Image Forming System Stacking Tray Visualization Control
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Solution Overview
Problem
In high-speed image formation services like print on demand and production printing, operators face challenges in visually recognizing the current and future stacking states of sheets across multiple large-capacity stackers, leading to reduced productivity due to difficulties in estimating when a stacker will reach its maximum capacity.
Innovation Solution
A control device that generates a system configuration image and sheet bundle image, distinguishing between processed, processing, and waiting jobs, allowing for easy visualization of the stacking state on a monitor screen, including imaginary trays for future stacking, enabling operators to recognize and manage sheet discharge efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple large-capacity stackers are used to handle high-volume sheet discharge, then the image forming apparatus can maintain high productivity, but it becomes difficult to visually recognize the stacking state and estimate when stackers will reach maximum capacity
Solution Approach 1:
The patent creates a visual copy (display image) of the physical stacker system that replicates the stacking state information. The display shows tray configurations, sheet counts, and capacity indicators that mirror the actual stacker states, allowing operators to monitor multiple stackers remotely without physically inspecting each one.
Solution Approach 2:
The control device acts as an intermediary between the stackers and the operator. It collects stacking state information from multiple stackers, processes this data, and presents it in a unified visual format through the display, eliminating the need for the operator to directly observe each stacker.
2Quantity of substance
If sheets are discharged to multiple stacking portions in a divided manner, then the system can handle large volumes of sheets, but it becomes difficult to recognize the total number of sheets and the number of times work needs to be performed
Solution Approach 1:
The patent merges the information from multiple分散 stacking portions into a single unified display. The control device aggregates sheet count data from all trays and stackers, presenting the total sheet volume and distributed quantities in one consolidated visual interface, making it easy to understand the overall stacking state.
Solution Approach 2:
The display provides continuous feedback about the stacking state, including current sheet counts, remaining capacity, and work frequency estimates. This feedback loop allows operators to monitor the system state and make informed decisions about when to perform collection work.
3Reliability
If the operator manually monitors stacker capacity to prevent overfilling, then sheets can be collected in time, but the number of works increases and productivity decreases
Solution Approach 1:
The system provides automated feedback indicators that show current sheet counts, remaining capacity, and predictive information about when collection work will be needed. This allows operators to plan work efficiently rather than performing frequent manual checks, reducing the overall number of interventions required.
Solution Approach 2:
The display shows predictive information about future stacking states and estimates when collection work will be needed. This allows operators to perform collection work proactively before stackers reach maximum capacity, preventing overfilling while optimizing the timing and frequency of interventions.
Data Source
AI summary
A control device includes a storage and a controller and controls a system having an image forming apparatus to form an image onto a sheet based on an image forming job, and a sheet stacking apparatus having a stacking tray. The storage stores stacking state information indicating a state of sheets stacked and/or to be stacked on the stacking tray. The controller controls to generate a system configuration image that visualizes a configuration of the system, to generate a sheet bundle image that visualizes a sheet bundle stacked on the tray, and to display a screen in which the sheet bundle image is combined at a position of the stacking tray in the system configuration image. The controller controls to display the sheet bundle image such that sheets of a processed job, sheets of a job being processed, and sheets of a processing waiting job are distinguished from each other.