Stacker Device Power Control for Safety and Productivity
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Solution Overview
Problem
Stacker devices face a trade-off between productivity and safety, as suspending the sheet stacking operation to prevent accidents results in downtime and reduced productivity, and existing safety mechanisms do not effectively improve productivity while maintaining safety.
Innovation Solution
A stacker device design that includes a discharger, multiple trays, a shutter, and a hardware processor that controls power to the driver based on the shutter's height position and the second tray's position, allowing for continuous operation while ensuring safety by managing the power shutoff positions to prevent accidental entry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power is shut off to the driver when the shutter is opened to ensure safety, then safety is improved, but productivity deteriorates due to suspension of stacking operation
Solution Approach 1:
The patent applies local quality by differentiating the power supply control for different regions or states of the system. When the shutter is opened, power is selectively shut off only to the driver responsible for tray movement, while other components may continue operating. This localized control maintains safety in the critical area (tray movement zone) without completely halting the entire stacking operation, thus resolving the contradiction between safety and productivity.
Solution Approach 2:
The patent implements dynamic power supply control based on the real-time state of the shutter and tray position. The power supply to the driver is dynamically adjusted - shut off when the shutter is opened and the tray could pose a safety risk, and restored when the shutter is closed and safe operation is confirmed. This dynamic approach allows the system to adapt its safety measures to actual operating conditions, maintaining productivity while ensuring safety when necessary.
2Reliability
If the shutter remains closed to maintain safety, then safety is improved, but productivity deteriorates due to restricted tray operation
Solution Approach 1:
The patent uses dynamic control to determine when the shutter should remain closed versus when it can be opened. By monitoring the tray position and operational state, the system dynamically adjusts shutter status - keeping it closed only when necessary for safety while allowing it to open when safe operation is confirmed. This resolves the contradiction by making safety measures adaptive rather than static.
Solution Approach 2:
The patent replaces the purely mechanical approach of keeping the shutter closed for safety with an intelligent control system that uses sensors and power supply management. Instead of relying solely on the physical barrier of the closed shutter, the system substitutes mechanical restriction with intelligent power control - shutting off power to the driver only when the shutter is open and safety risks exist, allowing the shutter to remain open for better productivity while maintaining safety through electronic control.
3Productivity
If power is continuously supplied to the driver for uninterrupted stacking, then productivity is improved, but safety deteriorates due to risk of hand or finger catching
Solution Approach 1:
The patent applies preliminary anti-action by proactively shutting off power to the driver before a safety incident can occur. When the shutter is opened, the system preemptively cuts power to the driver, preventing the possibility of hand or finger catching in the moving tray. This preliminary safety measure is taken before any actual danger arises, resolving the contradiction by prioritizing safety prevention while minimizing impact on productivity through selective power control.
Solution Approach 2:
The patent implements a feedback mechanism where the shutter state is continuously monitored and used to control power supply to the driver. When the shutter opens, this feedback signal triggers immediate power shutdown to the driver, preventing safety incidents. When the shutter closes, power is restored. This closed-loop feedback system automatically balances safety and productivity without requiring constant human intervention, resolving the contradiction through intelligent automated control.
Data Source
AI summary
A stacker device includes: a discharger that discharges sheets in response to a print job; a first tray on which the discharged sheets are stacked; a second tray that serves as a delivery destination of the sheets stacked on the first tray; a shutter that covers an opening on a front side of a housing; a driver that moves the first tray in an up-down direction; and a hardware processor that shuts off power to the driver based on a height position of the shutter and a position of the second tray in a front-rear direction.