Rack and Pinion Sorter for Compact Image Forming Apparatus
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Solution Overview
Problem
Existing large-scale copiers with sorting mechanisms require significant space due to their vertical or horizontal design, making miniaturization challenging.
Innovation Solution
An image forming apparatus utilizing a pinion and rack system for sorting, where the pinion meshes with a rack to drive the output mechanism and sort media into stacks, allowing for automatic adjustment of stack numbers and miniaturization without the need for additional space or moving discharge trays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a vertical sorter or horizontal discharge tray mechanism is used for sorting copies, then the sorting function is achieved, but the device occupies large space
Solution Approach 1:
The patent changes the sorting mechanism from traditional vertical or horizontal discharge tray movements to a compact reciprocating motion in a different spatial dimension. The output mechanism moves back and forth in a limited space area, utilizing dimensional transformation to achieve sorting without requiring large occupation area.
Solution Approach 2:
The patent employs a dynamic reciprocating motion mechanism where the output mechanism continuously moves forward and backward to sort copies into different stacks. This dynamic approach replaces static large discharge trays with a compact moving system that achieves sorting through controlled reciprocation, significantly reducing space requirements.
2Adaptability or versatility
If the discharge tray is moved horizontally to perform sorting, then the sorting function is achieved, but the mechanism cannot be miniaturized due to large space requirements
Solution Approach 1:
The patent transforms the sorting mechanism from horizontal discharge tray movement to a compact reciprocating motion system that operates in a different spatial configuration. This dimensional change enables miniaturization by confining the sorting action to a compact area with back-and-forth motion rather than requiring extensive horizontal space.
Solution Approach 2:
The patent replaces the traditional mechanical discharge tray system with a pinion-rack driven reciprocating output mechanism. This substitution enables precise control of the output mechanism's position and motion, achieving sorting functionality in a miniaturized configuration with reduced mechanical complexity.
3Manufacturing precision
If manufacturing and accumulated errors occur in the output mechanism, then positioning accuracy deteriorates, but calibration is needed
Solution Approach 1:
The patent incorporates a sensor that detects the position of the output mechanism and provides feedback to the controller. This feedback system enables real-time monitoring and correction of positioning errors, compensating for manufacturing and accumulated errors during operation, thereby maintaining high positioning accuracy without requiring complex recalibration procedures.
Solution Approach 2:
The patent implements an automatic calibration function that performs positioning correction during the boot-up process without requiring external intervention. The system self-calibrates by detecting the home position of the output mechanism and adjusting for any manufacturing or accumulated errors, eliminating the need for manual calibration and maintaining positioning accuracy automatically.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables compact sorting functionality by using continuous transmission with the pinion and rack, allowing for flexible stack adjustment and eliminating the need for extra space, while ensuring accurate calibration of the output mechanism during boot-up.
Implementation Method 1
a driving pinion (39) meshing with the rack (38) drives the rack (38) and the output mechanism (31) to reciprocate in a second direction (D2) and to sort the media (M) into stacks
Data Source
AI summary
An image forming apparatus comprises a printing module, a transporting mechanism and a sorting module. The printing module prints data on media in order. The transporting mechanism transports the media past the printing module. The sorting module is disposed downstream of the transporting mechanism, and comprises an output mechanism, a rack and a driving pinion. The output mechanism transports the media out in a first direction. The rack is connected to the output mechanism. The driving pinion meshing with the rack drives the rack and the output mechanism to reciprocate in a second direction, different from the first direction, to sort the media into stacks. Thus, the sorting function can be achieved without providing a larger space and moving a discharge tray, and this is advantageous to the miniaturization of the image forming apparatus.