Image Forming System Stapling Control for Glossy Sheets
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Solution Overview
Problem
Image forming systems face issues with stapling large quantities of glossy sheets, which are slippery and difficult to stack, leading to paper jams and inefficient post-processing due to the finisher's capacity limitations.
Innovation Solution
An image forming system with a controller that determines whether the number of sheets exceeds a reference number and checks the cumulative thickness, stopping further image formation when conditions are met, allowing for controlled ejection and prevention of paper jams by managing sheet stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the finisher receives a large amount of glossy sheets for post-processing, then the productivity increases, but the sheets become difficult to stack tidily and paper jams occur due to low friction force
Solution Approach 1:
The system performs preliminary determination of whether stapling is appropriate before the sheets enter the post-processing stage. The controller counts sheets and detects their properties in advance, deciding whether to activate the stapler beforehand. This preliminary action prevents stacking issues by ensuring sheets are stapled at the optimal moment, before they become difficult to handle due to volume accumulation.
Solution Approach 2:
The system implements feedback mechanisms where the controller continuously monitors sheet count and properties, and adjusts the stapling operation accordingly. When the sheet count reaches a threshold or when glossy sheets are detected, the system activates the stapler to maintain stacking stability. This closed-loop feedback ensures reliable handling throughout the post-processing operation.
2Reliability
If the finisher staples sheets when the number exceeds capacity, then the stacking stability improves, but the device complexity increases due to additional determination units
Solution Approach 1:
The stapling determination unit is integrated into the existing finisher controller, which already performs sheet counting and property detection for other post-processing functions. By making the controller multi-functional, the system avoids adding separate dedicated determination devices, thus reducing overall device complexity while maintaining stacking stability through intelligent control.
Solution Approach 2:
The finisher system performs self-determination of stapling necessity by utilizing its existing sensing and counting capabilities. The controller automatically analyzes sheet properties and count, then decides whether stapling is needed without requiring external intervention or complex additional hardware. This self-service approach simplifies the system architecture while ensuring reliable stacking.
3Ease of operation
If the finisher ejects sheets without stapling when capacity is exceeded, then the ease of operation improves, but the sheets are ejected untidily causing paper jams
Solution Approach 1:
The system applies preliminary anti-action by activating the stapler before sheets are ejected when stacking stability might be compromised. By anticipating the potential ejection issue and stapling sheets in advance, the system prevents untidy stacking and subsequent paper jams, while still maintaining automatic operation without requiring manual intervention.
Data Source
AI summary
An image forming system includes: an image forming mechanism configured to form an image on a sheet of a transfer material; a post-processor configured to perform post-processing on a plurality of sheets of transfer materials, respectively, there being on at least one of which a respective image has been formed by the image forming mechanism; a transporter to transport the sheets through the post-processor along one or more transport paths; and a controller operable to do the following including, determine a first stopping condition of whether the number of sheets exceeds a reference number, and detect a second stopping condition of whether a cumulative thickness of the sheets loaded in the post-processor exceeds a reference thickness, and stop further image formation by the image forming mechanism when at least one of the first and second stopping conditions is satisfied.