belts (not shown). A solenoid clutch SOL-I drivingly connects the rnotor
M to the separator 44 in response to a signal from the machine logic in timed
sequence in accordance with the programming arrangement in the logic.
A pair of document limiting rollers 46, 47, are disposed on the
downstream side of separator roller 44 and function to prevent passage of
more than one document sheet at a time. The upper limiting roller 46 is
arranged to be driven by the lower limiting roller 47 so long as friction
developed between rollers 46, 47 remains above a predetermined setting. In
the event of a decrease in roller friction, as occasioned by an attempt of two
superimposed document sheets to pass therethrough, the upper roller 46 is
turned in a document rejecting direction by a suitable drive means (not shown).
Document sheets emerging from limiting rollers 46, 47 are carried forward by
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intermediate rollers underneath a curved document guide 48 to a platen
tr ansport belt conveyor 49 which, in turn, carries the document onto the
platen 4.
A register edge 50 is provided across the inlet side to platen 4, and
5 serves to register or locate document sheets in pre-set position on platen 4 for
exposure thereof. The movement of the platen transport belt 49 is reversed
for this purpose after the document sheet has been carried past the register
50, reversal of transport 49 serving to move the document sheet backwards to
bring the document sheet trailing edge into abutment with register edge 50.
10 When exposure is completed, the platen transport belt 49 is again operaied inreverse to move the document sheet backwards off the platen 4, the register
edge 50 being retracted for this purpose by a suitable means (not shown). The
document guide fingers 51 deflect or guide the returning document upwardly
into the nip of a first return transport roller pair 52, which carry the returning
15 document sheet between return guides 53 and into the nip of a second return
transport roller pair 54 and back into tray members 42.
To maintain the returned document sheets which have been desig-
nated for convenience by the letter D', segregated from document sheets D
awaiting feeding and prevent inadvertent refeeding of returning document
20 sheets D' by the primary feed roller 44 following feed of the last one of theoriginal document sheets, a displaceable bail or separator bar 55 is provided
substantially opposite to and above the feed roller 44. The bar 55 is supported
from a rockable cross shaft 56 which is suitably journaled in the supporting
framework of document apparatus 2. Means (not shown) are provided to
25 selectively turn the shaft 56 and raise the bar 55 out frorn under the document
sheets D' resting thereupon and thereafter return the bar 55 back onto the
topmost one of the document sheets in the supply. All of the rollers
heretofore described are driven by the motor M by way of suitable pulleys and
belts ~not shown). Since the particular document apparatus 2 is a commerical
30 device being a part of ~<erox Corporation's product labeled the 9200(~
duplicator, and is adequately described in U.S. Patent No. 3,944,794, further
description thereof will not be included herein.
Further details of the processing devices and stations in the printer
system or processor are not necessary to understand the principles of the
35 present invention. However, a detailed description of these processing
stations and components along with other structures of the machine printer
01~
-Il-
are disclosed in U.S. Patent No. 4,054,380 which is commonly assigned with
the present invention.
As previously described, the document apparatus 2 includes a
document tray adapted for supporting a stack comprising a plurality of
5 document sheets in numbered sequence with page one of the multi-page
document on the bottom of the stack. Since the illustrated document handling
apparatus is of the bottom feed type, page one will be the first docume~nt
sheet imaged, and so on.
For either simplex or duplex modes of operation, copy sheets
10 exiting the fuser device 19 are directly conveyed by the transports 27, 28 toand through the exit slot 26 positioned at one end of the housing for the
xerographic processor 11. As sheets exit the slot 26, they are directed to the
finishing module 3 which comprises a rotary sorting mechanism, a stapler/
stitcher apparatus, an adhesive binding device, and an output elevator/
15 conveyor system. After leaving the processor 1, as shown in Figure 1, each
sheet is directed to a transport 60 within the finishing module 3.
The transport 60 includes a registration device (not shown) which
provides rear edge registration of the sheets so that each sheet is programmed
or placed in timed sequence relative to the ensuing sorting function. In
20 leaving the registration device in timed sequence at sheet receiving station 62,
the sheets are directed seriatim into the bins 63 of a rotary sorter 64 driven by
a motor drive M-2 connected to a supporting shaft 65. The drive and control
system therefor is adapted to impart indexing rotary motion successively or
continuously to the sorter, as will be described below.
