U.S. patent application number 10/498612 was filed with the patent office on 2005-02-24 for transportation system for sheet delivery between sheet or sheet stack processing equipment.
Invention is credited to Amdahl, Samuel, Hotkowski, Peter, McClellan, Robert, Russo, James, Todaro, Frank.
Application Number | 20050042072 10/498612 |
Document ID | / |
Family ID | 34193380 |
Filed Date | 2005-02-24 |
United States Patent
Application |
20050042072 |
Kind Code |
A1 |
Amdahl, Samuel ; et
al. |
February 24, 2005 |
Transportation system for sheet delivery between sheet or sheet
stack processing equipment
Abstract
A sheet or sheet stack handling system for performing at least
one operation on successive sheets or stacks of sheets, and
interface for the same, wherein the document handling system
includes at least two modules selected from a group consisting of
an elevator transfer station, a modular transfer station, a storage
station, a transportation cart, and a modular processing station.
When more than one modular processing station are coupled to form
the document handling system, the system may be utilized to perform
a series of operations on successive sheets or stacks of sheets.
Alternately, the individual processing stations or a group of the
processing stations may be utilized to perform only certain
functions on the sheets. The modules each contain a plurality of
parallel, spaced, elongated support surfaces that form a sheet
support surface. The parallel, spaced, elongated support surfaces
of the two modules are sized and disposed that they may intermesh
to allow a transfer of sheet stacks between the modules when one
set of parallel support surfaces is moved upward or downward
relative to the other.
Inventors: |
Amdahl, Samuel; (Arlington
Heights, IL) ; Hotkowski, Peter; (Chester, CT)
; Russo, James; (Chicago Heights, IL) ; Todaro,
Frank; (Old Saybrook, CT) ; McClellan, Robert;
(Bethel, CT) |
Correspondence
Address: |
LEYDIG VOIT & MAYER, LTD
TWO PRUDENTIAL PLAZA, SUITE 4900
180 NORTH STETSON AVENUE
CHICAGO
IL
60601-6780
US
|
Family ID: |
34193380 |
Appl. No.: |
10/498612 |
Filed: |
June 10, 2004 |
PCT Filed: |
December 13, 2002 |
PCT NO: |
PCT/US02/39834 |
Current U.S.
Class: |
414/789.9 |
Current CPC
Class: |
B65H 2301/42252
20130101; B65H 2405/312 20130101; B65H 31/30 20130101 |
Class at
Publication: |
414/789.9 |
International
Class: |
B65H 031/30 |
Claims
1. A document handling system for performing at least one operation
on successive sheets or stacks of sheets, the document handling
system comprising: at least two modules selected from the group
consisting of an elevator transfer station, a modular transfer
station, a storage station, and a modular processing station for
performing an operation on said successive sheets or stacks of
sheets, a transportation cart for transporting stacks of sheets
between the at least two modules, the transportation cart
comprising a plurality of elongated support surfaces disposed
substantially parallel one another to collectively present a sheet
support surface, said at least two modules each comprising a
plurality of elongated support surfaces disposed substantially
parallel one another to collectively present a sheet support
surface, said module plurality of elongated support surfaces of
each said at least two modules and said transportation cart
plurality of support surfaces being spaced such that at least a
portion of said transportation cart plurality of elongated support
surfaces can separately intermesh with the module plurality of
support surfaces to create joint sheet support surfaces such that
sheets or stacks of sheets disposed on one of the transportation
cart plurality of elongated support surfaces or on one of the
modules plurality of elongated support surfaces may be transferred
to the other of the transportation cart plurality of elongated
support surfaces or module plurality of support surfaces, whereby
the transportation cart is utilized to move said successive sheets
or stacks of sheets between said modules through the document
handling system.
2. The document handling system of claim 1 wherein the elevator
transfer station includes a moveable surface that moves the sheets
or stacks of sheets in a substantially vertical elevation.
3. The document handling system of claim 2 wherein the plurality of
elongated support surfaces of the elevator transfer station include
driven surfaces operable to apply a forward motion to the sheets or
stack of sheets to drive the sheets or stack of sheets through the
document handling system.
4. The document handling system of claim 1 wherein the plurality of
elongated support surfaces of at least one of the at least two
modules includes driven surfaces operable to apply a forward motion
to the sheets or stack of sheets to drive the sheets or stack of
sheets through the document handling system.
5. The document handling system of claim 4 wherein the plurality of
elongated support surfaces of the modular transfer station include
said driven surfaces operable to apply a forward motion to the
sheets or stack of sheets to drive the sheets or stack of sheets
through the document handling system.
6. The document handling system of claim 4 wherein the plurality of
elongated support surfaces of the modular sheet processing station
include said driven surfaces operable to apply a forward motion to
the sheets or stack of sheets to drive the sheets or stack of
sheets through the document handling system.
7. The document handling system of claim 3 wherein the driven
surfaces include a plurality of driven rollers.
8. The document handling system of claim 3 wherein the driven
surfaces include a plurality of driven belts.
9. The document handling system of claim 1 wherein the joint sheet
support surface is disposed substantially in a joint sheet support
plane, and the intermeshed plurality of elongated support surfaces
of at least one of the at least two modules is moveable in a plane
other than said joint sheet support plane whereby a sheets or stack
of sheets disposed on the joint sheet support surface may be
transferred to be supported substantially on the plurality of
elongated support surfaces of one of the at least two modules by
raising or lowering the elongated support surfaces moveable in the
plane other than said joint sheet support plane.
10. The document handling system of claim 1 wherein the modular
processing station is selected from the group consisting of a
printer, a tab cutter, a binder, a feeder, a cover closer, an
envelope stuffer, a punch, a stacker, a laminator, and a
sealer.
11. The document handling system of claim 1 comprising at least a
first and a second modular processing station for performing first
and second operations on said successive sheets or stacks of
sheets.
12. The document handling system of claim 11 wherein said modular
processing stations are disposed and coupled to operate inline such
that the first modular processing station performs said first
operation on the sheet or stack of sheets, the sheet or stack of
sheets is then automatically fed to the second modular processing
station, and the second modular processing station then performs
said second operation on the sheet or stack of sheets, the first
and second modular processing stations being further arranged to
operate offline wherein at least one of the first or second modular
processing station may be operated to perform said respective
operation independent of the remaining modular processing station
performing its respective independent operation.
13. The document handling system of claim 11 wherein said modular
processing stations are disposed and coupled to operate inline such
that the first modular processing station performs said first
operation on the sheet or stack of sheets, the sheet or stack of
sheets is then automatically fed to the second modular processing
station, and the second modular processing station then performs
said second operation on the sheet or stack of sheets, the first
and second modular processing stations being further configured to
be decouplable from each other, wherein when decoupled at least one
of the first or second modular processing station is operable to
perform said respective operation independent of the remaining
modular processing station.
14. A document handling system for performing at least one
operation on successive sheets or stacks of sheets, the sheet
handling system comprising first and second modular processing
stations for performing respective first and second operations on
said successive sheets or stack of sheets, said modular processing
stations being disposed and coupled to operate inline such that the
first modular processing station performs said first operation on
the sheet or stack of sheets, the sheet or stack of sheets being
successively then automatically fed to the second modular
processing station, and the second modular processing station then
performing the second operation on the sheet or stack of sheets,
the first and second modular processing stations being further
arranged and adapted to operate offline wherein at least one of the
first or second modular processing station may be operated to
perform said respective operation independent of the remaining
modular processing station performing its respective independent
operation.
