CA1170209A - Sorter - Google Patents

Abstract

SORTER

ABSTRACT OF THE DISCLOSURE

An apparatus is disclosed for receiving sheets from the discharge portion of an electrostatic copy mechanic apparatus receives, stacks and collates the sheets as desired.
The apparatus can be electrically independent of the copier, and is attached thereto by simple hanger and bracket arrange-ments. The apparatus includes a plurality of trays which are moved past the discharge opening of the copier and which are controlled and arranged, selectively to receive (1) a plurality of sheets in each tray; (2) a single copy o:E each sheet in each of several trays; or (3) a number of identical sheets in one tray and a difEering number of other sheets in successive trays.
The apparatus can collect, collate, and sort the sheets while the trays are moving in one direction past the copier discharge opening as well as when the trays are moving past it in the other direction. The apparatus Will automatically conclude its sorting cycle whenever there is an extra-ordinary delay in the discharge of tile sheets from the copier. In another embodiment, uillzing an appropriate connection to the copier, the apparatus can be arranged to complete its collating cycle-only when the exact number of desired copies has been sorted.
(i.e. independently of any misfeed, delay, or jam-up in the copier operation).

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Description

1 BAC~GROUND OF ~HE INVENTION
Copying machines equipped with sorting, collecting and collating devices are known, and we refer, for example, to Stemmle U.S. patent 3,788,640, of January 29, 1974, and Schulze U.S. patent 3,774,902 of November 27, 1973. The devices disclosed in those and similar U.S. patents are principally utilized in connection with the operation of fairly large and complicated zerographic copy machines.
A compact sorter more closely related to the device of the present invention, is disclosed in our pendins Canadian application, Serial No. 365,667-5 and in the pending application of Lawrence Serial No.
365,683-7, the apparatus of the present invention is lightweight, compact, easily adapted for operation with a wide variety o~ makes and styles of zerographic copiers; and, more importantly is inexpensive to manufacture.
The device of the present invention is portable and is simple to operate, requires no electrioal connection to the copier,~ and is trouble-free and simple in its construction In an art which has grown rapidly ln the last two decades, not only is it important to provide a means for producing multiple copies of a single sheet, but also multiple copies of a multiple-page document, and to do 50 in a manner which compliments the speed of production o~ the copier so that the ~- 2 ~7~ 9 1 collating, sorting, and assembling of the multi-page document does not consume more time than the copying did and so that the collated documents are ready as soon as the last of the pages of the document have been copied.
SUMMARY OF T~E INVENTION
A sorting and collating apparatus for sheets according to the present invention comprises a plurality of trays disposed in a vertical stack, a frame adapted to be mounted at the sheet outlet from the copy machine, sheet transport means in the frame ~-including a hori~ontal shaft and a sheet feeding member mounted upon and revolvable about the shaft, :
means for rotating the sheet feeding member about the shaft, tray shifting means operable by the shaft, and means on the trays engageable by the tray shifting means to raise and lower the trays upon revolution of : the shaft from below the transport means to above the transport means responsive to revolution of the shaft, and drive means to intermittently rotate the shaft.
A sorting and collating apparatus for shee~s according to a feature of the present invention comprises a frame, a plurality of trays disposed in a vertical stack, a tray support extending from the frame to support the outer end of the lowermost of the trays, a pair of sidewalls for the frame, vertically extended slot~ in the sidewalls, trunnions ~,s ',,'~,r~:

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1 on the inner end of each tray and extending through the slots, a drive shaft supported by the side walls, and a pair of transfer wheels mounted on the drive shaft, externally of said sidewalls. The transfer wheels each have at least one geneva-type slot adapted to engage the trunnions and the inner ends of the trays are biased together. A space is defined in the stack by engagement of the trunnions with the transfer wheels between the underside of the inner end of one tray and the upper side of the inner end of another tray. The transfer wheels are constructed and arranged to move a tray upwardly and downwardly as the wheels are rotated in opposite directions and as the slots in the wheels engage the trunnions of the trays and as the trunnions are moved along the slots in the frame. The apparatus further includes a reversible electric motor connected to the drive shaft and an electric circuit including a sensing switch, with the switch connected to the motor to instruct the motor to rotate the transfer wheels after a sheet of paper has passed across the switch.