During the normal collating sequence, the sorter rotates in the
direction indicated by the arrow 66. While a sheet is being directed into a bin
63, and the sorter 64 is indexed to position the next succeeding bin adjacent
the sheet receiving station 62, the sheet or sheets in the previous bin will be
operated upon by a tamping device 67. Each sheet entering a bin is tamped so
30 as to insure corner registration of a finished copy set just prior to a
stapling/stitching or adhesive binding action, as will be described below.
As the rotary sorter 64 continues its indexing rotation, the next
operating station after the tamper 67 is an adhesive binder station whereat an
adhesive binder 70 is arranged for effecting the application of hot adhesive
35 material to the spine of completed copy sets or booklets, if this operation has
been programmed in the programmer P by the operator, and when all of the
programmed copy sheets have been collected in the bins.
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Continued rotation of the sorter 64 brings the adhesive bound copy
sets, if such has been programmed, to a station whereat a cooling device 71 is
positioned for cooling the still hot adhesive material. Preferably, the device
comprises a fan and a manifold having discharge openings arranged to span the
openings of at least two of the sorter bins 63 and running axially of the sorter64. This arrangement provides sufficient cooling of the hot adhesive material
on the spline cf the copy sets or booklets in the bins. Still further rotation of
the sorter brings the indexing bins to a discharge station 72 whereat finished
copy sets are unloaded after stapling, adhesive binding, or as unbound copy
sets.
At the station 72, an unload transport system is positioned (see
Figure 5) comprising a nip roller pair 73, 74, and a belt 75 entrained around a
drive shaft 76 for driving the rollers 73, 74. The rollers 73, 74 are made of
very compliant foam material to permit the transport through the nip of copy
sets ranging between two sheets to fifty sheets without deforming the copy
sets or causing undue wear of the rollers. From the transport system, copy
sets are directed to the platform or tray 77 of an elevator 78 arranged for
vertical motion in either direction by a pair of elongated screws 79.
The next and final finishing station along the path of bin movement
is a stapler device 80 suitably mounted on the frame of the apparatus 3 for
pivotal movement in a plane inclined relative to a hori~ontal plane. The
device 80 is mounted at the end of the sorter 64 and, when activated, is
pivoted inwardly to a corner of the registered copy sets or booklets within the
bins 63.
The sorter 64 comprises circular front and rear end plates 81, 82,
respectively, (see Figure 4) to which the bin plates 63 are attached in radial
configuration. The inner edge of each of the bin plates 63 is formed with
bottom registration edge 83 against which sheets come to rest when inserted
into the bins. As each sheet is transported into -the bins, they are irnpelled
30 therein by the transport 60 and, in conjunction with the tamping device 67,
become registered against the registration edge 83. The tamping device 67
cooperates with the edge 83 to effect corner registration of each copy set or
booklet being assembled in the bins.
Each of the bins 63 has a copy set gripper bar mechanism
35 associated therewith for holding copy sheets within the respective bins during
rotation of the sorter 64. The gripper bars are opened to permit ingress of
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sheets into the bins when at the loading station 62, and the unloading station
72 by a bin opening/closing actuating mechanism associated with the gripper
bars as the affected bin approaches the respective station. The gripper bar
mechanism serves to hold the copy sheets in registered condition as the sorter
5 rotates during a reproduction run, and to prevent displacement of the sheets
when the bins are in inverted positions.
As shown in Figure 3, each of the bins has positioned therein a
gripper bar 84 extending the length of the bin axially of the sorter 64. Since
all of the bars and their associated opening and closing mechanisms are
10 identical, only one will be described in detail. Each bar includes a plate
member 85 which extends into a bin being pivotally retained at its lower end
on a bin plate 63 and at its upper end to a gripper bar so as to permit smooth
translational movement of each plate member 85 away from and against the
sheets in each bin, during actuation of a gripper bar. The outer edge of each
15 plate member is turned to form a gripper edge 86 and when in gripping
condition, engages the sheet(s) along the longitudinal edge thereof adjacent
the opening of its respective bin. The bar 84 is pivoted on a rod 87 extending
parallel to the axial shaft 65 and secured to suitable castings or brackets on
the frame for the sorter to permit rotation of the bar into and out of gripping
20 positions. A coil spring 88 at each end of the rod 87, each having an end
secured to the gripper bar and the other end secured to the bin plate 63 serves
to bias the bar 84 normally clockwise, as shown in Figure 3, to force the plate
member 85 against the sheets S and the gripper edge 86 into gripping or
retaining position with the sheets. Extending approxirnately 90 from the bar
25 84 at the pivoted edge thereof and positioned adjacent the rear plate 82, is a
crank arm 89 secured to the bar. The end of the arm remote from the pivot
rod 87 supports a roller 90 arranged for rotation on a pin secured to this end.