15. The document handling system of claim 14 further comprising at
least one module selected from the group consisting of an elevator
transfer station, a modular transfer station, a storage station, a
transportation cart, and a further modular processing station for
performing an operation on said successive sheets or stacks of
sheets, said at least one module interfacing with at least one of
the first or second modular processing station.
16. The document handling system of claim 11, further comprising at
least one modular transfer station disposed inline between the
first and second modular processing stations such that the modular
transfer station acts as a buffer to hold said sheet or stack of
sheets processed by the first modular processing station until such
time as the second processing station is operable to perform the
second operation on said sheet or stack of sheets.
17. An interface to a document processing system comprising at
least two cooperating modules selected from the group consisting of
an elevator transfer station, a modular transfer station, a storage
station, a transportation cart, and a modular sheet processing
station, wherein a transfer of sheets or stacks of sheets between
the cooperating modules is facilitated by the intermeshing of a
plurality of elongated support surfaces extending from each of the
cooperating modules, the interface being at least partially
actuatable by a user, the interface comprising: a user interface
portion for allowing interaction of the user with the document
processing system; and an automatic interface portion for
automatically receiving information in device-readable form.
18. An interface to a document processing system comprising at
least two cooperating modular sheet processing stations, wherein
the cooperating modular sheet processing stations are disposed and
coupled for inline processing of sheets or sheet stacks and, while
coupled, to allow the offline use of at least one of the
cooperating modular sheet processing stations, the interface being
at least partially actuatable by a user, the interface comprising:
a user interface portion for allowing interaction of the user with
the document processing system, and for initiating the offline use
of at least one of the cooperating modular sheet processing
stations; and p1 an automatic interface portion for automatically
receiving information in device-readable form.
19. The interface according to claim 17, wherein the user interface
portion includes a display portion and a user input portion,
wherein the display portion displays to the user at least one type
of information selected from document processing set up
information, document processing system diagnostic information, and
user input information.
20. The interface according to claim 19, wherein the user input
portion comprises a touch screen.
21. The interface according to claim 20, wherein the touch screen
is integral with the display portion of the user interface
portion.
22. The interface according to claim 19, wherein the user input
portion comprises a keypad.
23. The interface according to claim 17, wherein the automatic
interface portion is configurable to receive information from at
least one of a sensor input, a barcode reader input, and a digital
electronic input.
24. The interface according to claim 23, wherein the sensor input
indicates the presence of a sheet in an input stack.
25. The interface according to claim 23, wherein the sensor input
indicates the presence of a cart for transporting sheets or stacks
of sheets.
26. The interface according to claim 23, wherein the information
receivable from the barcode reader input comprises an indication of
a desired document processing operation.
27. The interface according to claim 23, wherein the digital
electronic input comprises a USB port.
28. The interface according to claim 23, wherein the information
receivable from the digital electronic input comprises information
from at least one of a printer, a computer, and the Internet.
29. A transportation cart for moving stacks of sheets between
processing modules in a sheet handling system, the sheet handling
system comprising at least two modules selected from the group
consisting of an elevator transfer station, a modular transfer
station, a storage station, and a modular processing station for
performing an operation on said successive sheets or stacks of
sheets, said at least two modules each comprising a plurality of
elongated support surfaces disposed substantially parallel one
another to collectively present a sheet support surface, the
transportation cart comprising a plurality of elongated support
surfaces disposed substantially parallel one another to
collectively present a sheet support surface, said module plurality
of elongated support surfaces of said at least two modules and said
transportation cart plurality of support surfaces being spaced and
disposed such that at least a portion of said transportation cart
plurality of elongated support surfaces can separately intermesh
with the module plurality of support surfaces of each of said at
least two modules, respectively, to create joint sheet support
surfaces such that sheets or stacks of sheets disposed on one of
the transportation cart plurality of elongated support surfaces or
on the module plurality of elongated support surfaces may be
transferred to the other of the transportation cart plurality of
elongated support surfaces or module plurality of support surfaces,
the transportation cart further comprising a securing arrangement
that selectively holds the stack of sheets in position on the sheet
support surface during movement whereby the transportation cart is
utilized to move said successive sheets or stacks of sheets between
said modules through the document handling system.
30. The transportation cart of claim 29 further comprising wheels
for movement of the cart.
31. The transportation cart of claim 30 wherein the wheels are in
the form of rollers.
32. The transportation cart of claim 30 wherein the wheels are in
the form of casters.
33. The transportation cart of claim 30 further comprising a handle
for imparting movement to the transportation cart.
34. The transportation cart of claim 30 wherein the securing
arrangement comprises at least one upright and a substantially
horizontal portion that is movable between a position wherein the
horizontal portion contacts the stack of sheets to secure the stack
to the sheet support surface and a position wherein the horizontal
portion does not contact the stack of sheets such that the stack
may be transferred to one of the modules.
35. The transportation cart of claim 34 wherein the securing
arrangement comprises a pair of uprights and the horizontal portion
extends between the uprights.
36. The transportation cart of claim 30 wherein the securing
arrangement comprises a belt.
37. The transportation cart of claim 30 wherein at least one of the
cart elongated support surfaces or the module elongated support
surfaces are selectively movable in substantially vertical
direction to facilitate transfer of a stack of sheets supported on
the elongated support surfaces of either the cart or the module to
the elongated supported support surfaces of the other of the cart
or the module.
38. The transportation cart of claim 30 wherein the cart elongated
support surfaces are selectively movable in substantially vertical
direction to facilitate transfer of a stack of sheets supported on
the elongated support surfaces of either the cart or the module to
the elongated supported support surfaces of the other of the cart
or the module.
39. The transportation cart of claim 38 further comprising a
housing.
40. The transportation cart of claim 39 wherein the housing is
selectively moveable in the substantially vertical direction
whereby the cart elongated support surfaces are movable in the
substantially vertical direction.
41. The transportation cart of claim 39 wherein the cart elongated
support surfaces are movable in the substantially vertical
direction relative to the housing.
42. A document handling system for performing at least one
operation on successive sheets or stacks of sheets, the paper
handling system comprising: at least two modular processing
stations for performing a first operation and a second operation on
said successive sheets or stacks of sheets, at least one modular
transfer station disposed inline between the first and second
modular processing stations such that the modular transfer station
acts as a buffer to hold said sheet or stack of sheets processed by
the first modular processing station until such time as the second
processing station is operable to perform the second operation on
said sheet or stack of sheets, said at least two modular processing
stations and at least one modular transfer station each comprising
a plurality of elongated support surfaces disposed parallel one
another to collectively present a sheet support surface, at least a
portion of said plurality of elongated support surfaces of the at
least two modular processing stations being disposed to intermesh
to create a joint sheet support surface such that sheets or stacks
of sheets disposed on one such plurality of elongated support
surfaces on one of the at least two modules may be transferred to
the plurality of elongated support surfaces on another of the at
least two modules, whereby said successive sheets or stacks of
sheets are moved through the document handling system.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a document processing system
utilizing a transport system for passing sheet stacks between
processing modules to provide optionally modular post-printer
document processing.
