Output Bin Stack Height Correction via Multi-Sensor Segmentation
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Solution Overview
Problem
Image forming apparatuses face inaccuracies in measuring the stack height of sheets in an output bin due to non-uniform curling and changes in sheets post-printing, leading to potential media jams and sheets falling, as the sensors detect height at a single location, which may not represent the actual highest level of the stack.
Innovation Solution
The apparatus calculates a corrected stack height by determining attributes of the print job, such as sheet thickness, print material coverage, and whether sheets are stapled, applying correction factors like staple, orientation, and time factors to the measured stack height to account for curling and other changes, ensuring a more accurate representation of the stack height and remaining bin capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor detects stack height at a single location, then the measurement process is simple and fast, but the measurement precision is insufficient due to non-uniform curling and sheet deformation
Solution Approach 1:
The patent divides the stack height measurement into multiple segments by using multiple sensors positioned at different locations (front, rear, and intermediate positions) along the stack. Each sensor measures the height at its specific location, and these segmented measurements are then combined through correction factor calculation to determine the overall stack height, thereby improving measurement precision without requiring a completely complex measurement system
Solution Approach 2:
The patent introduces correction factors as intermediary elements that bridge the gap between simple single-point sensor measurements and the actual complex stack height. These correction factors, derived from print job attributes and sheet characteristics, mediate the relationship between the sensor readings and the true stack height, allowing accurate measurement while maintaining system simplicity
2Measurement precision
If correction factors are applied to calculate corrected stack height, then the accuracy of remaining bin capacity determination is improved, but the calculation complexity increases
Solution Approach 1:
The patent changes the parameters used in the calculation by introducing multiple correction factors (staple correction factor, orientation correction factor, time correction factor) that modify the raw sensor measurements. These parameter changes allow the system to account for various sheet deformation conditions and produce accurate remaining bin capacity determinations while using straightforward mathematical operations
Solution Approach 2:
The patent performs preliminary actions by pre-determining correction factors based on print job attributes and sheet characteristics before the actual measurement takes place. These pre-calculated correction factors are then applied to the sensor readings, reducing the computational complexity during measurement and allowing accurate capacity determination without complex real-time calculations
3Reliability
If multiple correction factors are applied to account for curling and sheet changes, then the reliability of media jam prevention is improved, but the processing time increases
Solution Approach 1:
The patent applies preliminary action by pre-determining correction factors based on print job attributes and sheet characteristics before the measurement process. This allows the system to use simple, pre-calculated values during actual measurement rather than performing complex real-time calculations, thereby maintaining high reliability in media jam prevention while minimizing processing time
Solution Approach 2:
The patent changes the approach by using multiple simple correction factors (staple, orientation, time) that can be quickly applied to sensor measurements. These parameter changes allow the system to account for various curling and deformation conditions without requiring complex real-time analysis, thus maintaining reliability while reducing processing time
Data Source
AI summary
According to examples, an apparatus may include a processor and a memory. The memory may have stored thereon machine readable instructions that when executed by the processor, may cause the processor to determine a job thickness of a print job including sheets, determine an average sheet thickness of the sheets, and determine an average print material coverage on the sheets. The instructions may also cause the processor to identify, based on the determined job thickness, the determined average sheet thickness, and the average print material coverage, a plurality of correction factors to be applied in a calculation of a corrected stack height of print jobs in an output bin and apply the identified plurality of correction factors to a measured stack height in the output bin to calculate the corrected stack height.