7~Z~)9 1 According to a feature of the invention each transfer wheel has a pair of slots disposed 180 degrees from each other.
According to a further feature of the invention a friction wheel is adapted to engage an exit roll of a copier, and guide wheels and transport belts rotate freely about the drive shaft. A drive is provided between the frlction wheel and the guide wheels, to drive the guide wheels when the friction wheel i6 driven.

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~L~L7~32~9 DETAILED DESCRIPTION

For the purpose o~ illustrating the invention, there is shown in the accompanying drawings a form thereof which is at present preferred, although it is to be understood that the various instrumentalities of which the invention consists .
can be variously arranged and organized and that the invention is not limited to the precise arrangements and organizations of the instrumentalities~as herein shown and described. -In the drawings, wherein like reference characters indicate like parts:

FIG. 1 is a perspective view of a copier machine showing ~ -the paper-discharge opening and w`it~h a sorter of the present invention~about to be attached thareto.

FIG. 2 is a perspective view of the sorter of the present invention~attached to a copier machine.

FIG. 3 is a perspective view Orf ;~the~sorter of~the~present -~invent~lon~looklng at the~back or~receiv1ng~end;thereof~and with~the trays disposed both above~and below the sheet-receiv-ing area~

~ FIG~. 4 is a front~end vlew of~a sorter~of~the present in-ventlon. ~ ;

FIG.~5 is a perspective vlew of a motor and drive unit of ehe sorte o: tb- pre-ene in~en~ior~

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, FIG. 6 is a vertical, cross-sectional view ~aken generally along line 6-6 of FIG 4.
FIG. 7 is a fragmentary top-plan view of the drive mechanism of the sorter of the present invention, taken generally along line 7-7 of FIG 6.
FIG. 8 is a fragmentary end elevational view of the sorter of the present invention showing the discharge rollers and transfer wheels, along with the sheet-sensing mechanism.
FIG. 9 is a side-elevational view of a transfer wheel showing the switches which control the tray advancing mechanism.
FIG. 12 is a fragmentary cross-sectional view, illustrating a trigger mechanism of one embodiment of the present invention wherein the timing impulse for the sorter is derived from the action of the moving optical carriage of the copier~
FIG. 13 is a fragmentary transverse section on the line 13-13 of FIG. 6, found on page 3 of the drawings.
FIG. 14 is a fragmentary vertical sectlon~on the line 14-14 of FIG. 13, found on page 3 of the ; drawings.
Referring now to FIG. 1, we have illustrated an electrostatic copier 20 of a type well known in the art. It lncludes a body 21 havlng a cover 22 beneath which the material to be copied is placed on a transparent plate during the copylng action. It may include an on-off switch 23, a "number-of-copies"

, 1~L7~Z09 switch 24, a start button 25-a, and a "dark-light" control 25-b, all well known in the art. -Also shown in FIG. l are paper-trays 29-a and 29-b, and a tray selector 30. The tray 29-a holds letter-size papers 8~2" x ll"~ and the tray 29-b holds legal size paper, 81~" x .
13".

As a copy is completed, it is discharged through the opening 26, carried by the exit rolls 27 and 28. In a non-stacking copier, a receiving tray (not shown) receives the paper after discharge from the rollers 27 and 28.

. Also shown in FIG. l is a collater-sorter of the present ; invention, indicated generally by the numeral 31. The sorter ~ ~ : 31 generally includes a housing 32, having attached thereto a :
: cover 33 for the motor and drive mechanism, and a control panel : ~ : ~34. The housing 32 has brackets 35-a and 35-b (shown more .
: clearly in FIG. 3), which enable the~sorter to be:hung:on the side of the copi~r ad~acent the~ex1t roll;ers~27 and 28. In this posit1~on, the~control~panel 34~ of the:sorter lS adiacent ~
: to and aligned with~the~controls of the aopler~ so that all of :
: ~the control mechanismsare~grouped toge~her.~ ~

The control panel~:34 of the sorter 3l~inc1udes an~on-off switch 35-c, a pilot light:~36: to;indica;te when the power of the : sorter~is turned on,~a reset button:37, and a mode selector ~--switch 38.
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: ': ' :` 1~71D2~9 As can be seen in FIGURES l and 2, the sorter also includes a plurality of paper-receiving trays 39, and a tray-support bracket 40.