BACKGROUND OF THE INVENTION
[0002] In the sheet finishing industry, sheet stacks are
transferred between processing equipment as various steps are
performed on the stacks of sheets. This transfer is typically
classified as "in-line" or "off-line," and sometimes
"near-line."
[0003] "In-line" refers to two pieces of processing equipment
having their sheet paths joined together such that individual
sheets are passed from one system to the other sequentially and
processed as such. While there are many examples of such "in-line"
processing, one such prominent example is designed following the
Xerox DFA (Digital Finishing Architecture) Standard. The DFA
protocol spells out mechanical and software specifications for
attaching finishing machinery to DFA compatible Xerox sheet
printers. Many vendors make secondary equipment to create systems
using this standard, including Standard Finishing, C.P. Bourg,
Duplo, and others.
[0004] "In-line" systems are advantageous in that they require
minimal operator interaction, and therefore, have lower overhead
and least opportunity for operator error. The entire system is
locked in a one-to-one speed relationship, however, limiting the
performance of the entire system to that of the slowest component.
Accordingly, a major disadvantage of the "in-line" system is the
lack of a buffer to allow for continued processing by some portions
of the system if other portions of the system temporarily cease
operations. Another disadvantage is reduced versatility from two
types of processing modules that are complexly coupled, inhibiting
their separate use for other functions.
[0005] "Off-line" refers to sheets being transferred in some
non-automatic fashion, usually in stacks of sheets. Examples
include simple carts to and from which sheet stacks are manually
transferred by an operator. "Off-line" systems have the advantage
of being able to match a slower module to a faster device,
optimizing overall performance. It is commonly accepted that a
ratio of 2:1 or greater may be matched with such in-line
processing. Additionally, the components of such "off-line"
processing are not tightly coupled, allowing for more versatile use
of each module. "Off-line" processing, however, necessarily
requires greater operator interaction than "in-line" processing,
increasing labor costs as well as the opportunity for operator
error in the form of both mechanical damaged sheet stacks or
movement of the stacks out of sequence, when sequence is
important.
[0006] "Near-line" refers to a special case of "off-line"
processing where the carts are more elaborate and custommated to
automatically receive and discharge sheet stacks. The stacks may be
electronically tracked to ensure sequence of processing, as
disclosed in U.S. Pat. No. 6,192,295 B1 to Gunther. One example of
this type of "near-line" processing is marketed by GTI. In the GTI
cart system, stacks are laid on a cart and the cart is manually
rolled to a feeder. The GTI cart is designed to custom mate to the
GTI stacker and GTI feeder. Although operator error is less than
the opportunity with true "off-line" the chance is not eliminated.
The GTI cart has a clamping system that secures the stacks from
movement, however, the system requires considerable operator effort
to operate.
OBJECTS AND BRIEF SUMMARY OF THE INVENTION
[0007] In accordance with the invention, there is provided a
document handling system which utilizes one or more of an elevator
transfer station, modular transfer station, transportation cart,
storage station, and/or modular processing station to provide
in-line document processing in a modular environment while allowing
the use of one or more modular processing stations in an off-line
manner without disconnection of the module from other modules that
form part of the sheet handling system. Each of the transfer
station, cart, and storage station includes a plurality of
elongated support surfaces or fingers to create a sheet support
surface, slotted platform or deck such that the alternating fingers
and slots of the transfer station or cart storage station receive
the alternating slots and fingers of the cart to transfer stacks of
sheets supported on the upper surface to and from the cart and
transfer station or storage station. Stacks of sheets may likewise
be transported between adjacent processing modules by similarly
intermeshed transfer stations or intermediate belts, rollers, or
the like.
[0008] The transfer station includes a platform comprising a series
of driven surfaces in the form of, for example, driven rollers or
flat rotary belts, which are spaced to engage with a number of
different structures. The transfer station may be a separate
station or the transfer station components may be incorporated into
a modular processing station. For ease of understanding, this
application will refer to belts. It will be appreciated, however,
that alternate designs, such as those utilizing a plurality of
in-line driven rollers, are likewise form appropriate driven
plurality of elongated support surfaces, and are to be considered
to fall within the purview of the term "belt" as utilized herein.
The spaced belts can intermesh with the slotted surface of a
stacker, feeder, or other elevator mechanism such that the stack
processing module can deposit or remove sheet stacks from the
transfer station. Additionally, the spaced belts of the transfer
station platform may intermesh with the slotted deck of the cart,
such that the sheet stacks can be moved from one transfer station
to another using the cart, without connecting the two transfer
stations physically. Finally, the spaced flat belts of the transfer
station platform can intermesh with the spaced flat belts of
another transfer station or an intermediate station. Under these
circumstances, the belts of the second transfer station are spaced
at one-half pitch off that of its mate. In this way, transfer
stations can be connected to form a conveyor between processing
modules to transfer sheets or stacks of sheets, eliminating the
need for manual intervention to move sheets or sheet stacks between
processing modules during processing. The transfer station may be
provided with an elevator mechanism that moves a stack of sheets
supported thereon in a vertical elevation to provide the stack for
further transfer or for further processing operation. It is further
envisioned that preexisting processing stations may be retrofit
with such transfer or elevator transfer stations to allow their
integration into the document handling system.
[0009] The moveable cart would likewise have a slotted deck that
could intermesh between the individual belts of the transfer
station to form a joint sheet support surface. Preferably, the cart
may be manually, electrically, hydraulically, or otherwise powered,
and includes a mechanism whereby the cart deck can be raised or
lowered by cam, lever, electrical power, hydraulics or other
mechanism such that the cart may deposit a stack of sheets on the
transfer station platform or raise a stack of sheets from the
transfer station platform to remove the stack from the transfer
station. Preferably, the cart includes a quick clamp release system
to secure the sheet stack for transport. Additionally, the cart is
preferably symmetrical such that a stack may be picked up or
deposited from either side of the cart to readily provide phasing
of the edges of the stack. The transfer station or elevator
transfer station, as well as the processing modules themselves may
provide for alternate movement of the support surfaces into or out
of the sheet handling system to facilitate access by the cart. For
example, the support surface or deck may move in a substantially
perpendicular direction from the system to allow intermediate
access to a stack of sheets. In this way, the cart may readily be
utilized to access and remove a stack from the deck. The deck may
then be retracted back into the system.
[0010] Finally, the storage station includes a slotted stationary
platform where the slots are spaced to receive and intermesh with
the slotted deck of the cart. In this way, the cart may be used to
deposit the sheet stack on the storage station when the stack is
not transferred directly to the elevator transfer station. The
storage station may include upright stacking guides which may be
adjustable or permanently spaced or installed. The stacking guide
may also be removable for storage and to provide a tidy appearance.
As with the elevator transfer station, the cart may be used to
place a sheet stack on the storage station and the cart then
lowered, leaving the stack on the storage station. Similarly, an
empty cart may be intermeshed with the slotted platform of the
storage station and the cart slotted deck raised to lift the sheet
stack from the storage station for removal to an elevator transfer
station.
[0011] While the cart has been described as including a movable
deck, the storage station-and elevator transfer station may
alternately include movable platforms for raising or lowering a
sheet stack onto the cart having a stationary deck, or some
combination of such arrangements.
