Media Sheet Feeding Throughput via Sensor-Based Gap Control
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Solution Overview
Problem
Printing devices face limitations in achieving higher throughput due to the need for a detectable gap between media sheets to prevent paper jams, which is challenging to maintain with existing sensor placements and motor constraints, resulting in suboptimal interpage gaps and reduced maximum throughput.
Innovation Solution
A method that calculates a pick delay time based on media sheet length and predetermined throughput rate to ensure an interpage gap, allowing the trailing edge of a media sheet to clear a pick point before picking the next sheet, and uses media path sensors to detect the trailing edge, adjusting the picking process to handle misfed sheets and shingle intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sensors are placed close to the leading edge of the media stack to enable quick sensing, then the interpage gap can be minimized and throughput improved, but it becomes difficult to design and position the sensors accurately
Solution Approach 1:
The patent positions the media edge sensor downstream of the pick point rather than upstream, changing the spatial dimension of sensor placement. This allows the sensor to detect the trailing edge of the picked media sheet at a location where accurate positioning is more achievable, while still enabling calculation of the interpage gap based on the known distance from the pick point to the sensor location.
2Productivity
If the interpage gap is made small to increase throughput, then more sheets can be fed per unit time, but paper jams may occur if the gap is too small or missing
Solution Approach 1:
The system uses the media edge sensor to detect the trailing edge of each picked media sheet and provides feedback to the controller. The controller calculates the actual interpage gap based on the detection timing and adjusts the pick mechanism accordingly, ensuring the gap remains within the optimal range to prevent paper jams while maximizing throughput.
Solution Approach 2:
The patent calculates the required interpage gap in advance based on the distance from the pick point to the sensor location and the desired throughput rate. This preliminary calculation allows the system to set appropriate pickup timing and sensor detection thresholds before operation, ensuring sufficient gap maintenance while optimizing feed speed.
3Reliability
If the sensor is positioned far from the pick point to ensure detectable gap, then paper jams are prevented, but the interpage gap becomes larger than necessary reducing throughput
Solution Approach 1:
The patent replaces reliance on purely mechanical sensor positioning with a computational approach. The controller calculates the interpage gap based on the known fixed distance from the pick point to the sensor and the detected trailing edge timing, substituting mechanical precision requirements with computational calculation to achieve both accurate gap control and high throughput.
Data Source
AI summary
Methods for picking a following sheet of media before the prior sheet of media has been detected exiting a media input tray in an imaging apparatus to increase media throughput. The methods may further include processes for shifting an image area to a shingled sheet of media without having to stop the imaging process.