All of this mechanism is compactly designed and assembled so that the sorter is supported neatly and conveniently o~ the side of the copiér, above the paper supply trays 29 and 30, and in alignment with the exit rollers 27 and 28. It occupies no more space than the pre~ious non-collating and non-sorting trays supplied with the copier.

We refer now to FIG. 6 which, as a cross-sectional view, shows the relationship of..the trays 39 and the housing 32 of the sorter as they are supported.o~ the end wall of the copier 20. As mentioned above, the housing 32 is supported by brackets 35-a and 35-b on the end wall of the copier 20, holding the transport mechanism of the sorter in~operative juxtaposition to the exit rolls 27 and 28 of the copier.:

A friction drlve wheel 43 is in contact ~ith the lower exlt roll 28 of the~copler and also with the shaft 44 of the sorter so that when~the copler is operating, the exit roll 28 rotates in~a counter-clockwise direotlon (as:shown by the :arrow 45), and the friction~wheel ~43 will rotatP in:a d ockwise direction, and~the shaft 44 wlll rotate~in:a counter-clockwise direction. : : ~ ;

Attached to the shaft 44:are a plurality of pulleys or hubs 46 ~arry1ng the transpore b~lts 47 which cause the low~r : ;
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~3 7~2~9 exit roller 48 to tu.rn on the drive shaft 49. The exit rollers 48 are free-wheeling on the drive shaft and rotàte independently thereof.

Additionally, the upper exit roller 50 guides the paper between it and the drive belts 47 carrying the paper outwardly into the opening 41 of the trays 39 in the direction shown by the arrow 51.

The opening 41 is defined between an upper tray 39-a and a lower tray 39-b.

The trays are inclined as shown in FIG. 6 and supported at their inner end on trunnions,~rodsf~r~ bas 52, which are affixed to the edges of the tray, and the ends of which are guided in the slots 53.

Foam rubber pads 42 are located on the upper surface at the 1nner eDd of each tray 42-a. These pads are adapted to :
clamp the paper on the respective trays tightly in place when the trays are moved together above or:below the sheet-receiving opening 41. The outer end:of each t~ay has a~spacer~guide 42-a to keep the~tray ends separate~and~to enable~them to pass over each other freely as~the lnner~ends of the traY are moved ~ .
up and down in the slot 53.~

The bottom tray 3~9:-c is~supported at its~outer~end~by the tray-support bar 40,~at only one edge thereof ~ee FIG. 4), so : ~ ~ ; :`
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~7~ 9 that the operator can reach in to remove paper, either from the end of the trays or from the side of the trays.

The trays 39 are "dished" at the outer end,`as is seen particularly in FIG. 4, so that the curved sheet will be self-supporting, as it ex~ends beyond the outer end of the tray and .
wlll not droop over the edge thereof.

Although the rods 52 for each of the trays 39 ar0 free to slide up and down in the slot 53, the rods on the top tray 39-a and the bottom tray 39-c are longer than the rest and extend into engagement with a tray stop 55. The tray stop 55~prevents the uppermost tray 39-a from going to a position lower than that shown at 39-b in FIG. 6, and~a~lso prevents the lowermost tray 39-c from rising abo~e that position 39-b shown in FIG. 6.

Thls lnsures that there wlll always be a tray beneath the arrow Sl to receiYe a sheet of pa~per as lt exlts~from the trans-port belts 47.