[0012] The aforementioned document transport system facilitates an
improved and novel document processing system. In particular, a
modular transfer station mates with both processing module
elevators and other transfer stations to allow a new version of
"in-line" processing in which sheet stacks or individual sheets are
passed automatically between processing modules with a relatively
large buffer. The buffer allows large and numerous stacks to be
placed between the modules allowing for considerable pauses in one
module without a concurrent pause in the other modules in the
inline process, and allows considerable mismatches in processing
speeds between machines without forcing human intervention or
modification of the modules to synchronize their processing speeds.
Further, this movement between modules during in-line processing
can take place without intervention by an operator and the
incumbent risk of error.
[0013] Additionally, the cart that mates with the transfer station
can be docked in one of two directions with the transfer station,
allowing the operator to choose to reverse the processing
orientation of the stack desired. The cart also includes a quick
clamping system which allows the stack to be quickly secured
without extended operator involvement.
[0014] Further, the same transfer station can be utilized for both
a buffered version of in-line processing, and with the cart,
off-line and near-line processing that requires little operator
involvement.
[0015] In addition to the benefits provided by the document
transport system in allowing the in-line processing system
described herein, there are other salient features of the
invention. For example, one or more modules that form the modular
in-line processing system may be used in an off-line manner as well
without disconnecting the relevant module(s) from the in-line
system, or can be utilized as free standing, independent processing
modules.
[0016] These and other advantages of the invention, as well as
additional inventive features, will be apparent from the
description of the invention provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view of a plurality of elevator
transfer stations incorporated into processing modules construed in
accordance with teachings of the invention
[0018] FIG. 2 is a perspective view of a cart preparing to dock
with an elevator transfer station constructed in accordance with
teachings of the invention.
[0019] FIG. 2A is a schematic side view of the cart and elevator
transfer station of FIG. 2 wherein the cart is docked with the
elevator transfer station.
[0020] FIG. 2B is a front view of the cart and elevator transfer
station of FIG. 2a.
[0021] FIG. 3A is a schematic of cart docking arrangement in
accordance with teachings of the invention.
[0022] FIG. 3B is an enlarged fragmentary view of the wheels and
rollers of the cart of FIG. 3A engaging surfaces of the elevator
transfer station of FIG. 3a.
[0023] FIG. 3C is a schematic view of an alternate embodiment of a
cart docking arrangement.
[0024] FIG. 3D is a schematic of a second alternate embodiment of a
cart docking arrangement.
[0025] FIGS. 4A-F are bottom perspective or plan views of various
wheel configurations for the movable cart.
[0026] FIG. 5A is a perspective view of a cart incorporating a
cross bar operation mechanism.
[0027] FIG. 5B is an enlarged fragmentary front view of the handle
and cross bar of FIG. 5A.
[0028] FIGS. 5C-I are fragmentary perspective views of various
handle operation mechanisms, including buttons, levers, and cam
locks.
[0029] FIGS. 6A-C are cross-sectional views of embodiments of
locking arm uprights.
[0030] FIGS. 7A-D are fragmentary perspective views of various
locking bar operation mechanisms, including buttons and levers.
[0031] FIG. 8A is a fragmentary perspective view of an alternate
embodiment of a locking arm arrangement.
[0032] FIG. 8B is a cross-sectional view of the locking arm of FIG.
8A.
[0033] FIG. 9A is a fragmentary perspective view of a second
alternate embodiment of a locking arm arrangement.
[0034] FIG. 9B is a cross-sectional view of the locking arm of FIG.
9A.
[0035] FIG. 10A is a fragmentary perspective view of a third
alternate embodiment of a locking arm arrangement.
[0036] FIG. 10B is a cross-sectional view of the locking arm of
FIG. 10A.
[0037] FIG. 11A is a fragmentary perspective view of a fourth
alternate embodiment of a locking arm arrangement.
[0038] FIG. 11B is a cross-sectional view of the locking arm of
FIG. 11A.
[0039] FIG. 12 is an enlarged perspective view of a storage station
constructed in accordance with teachings of the invention.
[0040] FIG. 13 is a front elevational view of the storage station
of FIG. 12.
[0041] FIG. 14 is a side elevational view of the storage station of
FIGS. 12 and 13, and a cart prepared for docking.
[0042] FIGS. 15A-C are views of an alternate embodiment of a
storage station.
[0043] FIGS. 16A-C are views of a second alternate embodiment of a
storage station.
[0044] FIGS. 17A-C are views of a third alternate embodiment of a
storage station.
[0045] FIGS. 18A-C are views of a fourth alternate embodiment of a
storage station.
[0046] FIGS. 19A-C are views of a fifth alternate embodiment of a
storage station.
[0047] FIGS. 20A-C are views of a sixth alternate embodiment of a
storage station.
[0048] FIGS. 21A-D are views of a seventh alternate embodiment of a
storage station.
[0049] FIGS. 22A-D are views of an eighth alternate embodiment of a
storage station.
[0050] FIGS. 23A-D are views of a ninth alternate embodiment of a
storage station.
[0051] FIG. 24 is a view of a tenth alternate embodiment of a
storage station.
[0052] FIGS. 25A-B are views of an eleventh alternate embodiment of
a storage station.
[0053] FIGS. 26A-B are view of an alternate embodiment of a
platform and deck finger design.
[0054] FIGS. 27A-C are views of a second alternate embodiment of a
platform and deck finger design.
[0055] FIGS. 28A-B are views of a third alternate embodiment of a
platform and deck finger design.
[0056] FIG. 29 is a perspective view of an in-line document
processing system constructed in accordance with teachings of the
invention.
[0057] FIG. 30 is a schematic system diagram showing document
transport and operations executed with the in-line document
processing system according to an embodiment of the invention.
[0058] FIG. 31 is a flow chart detailing a process for managing
document positioning in an embodiment of the invention.
[0059] FIG. 32 is an operational diagram of an exemplary user
interface and related functions in an embodiment of the
invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0060] Turning now to the drawings, there are shown in FIG. 1
representative sheet or sheet stack processing module 30. The sheet
or sheet stack processing module 30 shown is intended to be
representative of any of the various types of modules, including
finishing machines such as binders, inserters, envelope stuffers,
sealers, punches, or any number of types of processing devices.
Significantly, the sheet or sheet stack processing module 30
includes one or more transfer stations 32 for receiving either
single sheets or stacks of sheets to be passed onto the processing
module 30. The sheet or sheet stack processing module 30 may
include a single transfer station 32 or a plurality of transfer
stations 32 such as are illustrated in FIG. 1. The transfer station
32 includes a sheet support surface or platform 34 around which a
belt 36 rotates to pass the sheets onto the sheet or sheet stack
processing module 30. The platform 34 of the transfer station 32
may extend directly from the processing module 30 or the document
processing system, as illustrated in FIG. 1, or the platform 34 may
be moveable, by electronic, mechanical, or other mechanism, in an
essentially horizontal manner from the processing module 30 for
access to a stack of sheets disposed on the platform 34.
