Stacking Device Conveyance Control for Sheet Sorting
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Solution Overview
Problem
Existing saddle stitch binding systems face productivity reductions due to the need to stop continuous conveyance of sheets to accurately sort signatures into sheet stacks, which slows down the processing speed.
Innovation Solution
A stacking device with a first conveyance unit for sequential conveyance and a second conveyance unit with rotating members that sandwich and control the conveyance of signatures, using sensors to manage rotation and prevent the next sheet stack from being conveyed until the stacking unit is ready, allowing continuous operation without stopping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conveyance of signatures is stopped temporarily to accurately sort signatures into sheet stacks, then sorting accuracy is improved, but processing speed is reduced
Solution Approach 1:
The patent implements continuous conveyance of signatures through the use of accumulation members that store signatures temporarily. The conveyance device operates continuously without stopping, while the accumulation members buffer the flow of signatures to ensure accurate stacking. This eliminates the need to halt the conveyance process for sorting accuracy.
Solution Approach 2:
The accumulation members perform preliminary storage of signatures before they reach the stacking position. By pre-accumulating signatures in a controlled manner, the system prepares the next signature to be stacked in advance, ensuring accurate sorting without interrupting the continuous conveyance flow.
2Productivity
If grip means pulls out lowermost sheet one after another to form pile, then continuous conveyance is maintained, but time is required for sequential extraction
Solution Approach 1:
The patent replaces the mechanical grip means that sequentially pulls out sheets with a conveyance system that uses continuous motion and accumulation members. The signatures are conveyed continuously and stacked using the rotational conveyance mechanism, eliminating the time-consuming sequential extraction process while maintaining continuous flow.
3Manufacturing precision
If knife reciprocates by stroke corresponding to signature length to drop stacked signatures, then stacking is achieved, but time is required for reciprocation motion
Solution Approach 1:
The patent uses periodic rotational action of the conveyance members instead of linear reciprocation. The conveyance members rotate in a continuous cyclic motion, naturally delivering signatures to the stacking position at regular intervals. This periodic rotation achieves accurate stacking without the time-consuming back-and-forth reciprocation motion.
Solution Approach 2:
The patent transitions from static knife positioning with linear reciprocation to dynamic rotational conveyance. The conveyance members rotate continuously, dynamically delivering signatures to the stacking position. This dynamic approach eliminates the inertial losses and time delays associated with starting and stopping reciprocation motion.
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 high-speed formation of sheet stacks by preventing the need for continuous conveyance interruptions, thereby improving the overall productivity of the binding system.
Implementation Method 1
the second conveyance unit being configured to convey the signatures through the pair of conveyance members by means of rotation of the pair of conveyance members while sandwiching both sides of the signatures between the pair of conveyance members
Data Source
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AI summary
A pair of conveyance rollers 40 are arranged for signatures S1. At least one of the conveyance rollers 40 is configured to be driven to rotate. The signatures S1 is conveyed through the pair of conveyance rollers 40 to a stacking unit 5 while being sandwiched from both sides thereof between the pair of conveyance rollers 40. In response to passage of a signature S1 for a sheet stack B through the pair of the conveyance rollers 40, the conveyance rollers 40 is switched from conveyance rotation to intermittent rotation to cause the pair of the conveyance rollers 40 to keep the signatures S1 for a next sheet stack B from being conveyed to the stacking unit 5. In response to the stacking unit5 becoming ready to receive the signatures S1 for the next sheet stack B, the conveyance rollers 50 is switched from the intermitted rotation or the stop to the continuous rotation to cause the pair of the conveyance rollers 40 to convey to the signatures S1 to the stacking unit 5.