~ prings~ 57 conDect the upper tray 39-a~aDd the~bottom tray 39-c~,~so as to b~ias the lower trays upwardly and lnsure that bars 52~of one~tray~will alwàys be ln~on~act~with the transfer wheel 58. Gravlty will ;always~insure that the lower-most of all trays above the transfer wheel 58 will have its ~ars restlng OD the;transfer wheel 58. ~ ~

The two transfer~wheels 58 are;located one~on each slde of tbe 1nner rames 56~o' the hAusing ~2. ~he transfer wheels are ~, 1~L7~209 aE~ixed to the drive shaft 49, one transfer wheel 58-a being shown at the left side in FIc..7,and the other transfer wheel 58-b shown at the right end of the shaft 49 in FI~. 7. ~ach of these transfer wheels 58-a and 58-b has a pair of slots 59 therein, disposed diametrically opposite as is seen-particu-larly in FIG. 6. When the transfer wheels are rotated clock-wise as seen in FIG. 6, the slot 59-a engages the pin or bar 52 on the tray 39-b which is biased upwardly beneath the wheel 58 by the spring 57. Rotation of approximately 90 of the wheel 58 elevates the tray to the position 39-a in FIG. 6, whereupon it will stay in tha~position, being supported by the outer cir-cumference of the transfer wheel. Each transfer wheel turns 180 per transfer, thus bringing the slot 59-b 180 to the posi-tlon prev1ousIy occupied by the slot 59-a shown 1n FIG. 6.

It s~ould be understood that the t~ansfe~ wheels may have a single slot 59 and turn 3609 ~per transfex. Such trans-~er wheels aremre particularly thersubject of our above-identifled application. However~in the present construction, the auxiliary~transport rollers~48,~elevate~the sheet above the trans~er wheels 58, 50 that a simple~drive strutUre for the~wheels 58~, can be employed~ __ ~ The trans~fer wheels 58~are turned by the drive~shaft 49 under the impetus of~the motor~61, through the;universal ~oint or drive p}n 62, which connects the hub 63~(affixed to the shaft 64 of the motor~61) and the hub 65 of the 1eft-hand trans-fer wheel 58-a. ~ ~ ~

Thus, on proper signaI, the transfer wheels are caused to rotate in 180~each time a sheet o~ paper is discharged from between the exit roll 50 and the belts 47 of the sorter.

, ~L~7-l~Z~9 The sheets gravitate to the inclined trays as they leave the transport, so that the trailing edge of the sheets may possibly be contacted by the belts 47, as a tray is transfered upwardly, to prevent such contact, I provide the novel structure best seen in FIGS. 13 and 14.

Drive shaft 49, has a cam sleeve 49a, made of elast-meric material rotatably disposed thereon, and clutch means drive the sleeve 49a in one direction with the shaft but permits the sleeve to remain stationary wheh the shaft rotates in the other direction. In the form shown, the clutch means comprises coiled springs 4~b lo~diny the sleeve 49a between stop collars 49c fixed on the shaft. A plate 49d (also shown in FIG. 6) is mounted on the back of the housing and can flex at its lower end to be normally raised at its upper end towards the sleeve 49a. Sleeve 49a has two lobes 1 and 2, and radial shoulders, 3 and 4, corresponding with the number of transfer slots in the transfer wheels 58. Thus, when the shaft 49 rotates clock-wise, as seen in FIG. 14, lifting à tray after deposit of a shçet, plate is flexed to the left and shifts a sheet e~ ~h-tw~se o the tray, so that the trailing edge of the sheet, which gravitates to the inclined tray, is displaced c sufficiently that it cannot contact the transport belts 47 when the tray is moved downwardly.~;Du~ring lsft hand rotation of the shaft, the~upper end of the plate 49d engages a rib 3 or 4 to hold the aam sleeve again~t rotation with the shaft, preventinq interferéncë of the~Plate ~; with~the downward moving tray, ~

The instructions for the transfer wheels to rotate is given by~the paper-exit switch;66, which is~mounted on the ~frame of the sorter and has its detector~67 disposed upwa~dly : ~

into the path of the sheet of paper as it is carried by the transport belts 47 from the exit rolls 27 and 28 of the copier toward the exit roll 50 of the sorter. The detector may be a micro switch or may be an optical beam of light or any ap-propriate means to sense the passage of the sheet a~ong the transport bel-ts. -The electric circuit is so arranged so that the switch 66 a~tuates an electric circuit and energizes the motor 61 after a sheet of paper has been discharged into the tray 39-b beneath the opening 41. Then the transfer wheels 58 rotate clockwise 180, lifting the tray from the poe~tinn 39-b to the position 39-a, and the sorter is ready to receive ano~her copy into the opening 41.