[0061] Turning to FIG. 2, in accordance with the invention, the
platform 34 is slotted, having a plurality of alternating platform
fingers 38 and platform slots 40, and the belt 36 includes a
plurality of individual belts spaced to rotate longitudinally along
the outer surface of the platform fingers 38. The platform fingers
38 are spaced such that they can intermesh with a slotted surface
of sheet or sheet stack processing module 30 such as a stacker,
feeder, elevator, or the like. In this way, the stack processing
modules so equipped can deposit or renew the sheet stacks from the
transfer station 32 for further processing. Additionally, the
fingers 38 of the platform 34 are spaced such that they may
intermesh with the platform fingers and slots 38, 40 of another
transfer station 32. In this way, a plurality of transfer stations
may be connected to form a conveyor between processing modules,
eliminating the need for manual intervention to move sheet
stacks.
[0062] In accordance with another feature of the invention, there
is provided a moveable transportation cart 42 that includes a
slotted deck 44. The cart 42 may operate electrically,
hydraulically, manually, or by any other appropriate method. As
with the transfer station platform 34, the slotted deck 44 of the
cart 42 includes spaced deck fingers 46 having open deck slots 48
disposed therebetween. Significantly, the deck fingers 46 and slots
48 as well as the platform fingers 38 and slots 40 are spaced such
that they may intermesh, as shown in FIGS. 2 through 2B, the deck
fingers 46 being disposed in the platform slots 40 and the platform
fingers 38 being disposed in the deck slots 48. Thus, sheet stacks
disposed on the upper sheet support surface of the slotted deck 44
may be passed to the platform 34 of the transfer station 32, or the
cart 42 may be utilized to sheet stacks disposed on the platform 34
of the transfer station 32. In this way, the cart 42 may be
utilized to provide or retrieve stacks of sheets at one or the
other end of a system of a plurality of coupled processing modules,
or it may be utilized to remove stacks of sheets at intermittent
positions from individual processing modules within the system.
[0063] In order to facilitate movement of the sheet stack between
the slotted deck 44 of the moveable cart 42 and the platform 44 of
the transfer station 32, at least one or the other of the slotted
deck 44 or the platform 34 is vertically moveable relative to the
other. In the currently preferred embodiment, the slotted deck 44
is vertically moveable relative to the platform 34. In this way,
the deck and platform fingers 46, 38 may be intermeshed and the
slotted deck 44 either advance upward relative to the platform 34
to remove the sheet stack from the platform 34 or downward relative
to the platform 34 to place a sheet stack on the platform 34. It
will be appreciated, that this same function could be performed by
movement of the platform 34 itself up or down vertically relative
to the slotted deck 44.
[0064] In the currently preferred embodiment, when the slotted deck
44 is moved upward or downward vertically relative to the platform
34 and the cart body 50 itself Alternatively, the entire cart body
50 and the slotted deck 44 may be moved vertically upward or
downward relative to both the platform 34 and the ground. This
vertical movement may be accomplished by way of a cam arrangement,
a lever, a gearing arrangement, electrical power, hydraulics, or
other method to deposit or remove a stack from the belt system by
any appropriate mechanism.
[0065] A number of cart docking arrangements may be provided to
facilitate movement of the cart into position and to facilitate the
intermeshing of the deck fingers 46 and the platform fingers 38. A
few such possibilities are illustrated in FIGS. 3A through 3D. It
will be appreciated that these are only schematic renditions, and
that the platform 34 of the transfer station 32 and the deck 44 of
the moveable cart 42 will both include slotted surfaces designed to
intermesh with one another.
[0066] In order to facilitate movement of the cart 42, the cart
includes one or more wheels, rollers, casters, or the like 52 which
extend from the cart 42 to contact the ground. As shown in FIGS. 3A
and 3B, the cart 42 may include sets of wheels disposed at various
distances from the ground. In this embodiment, the cart includes a
large pair of wheels 52 on either side as well as two pairs of
smaller casters 54. The transfer station 32 includes a pair of
ramps 56 such that the wheels 52 are disposable on either side of
the ramp 56. As the wheels 52 continue to roll along either side of
the ramp 56, the casters 54 contact the ramp 56, and the cart 42
continues moving forward, lifting the wheels 52 off the ground. In
order to further center the cart 42, the ramp 56 further includes a
central raised guide 58 and the cart 42 includes rollers 60 which
are mounted horizontally and disposed to contact either side of the
central raised guide 58 as the cart 42 continues up the ramp
56.
[0067] Another cart docking arrangement is disclosed in FIG. 3C. In
this embodiment, the cart 42 includes a pair of outwardly opening
C-shaped channels 62 disposed along either side, and the transfer
station 32 includes elongated rigid rectangular sections 64 along
either side of the slotted platform 34. The rigid rectangular
sections 64 preferably include a chamfered section disposed to the
center and guide the cart 42 forward toward the platform 34.
Additionally, the rectangular sections may include one or more
rollers 68 disposed along one or more of the surfaces which engage
the C-shaped channels 62 as the cart 42 is moved forward into the
transfer station 32.
[0068] Yet another cart docking arrangement is illustrated in FIG.
3D. In this embodiment, the transfer station 32 includes a ramp
arrangement 70 which includes a central channel 72 for receiving an
alignment peg 74 extending downward from the moveable cart 42. The
central channel 72 tapers from a relatively open section 76 distal
the transfer station to a confined section 78 proximal the transfer
station. In this way, as the cart 42 moves inward to the transfer
station 32, the alignment peg 74 engages the open section 76 of the
central channel 72 and is guided into the confined section 78.
[0069] In order to allow free movement of the cart 42 relative to
the ramp arrangement 70, the ramp 70 includes a pair of rollers 77
disposed along either side of the central channel 72 as the ramp
angles upward, and the upper surface of the ramp 70 includes a
plurality of ball transfers 79 which allow the cart to move into
axis relative to the transfer station 32.
[0070] Thus, it will be appreciated that the cart may have any
number of potential configurations of wheels, rollers, casters, or
the like. By way of example only, various potential wheel
configurations are illustrated in FIGS. 4A through F. FIG. 4A is a
configuration with a pair of large, straight wheels on either side
of the platform and four casters disposed at four corners of the
cart. FIG. 4B includes four casters disposed at the four corners of
the cart with two inboard straight wheels and horizontal wheels
disposed along one edge. FIG. 4C includes a pair of straight wheels
disposed outboard the cart and a pair of casters disposed at the
front and rear of the cart. FIG. 4D includes four casters disposed
at the four corners of the cart. FIG. 4E includes a pair of
straight wheels disposed outboard the cart along one edge and a
pair of casters disposed at the opposite two corners of the cart.
FIG. 4F shows a pair of straight wheels disposed outboard the cart
along one edge with a single caster disposed along the opposite
front edge. According to one aspect of the invention, the cart 42
is preferably symmetrical so that it may be docked at the transfer
station 32 in either direction. It will be appreciated that the
wheel and docking arrangements illustrated in FIGS. 3A-D and 4A-D
are bi-directional in that the cart 42 could be docked with a
transfer station 32 from either direction. Conversely, the wheel
and caster arrangements shown in FIGS. 4E and 4F are
mono-directional in that they would likely be docked only in one
direction with the transfer station 32.
[0071] In order to facilitate easy movement of the cart 42 by an
operator, cart 42 includes a handle 80 pivotably mounted to the
cart body 50. The handle 80 is preferably of an inverted U-shape
and may be locked in a vertical position or unlocked and swiveled
to either side so that the cart 42 may be moved from either side.
