Sheet Discharge Device Segmented Bundle Formation
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Solution Overview
Problem
In image forming systems, the displacement of the lowermost sheet in a sheet bundle due to friction coefficient differences between sheets and the stack tray surface leads to alignment issues, especially when forming bundles with larger sets of sheets, and this problem is exacerbated by environmental and installation factors.
Innovation Solution
A sheet discharge apparatus that forms sheet bundles by dividing sheets into multiple sets and discharging them in stages, with the number of sheets in the first set being smaller than in subsequent sets, and utilizing a buffer mechanism to temporarily hold sheets until a predetermined number is reached, ensuring proper alignment and reducing friction-related displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sheets are discharged in large sets to form sheet bundles efficiently, then productivity is improved, but the lowermost sheet position becomes displaced due to increased friction
Solution Approach 1:
The patent divides a large set of sheets into multiple smaller sub-sets and discharges them sequentially. For example, instead of discharging 10 sheets at once, the system discharges them in groups of 3-4 sheets per operation. This segmentation reduces the cumulative friction effect on the lowermost sheet while still achieving the desired sheet bundle formation, thereby maintaining alignment accuracy without sacrificing overall productivity.
2Manufacturing precision
If the entire stack tray is moved for jog sorting, then sheet bundle alignment is improved, but a high torque motor is required
Solution Approach 1:
Instead of moving the entire stack tray with heavy sheets, the patent segments the sheet discharge process into multiple smaller operations. Each operation handles a smaller subset of sheets, significantly reducing the weight and friction that the motor must overcome. This allows the use of a lower torque motor while maintaining effective jog sorting capability.
Solution Approach 2:
The patent performs preliminary sheet separation and positioning actions before the main discharge operation. By pre-organizing sheets into smaller manageable groups and positioning them appropriately on the processing tray, the system reduces the effort needed during the actual discharge and tray movement operations, thereby reducing motor torque requirements.
3Manufacturing precision
If sheets are discharged in multiple small sets, then sheet alignment is maintained, but the number of discharge operations increases
Solution Approach 1:
The patent implements a dynamic control system that automatically adjusts the sheet discharge parameters based on real-time conditions. The controller monitors sheet accumulation, friction conditions, and alignment status, dynamically determining the optimal number of sheets per discharge operation. This dynamic adaptation streamlines the discharge sequence by eliminating unnecessary operations while maintaining alignment precision.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the position and alignment of discharged sheets. Based on this feedback, the controller optimizes subsequent discharge operations, adjusting the number of sheets per operation and timing to minimize the total number of discharge cycles required while maintaining alignment accuracy.
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
This approach prevents the displacement of the lowermost sheet during bundle formation, maintaining accurate alignment and reducing the need for high-torque motors, thus enhancing the reliability and efficiency of the sheet discharge process.
Implementation Method 1
the position of the lowermost sheet constituting the first one of the plurality of sets that contacts the stack tray may be displaced. This phenomenon is caused due to the difference between friction coefficients of the sheet and the surface of the stack tray.
Data Source
AI summary
A sheet discharge apparatus includes a first tray for stacking sheets, and a sheet bundle forming unit that forms a sheet bundle on the first tray. The sheet bundle forming unit forms a first sheet bundle on the first tray, and forms a second sheet bundle on the first sheet bundle to be offset from the first sheet bundle. When forming each of the first sheet bundle and the second sheet bundle on the first tray, the sheet bundle forming unit divides sheets constituting each of the sheet bundles into a plurality of sets and discharges the sheets in a plurality of times for each sheet bundle. A number of sheets included in a first sheet set of the first sheet bundle is set smaller than a number of sheets included in a first sheet set of the second sheet bundle.