The motor 61 is~a reversible motor, and the electric cir-cuit is arranged so that after all of the trays have moved up-wardly from the lower "home" position, the next series or mode of sorting/take place on the downward movement of the trays.
Thus when the motor is next energized, it rotates in the oppo-site direction, causing:the transfer wheels to rotate in a counter-clockwi~se direction when vlewed ln FI6. 6, thus causing the:Iower-most tray of the stack in the upper position~-to be carried to the posit1oD:39-b ln FIG. 6~, after the~first sheet of the second page to be copled ln the sorting~arrangement has been discharged into the opening 41. Thereafter, continuous ~7~D2~9 discharge of the next 9 copies will cause the trays 39 to "stack" downwardly, until all of the trays are located at or below the position 39-b.

Sequentially thereafter, the third page of the document will be added to the trays as the trays move upwardly, thè fourt h will be added as the trays move downwardly, etc.

As is well known in the art, multi-page documents are copled in reverse order in a machine which discharges copies face up. This stacks the sheets in proper order and eliminates re-arranging the order when the copying ls completed.

As has been previously here described and with reference to FIG. l,~a reset button 37 is included in the circuit so that all of the trays can be s~nt downwardly to the "home" position if so desired, rather than "stackingl' downwardly as a new page is added to the assortment. ;

It will be noted from the prev~ious~ description ~hat the heart of the control and drlve mechànism~ls~the~shat 49~ This shaft not~only supports and causes thé tran~sfer wheels to rotate in synchronism, but also~permlts t~he transfer wheels to~be located externally of the paper path. The roll~ers 48 which carry the transport belt~s 47, are a~lso supported on the shaft 49, freely wheeling, so~that~all of the drlve~mechanism is located outside the path of~the paper as it goes through the ::
sorter.

-14_ ~ 7~ 9 ¦ Although we have describecl the paper exit switch 66 as l being the preferred method of detecting the passage of paper ¦ into the opening 41, and to direct the movement of the trays 39, we have illustrated in FIG 12 an alternate control which is a trigger 70 actuated by the moving optical carriage 68 of the copier 20 A bracket 69 can be ad~usted along thè carriage 68, so that at the end of the movement of the optical carriage 18, the bracket 69 strikes the trigger 70, urging it against the spring 71 and into and out of appropriate contact with the switch 72 The switch 72 acts in a manner similar to the switch 66 A suitable time delay is interposed in the electri-cal circuit so that the rotation of the transfer wheels 58 will take place after the copied sheet of paper has passed out of ¦ engagement between the belts 47 and the exit roll 50 of the ¦ sorter In one~embodiment o~ control mechanism and t~el5ensing ¦ exit~switch 67! the sorter c~n be ~comple~ely elèQ~t~ï~ally I ¦ independent of the copier. ~

~ ~ ~ We~ha~ aloo~shcwn 7n FIG ~9 a~swi~ch 7- whi~h contac s : I
the hub of the transf~r wheel 58-a and insures that the trans-fer wheels rotate only 180 per passage o~ each sheet of paper througb t ~s~ter --~ - `- ~

~3 7~Z~)9 Additionally, we have indicated in FIG. 9 a "tray-home"
switch 74 which can be set to insure the return of the trays into the lower or "home" position after all of the trays have been advanced upwardly to receive the paper to be sorted and when sorting is not to be done on the downward movement of the trays. .

It will be also noted by reference to FIG. 7 that the hubs 46 on the shaft 44 all rotate in unison and thus drive the transport belts at a uniform speed.

We have shown the trays 39 as being inclined upwardly and outwardly in FIG. 6 as this configuration prevents the paper from "floating" out of the tray àfter discharge from the exit roll of the sorter. Moreover, the slight inclination causes ¦ the paper to settle back downwardly in the tray on top of the foam pieces 4?, thus insuring that all of the sheets will be -clamped between foam and the underslde; of the next uppermost tray when the trays are not ln position 39-b. ~The foam rubber pads are about l/4l' thick and when~a full load of paper has been placed in each of~the trays and the~trays assembled eitber above or below the opening 41, the foam is compressed to about 1/32" of an lnch so that no space is lost~and yet the sheets are flrmly grlpped ln~place on~the tray. ~

Time delqy elements ~xe incorpor~ted: ~n the cQntxols so that t e ro~enent o~ the e~ays will not tak~

~ ~L7~Z~9 ¦ place until after the paper exit switch is out of contact with ¦ a sheet of paper and the paper has been appropriately dis-¦ charged into the opening 41 onto the underlying tray.