Unlocking of the handle would likewise release the brake on the
wheels 52 to allow the cart to move forward or backward. The handle
release mechanism may be in the form of cross bar 83 as shown in
FIGS. 5A and B, buttons 84, 86 centered along the top or bottom of
the handle 80 as shown in FIGS. 5C and D, or a button 88 disposed
along the side of the handle as shown in FIG. 5E. Alternately, the
handle release may be in the form of a lever 87, 89 centered or
disposed along the side of the handle as shown in FIGS. 5F and G.
or dual levers 91 as shown in FIG. 5H. Alternately, the handle
release may be in the form of a swivel cam lock 93, as shown in
FIG. 5I. It will be appreciated by those skilled in the art that
these handle release arrangements are provided by way of an example
only and are not meant to restrict the invention in any way.
[0072] The handle 80 may be formed by any appropriate means, and
may include multiple components fabricated by different methods.
For example, it may include extruded, cast, or molded portions and
may be fabricated from plastic or metal, such as aluminum, for
example, or any other appropriate material.
[0073] As may be seen in FIG. 2, the handle 80 is preferably
pivotably coupled to the cart body 50 at a relatively low location.
In this way, the application of a moving force by the operator
creates a minimal moment, providing a stable arrangement with
minimal opportunity for the cart 42 to be overturned.
[0074] In order to stabilize the sheet stacks on the upper slotted
deck 44 of the movable cart 42, the cart 42 is provided with a
locking arm arrangement 100. As shown in FIG. 2, the locking arm
arrangement 100 can include a simple pair of uprights 102 disposed
along either side of the deck 44 to which a selectively lockable
sheet or sheet stack clamp or locking arm 104 is slidably mounted.
In this way, once a sheet stack is placed on the slotted deck 44,
the operator may unlock the locking arm 104 and slide it downward
along the uprights 102 to contact the upper surface of the stack
and to secure them into position on the cart 42 before movement.
The uprights 102 have any appropriate structure, such as the simple
bars illustrated in FIG. 2, or, for example, extruded hollow
sections such as are shown in FIGS. 6A-6C. The embodiment
illustrated in FIG. 6C further includes elongated channels 106
which may be utilized to store slidably enclosed guide rods 108.
Guide rods allow stacking directly on a cart. The uprights 102, as
well as the locking arm 104, may be fabricated of any appropriate
material, such as plastic, steel, or aluminum.
[0075] As with the handle 80, the locking arm arrangement 100 may
include any number of locking arrangements. In the currently
preferred embodiment, the locking arm 104 includes a centrally
elongated opening 110 which may be utilized as a handle for moving
the locking arm 104 upward and downward along the uprights 102. The
locking mechanism for the locking arm 104 may include arrangements
such as a depressible button 112, 114 disposed along either the
upper or lower surface of the handle portion 110 as illustrated in
FIGS. 7A and 7B, or a depressible lever 116, 118 similarly disposed
along either the upper or lower surface of the handle 110, as shown
in FIGS. 7C and 7D. It will be appreciated, however, that alternate
locking bar operation mechanisms may be provided.
[0076] The locking arm 104 may be constructed of any appropriate
materials and by any appropriate method. For example, as shown in
FIGS. 8A and 8B, the locking arm 104 may include a formed metal
cross bar 120 with separate plastic or metal inserts 122 inserted
through either side of the cross bar 120 in order to form the
handle 110. For the sake of simplicity in this and the following
illustrations of various embodiments of the locking arm 104, the
sides are illustrated with a top and centered button 112 release of
the lock to allow the locking arm 104 to slide up and downward on
the uprights 102. The cross bar 120 may alternately be extruded
from plastic, as shown in FIGS. 9A and 9B. As with the embodiment
in FIGS. 8A and 8B, plastic or metal inserts 122 are received in
openings through either side of the cross bar 120 to form the
handle 110. Alternately, the cross bar 120 may be extruded with an
ergonomic design which allows the user to grip the cross bar 120
for movement of the locking arm 104. Such a design is illustrated,
for example, in FIGS. 10A and 10B. Further, the cross bar 120 may
be formed in two or more parts which are then bolted or riveted
together, as shown in FIGS. 11A and 11B. Such cross bar components
may be either extruded or cast, for example. It will be
appreciated, however, that alternate design arrangements of the
cross bar fall within the spirit and scope of this application.
[0077] In accordance with another important aspect of the
invention, there is provided a storage station 130, as is shown,
for example, in FIG. 12. Storage station 130 includes legs 132,
which in the preferred embodiment are of an L-shape, including a
vertical portion 134 and a horizontal portion 136. Feet 138 are
preferably provided below the horizontal portion 136 of the legs
132. Spine body 140 extends between the upper ends of the vertical
portion 134 of the legs 132. In order to receive and intermesh with
the slotted deck 44 of the movable cart 42, a slotted platform 142
extends from the spine body 140 of the storage station 130.
Significantly, the fingers 144 and slots 146 of the slotted
platform 142 are spaced such that the slots 146 receive the deck
fingers 46 to dispose the platform fingers 38 adjacent the storage
station fingers 144 in alternating positions. In this way, the
operator can transfer sheet stacks between the deck fingers 46 and
the storage station fingers 144.
[0078] As shown in FIG. 12, in order to maximize storage space, a
second spine body 140a and slotted platform 142a may be positioned
adjacent the storage station 130. In this way, the adjacent storage
station 130a utilizes one of the legs 132 of storage station 130
and an additional leg 132a. It will thus be appreciated that a
continuous line of storage stations may be disposed adjacent one
another in order to maximize storage space.
[0079] In order to provide added support to a sheet stack supported
on the slotted platform 142 of the storage station 130, a back stop
stacking guide arrangement 148 may be provided such as is shown in
FIGS. 12-13.
[0080] As with the transfer station 32 and movable cart 42, the
storage station 130 and related components may be of any
appropriate design and material, and constructed according to any
appropriate method. For example, those storage stations designs are
illustrated in FIGS. 15A-25B. Legs, for example, may be extruded as
shown in FIGS. 15A-C, stamped and formed as shown in FIGS. 16A-C or
FIGS. 17A-C, formed of bent tubing, as shown in FIGS. 18A-C, FIGS.
19A-C, and FIGS. 20A-C, and may include side panels as shown in
FIGS. 21A-B. The stacking guide may be a relatively permanent
structure as shown in FIGS. 16A-C, a flip-up surface as shown in
FIGS. 21A and 21B, or removable structure as shown in FIGS. 22A-D,
FIGS. 23A-D and FIGS. 15A-C. The stacking guide may include
adjustable components such as are shown in FIGS. 23A-B, FIGS.
24A-B, FIGS. 15A-C and FIGS. 16A-C. The slotted platform 142 may
include chamfered or non-chamfered guiding arms 152 along either
side of the fingers 144 as shown in FIG. 12, FIGS. 15A-C, and FIGS.
23A-D, or the platform 142 may lack such guide arms altogether, as
shown in FIGS. 22A-D. Moreover, the spine body 140 can include a
hinged cover 154, such as is shown in FIGS. 22A and 22B. According
to this embodiment, the stacking guides 148 can be stored beneath
the cover 154. The cover 154 itself can be extruded, molded, or
stamped and formed.