The rollers 90 for all of the gripper bars, one for each bin in the
sorter 63, are adapted to engage two cam control devices arranged at the rear
30 of the machine adjacent the rear plate 82 and spaced peripherally of the
sorter. One of the cam devices is illustrated in Figure 3 by the reference
numeral 91 as being operative on the gripper bars when the same are adjacent
the loading station 62 for the finishing apparatus and the other cam device
illustrated by the reference numeral 92, in Figure 5, is operative on the
35 gripper bars when the same are adjacent the unloading station 72.
~:2'1 5~
-14-
The cam device 91 is formed with two cam surfaces 93, 94
engagable with the rollers 90 and separated by a projection or high point 95 forthe joint cam surfaces. The cam surface 93 serves to drive the gripper bars 84
and consequently the associated gripper edges 86 counterclockwise, out of
5 engagement with the sheets, against the bias of the springs 88. The sequence
of this operation is as follows.
As the sorter 64 rotates in the clirection of the arrow 66, one of the
gripper actuating rollers 90a contacts the cam surface 93 which is sloped
toward the high point 95. Continued rotation causes the roller 90a to ride
higher on the surface 93 to initiate counterclockwise rotation of the associ-
ated gripper bar 84a and, consequently, release of the gripper edge 86a from
the sheets in the affected bin 63a. Further rotation of the sorter beyond the
position shown in Figure 3 carries the roller 90a over and beyond the high point95 which produces the greatest separation of the edge 86a from the sheets S.
15 At this event, a sheet of paper Sl starts its movement from the transport 60
into the affected bin 63b to which the affected gripper bar is associated. As
shown in Figure 3, the roller 90b has been carried beyond the high point 95 and
upon the cam surface 94; however, the return movement of gripper edge 86b is
just beginning since the portion of the cam surface 94 from engagement of the
20 roller 90b to the high point 95 is effectively a dwell cam action producing very
little return movement. Therefore, in this position of the parts, the sheet Sl
has progressed a little further in the bin 63b. Still further rotation of the
sorter carries the roller 90c further along the cam surface 94, which is shaped
to permit clockwise return rotation of the gripper bar 84c and the edge 86c
25 toward the sheets S in the bin 63c. Finally, still further rotation of the sorter
moves the roller 90d toward the end of the cam surface 94 thereby effecting
complete return of the gripper bar 84d and the edge 86d against the sheets in
the bin 63d.
In the foregoing sequence, at least three bins 63 have their
30 associated gripper bars separated from sheets contained therein. This permitsadequate spacing and timing for the tamper 67 to effect corner registration of
the sheets contained in the bins. By having at least three unobstructed bin
openings, there is assurance that each sheet will have sufficient time to enter
each bin and be registered. In addition, the mechanical action in this lengthy
35 sequence lessens the chances of jams caused by the mis-timing of sheet arrival
or, as a result of machine tolerances.
1~5~L3
-15-
The rotary sorter 64, during a reproduction job, continues to rotate
in the direction of the arrow collating the stream of sheets entering the sorteruntil the job is completed, if the programmed number of copy sets or booklets
is less than the number of bins, preferably 24 bins, or will discontinue
collecting sheets when the 24 bins are all occupied with complete booklets.
Upon this occurrence, depending upon which of the type of binding actions has
been programmed, adhesive binding or stapling/stitching, the sorter will rotate
in the same manner as when collating to bring each booklet to either the
adhesive binding device 70 or the stapler/stitcher 80. To maintain produc-
tivity, a binding action is initiated as soon as a booklet is completed and has
been moved into a binding position, even as the last sheet of each booklet is
being received in the sorter bins.
As previously stated, the cam device 92 is associated with the
discharge or unload station 72 for controlling the discharge of bound sets of
sheets. As shown in Figure 5, the cam device 92 is formed with a cam surface
97 against which the gripper mechanism rollers 90 are directed when the
device 92 is in the path of movement of these rollers and in a position to
intercept the same. The device 92 is pivoted on a pivot 98 and is actuated into
and out of the path of the movable rollers 90 by a motor and drive M-3 which
is under control of the programmer P for the machine. The motor and drive
M-3 includes a driven shaft 99 having a rotating eccentric cam 100 attached
thereto and engagable with the end of the device 92 remote from the pivot 98.