The "tray-home" switch previously referred to can be set to operate in conjunction with the reset switch so t`hat the direction of the motor may be reversed, and the trays caused to move in the appropriate direction at the end of the,upward or downward movement of the complete sets of trays.

As can be seen, this type of simple hang-on, plug-into-wall sorter, requires no mechanical or electrical skill to l lnstall and can be done by the customer, and there are no al-¦ teratlons or electrical connections`needed to the copier.

¦ As stated, the design o~ the trays is such that in at ¦ least some area, the paper is always exposed, permitting either ¦ end unloading or side unloading of the paper.

¦ ~lthough the paper extends beyond the end of the trays, the tra~sare curved, and this curved paper acts like a "beam"
; and is stlffened and will not droop beyond the edges of the ¦ trays. Thus, both short and long sheets can be handled wlth equal ease. ~ ~

Furthermore, ~he trays are~supported in such a manner at the outer end above the tray~support bar 54, so th~t the ¦ stacked trays can be opened at their outer end for easy re-¦ moval of the sheets, to cIear t~ejams (if any exist) and to reach s rt ~heets.

~7~2~9 .. , . .. . .. ,. .. . ., . .. _ .. .... . ........ ...... ... ... ... . _ .. _, _ _ . _ .. .... .. _ _ It is to be understood that the present invention may be embodied in other specific forms without departing from the spirit or special attributes hereof, and it is, therefore, de-sired that the present embodiment be considered in all respects as illustrative, and, therefore, not restrictive, reference being made to the appended ~laims rather than to th,e foregoing description to indicate the scope of the invention. .

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Claims (7)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEDGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A sorting and collating apparatus for sheets comprising a frame, a plurality of trays disposed in a vertical stack, a tray support extending from said frame to support the outer end of the lowermost of said trays, a pair of sidewalls for said frame, vertically extended slots in said sidewalls, trunnions on the inner end of each tray and extending through said slots, a drive shaft supported by said sidewalls, a pair of transfer wheels mounted on said drive shaft, externally of said sidewalls, said transfer wheels each having at least one geneva-type slot adapted to engage said trunnions, means biasing the inner ends of said trays together, a space defined in said stack by engagement of said trunnions with said transfer wheels between the underside of the inner end of one tray and the upper side of the inner end of another tray, said transfer wheels constructed and arranged to move a tray upwardly and downwardly as the wheels are rotated in opposite directions and as the slots in the wheels engage the trunnions of the trays and as the trunnions are moved along the slots in the frame, a reversible electric motor connected to said drive shaft, an electric circuit including a sensing switch, said switch connected to the motor whereby to Instruct the motor to rotate the transfer wheels after a sheet of paper has passed across the switch

2. The apparatus of Claim 1 wherein each transfer wheel has a pair of slots disposed 180 degrees from each other.

3. The apparatus of Claim 1 wherein a friction wheel is adapted to engage an exit roll of a copier, guide wheels and transport belts rotating freely about the drive shaft, drive means between said friction wheel and said guide wheels, to drive said guide wheels when said friction wheel is driven.

4. The apparatus of Claim 1 including a reversing switch adapted to engage a tray to cause the motor to turn in one direction to move the trays in an upward direction and also to cause the motor to move the trays downwardly.

5. The apparatus of Claim 3 including a stop to insure that one tray is always located in paper-receiving position adjacent and beneath the discharge end of the transport belts.

6. The apparatus of Claim 1 wherein the drive shaft is centrally located beneath the path of the paper through the apparatus.

7. The apparatus of Claim 1 including a cam and finger constructed and arranged to align the sheets of paper in each tray and to space said sheets from the frame of the apparatus.