[0081] The platform fingers 144 may be of an appropriate design and
formed by any appropriate method. For example, the platform fingers
144 may be stainless rods, as shown in FIG. 23A. Alternately, they
may be cast as shown in FIGS. 16A-C, or extruded, as shown in FIGS.
15A-B or FIGS. 26A-B. The extrusion may be a simple rectangular
design with optional end caps as shown in FIGS. 27A-C, or a
vertically extruded design with an optional cap as shown in FIGS.
28A-B.
[0082] FIG. 29 shows a perspective top side view of an in-line
document processing system 2901 according to an embodiment of the
invention. The system 2901 comprises a plurality of processing
modules, such as modules for binding, inserting, envelope stuffing,
sealing, punching, or any number of types of processing as
described above. The illustrated example includes a tab cutter
2903, punch 2905, binder 2907, cover closer 2909, and book/face
stacker 2931. The system 2901 also includes an offset stacker 2935
and cover feeder(s) 2937 to facilitate the stacking of the
materials for processing and to provide document covers where
needed for processing. Consistent with the above description, the
cart 2933 is shown interfacing with the system 2901 at the
book/face stacker 2931. In order to facilitate processing modules
having disparate processing speeds, a buffer/transport system 2939
is shown disposed between a printer 2941, or other document source,
and the rest of the system 2901. While not otherwise illustrated,
such one or more buffer transport systems 2939 may be provided at
other positions in the system 2901, that is, between other
processing modules, in order to provide or enhance similar
buffering between processes. The operation of the in-line system
2901, including the buffer/transport system 2939 will be described
hereinafter, with the understanding that the processing modules
2903-2931 shown are exemplary and may be wholly or partially
supplemented or replaced by other types of processing modules
within the scope of the invention.
[0083] Initially, a print job or other process at document source
2941 produces one or more documents for processing. A document will
generally comprise a plurality of sheets, but may in unusual cases
have only a single sheet. The document source 2901 may interface to
a document supplementation device such as tab cutter 2903. In the
illustrated example, the tab cutter 2901 provides and inserts index
tabs or other dividers into documents produced by document source
2901, either during or after document production. A plurality of
such documents is then flush or offset stacked to provide a single
stack or succession of stacks, each including a plurality of
documents. The sheet stacks formed by this process, preferably
including tabs where appropriate, are conveyed to the first process
module 2905, illustrated as a punch 2905, via the buffer transport
segment 2939.
[0084] The buffer transport segment 2939 is usable either to convey
documents to the first process module 2903 for processing, or to
divert incoming documents to a temporary storage space, or buffer.
The primary reason for sometimes buffering the document stream in
this manner is to facilitate in-line processing between modules
with different processing or production rates. For example, in the
illustrated scenario, the printer 2941 may produce documents at a
faster rate than the punch 2903 can process such documents. In this
case, the buffer would absorb the difference in capacity. In this
manner, for example, if the printer 2941 produced documents twice
as fast as the punch 2905 could process them, the buffer would
absorb approximately half the documents produced while documents
continued to be produced.
[0085] After document production at the source 2941 ends, the
buffer may be gradually emptied as the rest of the processing
system 2901 continues to run. It will be understood that the
maximum time during which such a mismatch can be alleviated by
buffering is tied both to the degree of mismatch and the document
capacity of the buffer system. It is also within the invention to
provide a number of buffers, such as a primary buffer and one or
more overflow buffers for excessive or unexpected mismatches or
surges in document production. Note that the buffer between a
slower supplying module and a faster consuming module will
generally not be used, except to facilitate intervening offline
processing. That is, the rate mismatch must be buffered only when
the faster module precedes the slower. Although only a single
buffer/transport unit 2939 is visible in the illustrated example,
such a transport and buffer system will preferably be provided at
the junction of any two processing modules, unless the modules
incorporate a mechanism for transport to the next module, and, in
the case of rate mismatch, for buffering excess incoming
documents.
[0086] Once the document processing system 2901 has finished
processing one or more documents, the documents are output to a
user accessible location such as to a cart 2933 as described above
or otherwise. In the illustrated example, the finished documents
will have been punched, bound (with closed cover), and stacked.
[0087] Note that one or more modules in the document processing
system 2901 are preferably usable in an offline manner without
disconnection from the system 2901. Such off-line use could occur
during in-line processing by buffering in-line documents during the
offline processing. For example, in the illustrated example, the
punch module 2905 may also be used in an off-line mode by a user,
via an access on the side of the module 2905. Alternatively, an
offline stack of documents may be fed to the input belt by a cart
or other appropriate method. Thus, the user may initiate an offline
use of the punch 2905 via a user interface thereon. In response to
user initiation, the punch 2905 preferably completes work on the
current document being processed and then begins to buffer all
incoming documents for a brief period while the user completes an
offline use, such as by inserting a document or documents to be
punched and then retrieving the punched materials. When the user
has completed the offline use, the punch 2905 preferably begins
again to process documents in an inline fashion, either from a
buffer or directly from the preceding module.
[0088] Conveniently, all or a lesser number of the processing
modules may be utilized in an in-line processing job. In this
regard, if a particular processing module is not to be utilized,
the individual lifts, sets, or stacks may proceed through the
module along the standard processing line with the relevant
function (e.g. the punch) disengaged. Alternatively, a bypass path
may be provided through the module.
[0089] FIG. 30 is an operational diagram showing the functional
elements of an inline processing system, as described above
architecturally, and the operational relationships between those
functional elements. First note the operator control interface
3001. This interface is preferably in the form of a graphical user
interface that presents the user with a mechanism for becoming
apprised of available values, settings, parameters, etc., and for
selecting or setting such constraints accordingly. For example, a
user may be presented with an interface for selecting which
parameter to modify, one of which is a sheet size. After selecting
the option related to sheet size, the user may be presented with an
array listing available sheet sizings, at which point the user will
select a desired size and complete the process. Other preferably
modifiable constraints include a preferred edge for binding,
whether or not a cover will be provided, the type of binding, if
any, desired, and so forth.
[0090] The common elements tying major processing functions
together are one or more transfer stations 3003. Documents to be
processed are supplied initially via a transfer station or
otherwise, generally in a stacked form, from one or more stackers
3005, 3007 and associated interface(s) 3011 where necessary. At
that point, the stacked documents are supplied, preferably via a
conveyor input as described more extensively above, to a feeder to
be provided to the subsequent processing modules. From the feeder,
the documents enter a first processing module such as a punch
module 3015 for punching a series of holes through an edge of each
document to facilitate later binding. 100911 Note that the punch
module 3015 is shown as receiving one or more die sets 3017, which
are used to define the precise manner in which the holes are made
in the edge of each document. Further note that the punch module
3015 may also receive cover material from a cover feeder 3019 when
desired. These covers are preferably associated with each document
prior to actual punching so that the holes punched in the cover
match to the holes punched in the associated document.
[0091] If further processing, such as binding, is to occur, then
the punched document stacks, including punched covers where
appropriate, are fed to an accumulator and/or other interface 3021
to a binding module 3023. The interface 3021 between the punch
module 3015 and binding module 3023 may be either a custom
interface such as when the modules are designed to cooperate, or
alternatively by way of a transfer station. The binding module 3023
applies a binding to the punched documents received from the punch
module 3015. Such bindings may be comb bindings, wire spiral
bindings, polymeric nail-type bindings, or any other type of
binding usable to secure punched pages together via cooperating
holes. The binding module 3023 optionally receives and uses one or
more crimp sets 3025 to define the manner in which a crimped
binding is applied.