Upon rotation of the cam 100, caused by a signal conducted to the rnotor and
drive M-3 for this purpose from the machine programmer, the lobe thereon for
each revolution, causes the device 92 and therefore the cam surface 97, to be
moved into and out of the path of movement of the rollers 90, as the sorter 64
is rotated.
When in camming position, as shown in Figure 5, the surface 97 is
adapted to effect rotation of a gripper bar 89e counterclockwise against the
bias of the springs 88 as the gripper actuating roller 90e rides upon the cam
surface. To this end, the roller 90e engages the surface 97 and commences to
rotate the gripper bar 89e. Continued rotation of the sorter 64 completes the
full rotation of the gripper bar and corresponding movemen~ of the gripper
edge 86e away from the set S, as the set is moved adjacent the unload station
72 between the rollers 73, 74 of the unload transport system. At this position,
the set S Ealls out of the bin 63 containing the sarne and upon the transport
- 1 6- ~L2~5~
belt to be carried to the elevator -tray 77 to be stacked thereon. Further
rotation of the sorter moves the gripping actuating roller 90f away from the
cam surface 97 to permit rotation of the gripper bar to its normal biased
position for a bin 63 which has been emptied or unloaded.
Energization of the motor and drive M-3 to effect unloading of the
bins 63 of bound sets of sheets is under control of the programmer P. During
collation of the sets, the motor remains deenergized, thereby maintaining the
camming device 92 inactive as the rotary sorter 64 rotates to receive the
sheets in the sets. When collation of the sets has been completed, a signal to
10 this effect is initiated, for example, by a counter which counts sheets entering
the sorter at the transport 60 and which divides the total number of sheets by
the number of bins 63, or by the programmed number of sets to be collated if
less than the number of bins. This signal is transmitted to the machine
programmer and, at a suitable point in time, generally starting from the first
15 bound set, the motor M-3 is energized and remains energized until the sorter
64 is unloaded. Each revolution of the cam 100 is tirned to the index
movement of the sorter, one revolution per index or bin, so that rotation of
the sorter, one bin movement and one rotation of the cam combine to produce
unloading of the sorter, a bin at a time, and at the speed of rotation of the
20 sorter which is utilized for loading the bins. In this manner, at certain times
during a reproduction job, loading and unloading can occur simultaneously as
the sorter rotates at the same constant speed.
As the completed, bound and unloaded sets are deposited on the
tray 77, the same lowers, for example, by a height sensor and incremental
25 actuation of a motor driving the screws 79. When the tray 77 is full and in its
most lowered position, further unloading is terminated, and the tray auto-
matically moves upward to its highest position, illustrated by dotted lines 110,(see Figure 1) permitting the operator to remove the complete sets. When the
sets have been rernoved, the tray automatically returns to its unloading
30 position as shown.
The adhesive binding apparatus 70 includes an adhesive applicating
roller 115 partially immersed in container 116 for adhesive material M. The
container is mounted on a frame 117 which is movably mounted on the bed of
the finishing apparatus 3 by a pair of roller races 119. A motor M-4 is also
35 mounted on the frarne 117 and is drivingly connected to the roller 115 when
energized by a signal from the programmer P. Such signal is automatically
~2~ 3
-17-
initiated when adhesive binding has been programmed and the sets of sheets S
have been completed and ready for binding.
Means, such as a motor M-5 and a crank system 120, are employed
to move the roller 115 into and out of its position to apply adhesive material
5 to the splines of the booklets or sets S. Upon energization of the motor M-5,
by a signal from the progrmamer P, after the motor M-4 has been energized to
drive the roller 115, the binding device 70 is moved into its operative position,
as shown in Figure 8. A pair of heaters 122 are suitably positioned under the
container 116 for maintaining the adhesive material at a hot melt temperature
10 best suited for entering the spline of each booklet to be absorbed therein. Asignal from the programmer P is utilized to produce heating of the material
and may be set to be instituted when the adhesive binding mode of operation
has been programmed.
Figure 7 is a schematic illustration depicting the application of
15 adhesive material to the splines of completed booklets or sets S. As the sorter
64 rotates, the edges of the booklets to which adhesive material is to be
applied, define a circular path of movement illustrated by the dotted line L.
The applicator roller 115 is movable toward this line during the adhesive
binding mode in order to apply the material M, supported in the periphery of
20 the roller, to the spline edge of each booklet. Each booklet is finished with a
thin layer of adhesive material, as illustrated by the reference numeral N,
along the bound edge. The circular line of movement L is slightly spaced frorn
the periphery of the roller 115 so that the adhesive material may be deposited
with some thickness to the edge of the booklets. In addition, this arrangement
25 provides beads of material B at both corners of the spline. In accomplishing
best results, the peripheral speed of the roller 115 is made to equal
approximately the peripheral speed of the splines of the booklets along the lineL.
