Sheet Processing Apparatus Alignment Mechanism for Stapling
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Solution Overview
Problem
Conventional sheet processing apparatuses face misalignment and stapler jam issues due to incorrect detection of sheet sizes, leading to staples striking air and apparatus breakage, especially when letter-size sheets are conveyed as A4-size sheets.
Innovation Solution
A sheet processing apparatus with alignment members that adjust their position based on the detected sheet size, ensuring proper alignment and stapling by moving towards a reference member by an alignment distance necessary for the smaller sheet size, preventing staples from striking air and reducing misalignment and jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the alignment member is positioned based on detected sheet size, then alignment accuracy is improved, but the system becomes vulnerable to detection errors causing misalignment
Solution Approach 1:
The alignment member is pre-positioned at a location that ensures proper alignment for the smaller sheet size (letter-size). This preliminary positioning ensures that even when a larger sheet (A4-size) is incorrectly detected as a smaller sheet, the alignment member will still be in a safe position that prevents stapling errors and misalignment issues.
Solution Approach 2:
The system proactively compensates for potential detection errors by positioning the alignment member conservatively for the smaller sheet size. This preliminary anti-action prevents the harmful effect of misalignment and staple striking air that would occur if the alignment member were positioned based on incorrect larger sheet size detection.
2Manufacturing precision
If the alignment member is positioned for larger sheet size, then larger sheets align properly, but smaller sheets will be misaligned and staples may strike air
Solution Approach 1:
The alignment member is pre-positioned at a location optimized for the smaller sheet size before any sheet is processed. This ensures that when smaller sheets are conveyed, they will be aligned correctly and staples will not strike air. The preliminary positioning for the smaller size protects against the harmful effect of staple misfire.
3Productivity
If sheet size detection is used to control alignment, then alignment is optimized for detected size, but detection errors lead to processing errors
Solution Approach 1:
The alignment member position is predetermined and set in advance based on the smaller sheet size, eliminating the need for real-time size-based position adjustments. This preliminary action maintains processing efficiency while improving reliability by preventing errors from detection mistakes.
Solution Approach 2:
Instead of creating multiple alignment positions for different sheet sizes, the system uses a single conservative alignment position that works for all sizes. This copying approach simplifies the system and eliminates detection-related errors while maintaining productivity.
Data Source
AI summary
A sheet processing apparatus according to an aspect of the invention can process a first-size sheet having a first length and a second-size sheet having a second length smaller than the first length. The sheet processing apparatus includes an intermediate stacking portion on which the sheets are stacked; a stapler which performs a stapling process to the sheets; a second alignment reference wall and a first jogger which align the sheets with a stapling process position; and a second jogger which is moved toward the second alignment reference wall and first jogger. Irrespective of a sheet size, the second jogger is moved toward the second alignment reference wall and first jogger by an alignment distance necessary to align the second-size sheet with a stapling process position, which allows the stapler to staple the sheets with at least one of two staple legs.