[0092] From the binding module 3023, the bound documents are
optionally fed to a cover closer 3027 via a custom interface or
transfer station. At this point, the finished documents are passed
in a stacked manner to a transfer station, preferably via a book
stacker 3029. Note that the finished documents may also be provided
to a shingle conveyor 3031 from the cover closer 3027. Also, if
binding is not desired, the punched documents may be passed to a
stacker 3035 for retrieval from the processing system. At any
stage, a user may manually retrieve or place documents as indicated
by "manual in/out" component 3033. The user may optionally use a
cart 3037, such as described above in detail with respect to FIGS.
1-29, to effect the manual placement or removal of documents.
[0093] A flow chart of the actions and motor run sequences for
entry and exit of document stacks from a processing system such as
described above is shown in FIG. 31. Initially, a lift door is
opened at step 3101 allowing access to a lift mechanism. The lift
door may be manually actuated but is preferably motor-driven either
automatically or in response to a user action. Once a stack is
placed through the lift door, then at step 3103, an input belt
motor is run to place the stack in position for lifting. Note that
as discussed above, there may also be lateral movement, automated
or otherwise, of the lift surface or other document-supporting
surface to facilitate manual loading and unloading of sheets and/or
sheet stacks to and from the processing system. At step 3105, the
position of the stack is checked to ascertain whether the stack is
appropriately placed for lifting to begin. If it is determined at
step 3105 that the stack is not yet properly positioned, then the
process reverts to step 3103 to continue running the input belt
motor. Otherwise, at step 3107, the input belt motor is stopped,
and the lift door is closed.
[0094] At step 3109, a run command is issued to commence processing
of the stack. The run command may be either automatically issued
when the stack is properly positioned after step 3107, or may be
manually issued by a user such as through making a selection from a
graphical user interface. At step 3111, pursuant to the run
command, a lift motor is run at high speed to lift the stack into
position for further processing. Subsequently, the vertical
position of the stack is checked at step 3113. If the stack is not
yet at full height, the process reverts to step 3111, running the
lift motor at high speed. Otherwise, at step 3115, the lift motor
is slowed to low speed, the main motor is run to process the
documents, and the stacker motor is run at low speed to output the
processed documents.
[0095] From step 3115, the process continues to step 3117, where
the document processing is periodically monitored for the
occurrence of a sheet jam. If no sheet jam is found to have
occurred, the process checks the status of the stack at step 3119
to determine whether the last needed lift has been performed. If it
has not, then the process returns to step 3115 and the steps that
logically follow. Otherwise, if the last lift has been performed,
or if a sheet jam was detected at step 3117, the process moves to
step 3121, causing the lift motor to reverse and return the
remainder of the stack to the bottom position, causing the main
motor to be stopped, and causing the stacker motor to run at high
speed, clearing any free papers from the processing apparatus.
[0096] At step 3123, the status of the lift is checked, and if the
stack is not yet at the bottom position, then the process returns
to steps 3121. Otherwise, the process moves to step 3125, whereat
the stacker motor is stopped and an access door to the stacker is
opened. Once the stacker access door is opened, an output belt
motor is run at step 3127 to bring the stack into a position from
which a user can access the stack or from which the stack can be
moved into a position that is user accessible. As discussed above,
there may also be lateral movement of the lift surface, or other
document-supporting surface, to facilitate loading and unloading of
the stack. The status of the stack is checked at step 3129 to
determine whether the stack has exited the process, such as by
checking whether any part of the stack has not yet passed the
stacker door. If the stack has not yet exited, the process returns
to step 3127 where the output belt motor continues to run.
Otherwise, at step 3131, the stack motor raises a stack platform on
which the stack was most recently sitting back to a top position,
ready for processing of another stack.
[0097] The logical organization of an exemplary user interface
usable to implement an embodiment of the invention is shown
schematically in FIG. 32. The primary user interface shown is a
visual keypad/touch screen 3201. The keypad/touch screen 3201
allows user entries through a touch-sensitive screen and/or through
a standard push button keyboard interface. A screen portion of the
keypad/touch screen 3201 presents information visually to the user.
Initially, a user is preferably presented with a main screen 3203
showing links to various other screens including a set-up screen
3205, a diagnostic screen 3207, and a menu screen 3209. The user
may navigate to any of the screens 3205, 3207, 3209 by selecting an
appropriate icon or button at the keypad/touch screen 3201.
[0098] Adjustments that may be made preferably include adjustments
for sheet width, length, tab adjust, throughput speed, lift size,
book size, and/or final die set adjust as shown in adjustments
section 3211. As indicated by die set section 3213, the user may
set the process so that the necessary die set may be automatically
determined and/or adjusted. Note that the interface to the process
also includes a non-user interface 3215 for automatically receiving
information from sensors, barcodes, and/or other sources and for
causing one or more automatic actions in response thereto. The
sensors and other information sources illustrated include the
following: a sensor that detects a top sheet in a stack, a cart tag
that may be automatically recognized, information received over a
USB port, a bar code that can be read to determine a desired
process etc., information received from a laptop or other computer,
information received from a printer, information received by
download such as over the Internet, a remote information source,
etc. Note that any of the above can supply document content or
processing instructions.
[0099] All references, including publications, patent applications,
and patents, cited herein are hereby incorporated by reference to
the same extent as if each reference were individually and
specifically indicated to be incorporated by reference and were set
forth in its entirety herein.
[0100] The use of the terms "a" and "an" and "the" and similar
referents in the context of describing the invention (especially in
the context of the following claims) are to be construed to cover
both the singular and the plural, unless otherwise indicated herein
or clearly contradicted by context. The terms "comprising,"
"having," "including," and "containing" are to be construed as
open-ended terms (i.e., meaning "including, but not limited to,")
unless otherwise noted. Recitation of ranges of values herein are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range,
unless otherwise indicated herein, and each separate value is
incorporated into the specification as if it were individually
recited herein. All methods described herein can be performed in
any suitable order unless otherwise indicated herein or otherwise
clearly contradicted by context. The use of any and all examples,
or exemplary language (e.g., "such as") provided herein, is
intended merely to better illuminate the invention and does not
pose a limitation on the scope of the invention unless otherwise
claimed. No language in the specification should be construed as
indicating any non-claimed element as essential to the practice of
the invention.
[0101] It will be appreciated that a novel and useful document
processing system has been disclosed herein by way of examples, and
that it is the claims, rather than these examples that define the
scope of the invention. In particular, preferred embodiments of
this invention are described herein, including the best mode known
to the inventors for carrying out the invention. Variations of
those preferred embodiments may become apparent to those of
ordinary skill in the art upon reading the foregoing description.
The inventors expect skilled artisans to employ such variations as
appropriate, and the inventors intend for the invention to be
practiced otherwise than as specifically described herein.
Accordingly, this invention includes all modifications and
equivalents of the subject matter recited in the claims appended
hereto as permitted by applicable law. Moreover, any combination of
the above-described elements in all possible variations thereof is
encompassed by the invention unless otherwise indicated herein or
otherwise clearly contradicted by context.
* * * * *