Inserter Speed Synchronization for Image Forming Systems
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Solution Overview
Problem
Conventional inserters in image forming systems lower productivity due to the need for frequent changes in conveying roller speeds to accommodate varying sheet speeds, leading to widened sheet intervals and impaired image quality when color insert-sheets pass through the fixing unit.
Innovation Solution
An inserter with a controller that dynamically adjusts the conveying speed of insert-sheets based on the speed of preceding or succeeding sheets, ensuring synchronized speed matching with the image forming apparatus to minimize speed changes and maintain consistent sheet intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conveyance unit discharges sheets at constant speed, then the sheet conveying is simple, but the sheet intervals are widened and productivity is lowered due to frequent speed changes
Solution Approach 1:
The conveyance unit dynamically adjusts its conveying speed to match the discharge speed of the image forming apparatus. The controller receives speed information from the image forming apparatus and modifies the conveyance speed accordingly, enabling the system to adapt to varying sheet speeds without widening intervals or reducing productivity.
Solution Approach 2:
The controller receives feedback about the discharge speed of sheets from the image forming apparatus and uses this information to adjust the conveyance speed. This closed-loop control ensures synchronized operation between the image forming apparatus and the inserter, maintaining optimal sheet intervals and productivity.
2Adaptability or versatility
If color insert-sheets pass through the fixing unit, then the insert-sheets can be processed, but the image quality deteriorates due to heat-pressing
Solution Approach 1:
The inserter extracts the insert-sheet supply function from the image forming apparatus by providing a separate insert-sheet container unit. This allows color insert-sheets to be fed and conveyed without passing through the fixing unit, preventing heat-pressing damage while maintaining the ability to process various insert-sheet types.
Solution Approach 2:
The inserter acts as an intermediary device between the image forming apparatus and the finisher. It receives print sheets from the image forming apparatus and insert-sheets from its own container, combines them, and delivers to the finisher. This intermediary role allows color insert-sheets to bypass the fixing unit while still achieving the desired sheet combination function.
3Stability of the object's composition
If the conveyance speed is frequently changed to match sheet speeds, then the sheet speed synchronization is achieved, but the productivity is lowered due to widened sheet intervals
Solution Approach 1:
The conveyance unit employs dynamic speed adjustment based on real-time feedback from the image forming apparatus. Rather than using fixed speed steps, the system continuously adapts the conveyance speed to match the discharge speed, maintaining stable sheet synchronization without introducing delays that would widen intervals and reduce productivity.
Data Source
AI summary
The inserter including a storing unit, a sheet-feeding unit; a conveyance unit; and a controller that determines for every sheet a conveying speed of the sheet to be discharged to the downstream side device by the conveyance unit, in which the controller determines: the conveying speed of the sheet, which was discharged from the image forming apparatus, when the sheet is discharged to the downstream side device by the conveyance unit, based on the conveying speed when the inserter receives the sheet discharged from the image forming apparatus; and a conveying speed of the insert-sheet, which was fed by the sheet-feeding unit, when the insert-sheet is discharged to the downstream side device by the conveyance unit, based on a conveying speed of one of a preceding sheet and a succeeding sheet, when one of the preceding sheet and the succeeding sheet is discharged to the downstream side device.