The stapler 80, as shown in Figure 8, is mounted for pivotal
30 movement on a pivot pin 130 suitably supported on the frame for the apparatus3. The pin 130 is oriented at an angle relative to the horizon (see Figure 1) sothat the plane of pivotal movement for the stapler is such as to be coplanar or
in alignment with each booklet to be stapled while in its radial orientation
within the sorter 64. In this manner, the anvil 131 and stapling head 132 tor
35 the stapler will be arranged to receive a corner of the booklet at the properstapling angle, and with sufficient clearance to avoid jamming. Each of the
501~3
-18-
plates 85 associated with the gripper mechanism is formed with a notch 133
(see Figure 4) at the rear ends thereof to receive the anvil 131 and head 132 ofthe stapler 80 during a stapling operation.
Movement of the stapler in its plane of pivotal movement is
5 effected by a motor M-6 mounted on the frame for the apparatus 3. A crank
mechanism 134 connected between the stapler and the frame produces pivotal
movement of the stapler into and out of its stapling position for each indexing
action by the sorter 64. When energized by a signal from the programmer P,
the motor M-6 rotates the stapler 80 to position the anvil 131 and head 132
10 into the notch 133 as shown in dotted lines in Figure 8. A solenoid SOL-3
mounted in the stapler 80 is then energized by a signal from the programmer P
to produce a stapling operation. The motor M-6, still being energized, returns
the stapler to its inoperative position away from the now rotating sorter 64.
In operation, the motor M-6 remains energized during the entire reproduction
15 job which includes stapling of completed booklets and the solenoid SOL-3 is
intermittently energized for each stapling opera-tion. The indexing rotative
movement of the sorter 64 by the motor and drive M-2 is in timed relationship
with the reciprocal movement of the stapler 80 between its inoperative and
operative position by the motor M-6, and the energization of the solenoid SOL-
20 3 to effect stapling. In this manner, productivity is maintained without pitch
loss and very high speed production is available.
Figure 9 is a block diagram of a control arrangement for the
reproduction and finisher system in Figure 1. The programmer P is operatively
connected to four remotes: (I) the processor I for controlling the xerographic
25 processing, copy sheet feed and movement, timing and monitoring and all
other parameters in the processor; (2) the input station comprising the flash
illumination system 6 and circuitry and copy size reduction of this feature is
available; (3) the automatic document handling apparatus 2; and (4) the
finishing station 3.
The finishing station 3 includes a driver operatively connected to a
servo controller which, in turn, is connected to a power amplifier serving to
energize and operate the rotary sorter indexing motor M-2. The remote for
the finishing station 3 also includes drivers for the unload or discharge cam
motor M-3, the adhesive applicator motor M-4, the adhesive binder positioning
35 motor M-5, and the stapler positioning motor M-6.
~2 ~5~3
-19-
The flow diagram of Figures lOa, lOb, lOc depict operational
control for the handling of the stream of copy sheets from the processor and
document handling apparatus 2 as the sheets enter the finishing station 3. The
stream comprises a series of multiple copies of the same document sheet
5 which are collected in the rotary sorter 6l~. In Figures lOa and lOb, collation
proceeds until completed for the document sheets in the apparatus 2 and
depending upon the number of copy sets or booklets that were programmed and
the number of bins in the sorter. If the programmed number of sets is less
than the number of bins, then after the last bin receives the last sheet, the
10 loading operation commences, as depicted in Figure lOc. If the programmed
number is larger than the number of bins, then after the bins are loaded with
completed sets, the binding operation commences. After unloading of the
entire sorter when binding has been completed, collation commences as
before, and so on. Suitable sensors and switches are placed in the system to
15 insure sheet counts and positioning for job timing.
From the foregoing, it will be apparent that an electrostatographic
system with finishing station has been described which will produce adhesively
bound collated sets and at a high production rate without loss of throughput, infact, at a rate in accordance with the full processing speed of the copy
20 processing machine. Since copy machine/finishers employing document
handling apparatus which recirculate document sheets on an individual basis
are limited in their reproduction rate due to the mechanical limitations of the
document apparatus, the present invention minimizes this limitation, so that
still higher rates of reproduction are attainable in utilizing the principles of25 the invention.
While the invention has been described 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 following
claims.
