CA1195055A - Very high speed duplicator with finishing function - Google Patents

Abstract

ABSTRACT

A copying/finisher system is described as having a compiling station for receiving a collated copy set prior to stapling. The compiling station is defined by a reciprocably movable, horizontally arranged collecting plate upon which the copy sheets are collected. The arrangement presents the leading edge of the sheets to the clamping position of one or more staplers.
After collection of the copy sheets, the leading edge of the set is clamped and stapled while the plate is moved to permit dropping of the finishing set.

Description

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~

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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.

-2b-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 -6~

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.

-6a-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"'"

Claims (2)

WHAT IS CLAIMED IS:

1. In a reproduction system having a document handling apparatus adapted to transport individual document sheets from a supply stack to an exposure station and effecting an exposure station 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 exposed sheets, the combination of:
a finishing apparatus adapted to receive collated sets of copy sheets of a set of document sheets 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 operation, said finishing apparatus including a compiling station whereat collated copy sheets are collected and having a movable member upon which sheets are supported during collection in a set prior to binding, means for registering the copy sheets being collected along the leading edge thereof to provide an aligned edge for the set 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 move-ment of said set, and means for moving said member out of its supporting position during the binding operation to effect removal of the set from said compiling station.

2. The system of claim 1 wherein said binding device is a stapling device.