Jam detection system for a continuous paper sorting machine

Abstract

 Jam detection system for a continuous paper sorting machine in which the receiver (16) is comprised of stacks of paper storage trays (36) with entrances for receiving paper sheets from a feeder (14). The receiver (16) moves relative to the feeder mechanism (14), such that the bin entrances move past sheet feeder deflectors and guides (34). The feeder (14) has an infeed conveyor (24) from a press or duplicator (12) which moves the sheets for directing the copies either into a proof tray (20) or on into the feeder (14). The sheets are then fed to an intermediate conveyor (26 or 28) and from there to a reversible generally vertically disposed feeder conveyor (32). Sensors (40,42 and 44) are included in the sorting machine at predetermined locations as part of the control system and for jam detection. The jam detection system is designed to provide a visual read-out code for indicating the nature of and likely location of a paper jam.

Description

[0001] This invention relates to sheet distributing or sorting devices and more particularly to an apparatus which sorts continuously large numbers of multi-page documents and in which a novel and unique jam detection system is incorporated in the machine controls. Reference is made to the following copending United States Patent Applications which are incorporated herein and which are directed to other features of the instant machine in which the jam detection system is incorporated. They are:

1. "Continuous Paper Sorting Machine" Serial No.: 897,272, filed April 17, 1978;

2. "Bir Receiver Mechanism for a. Continuous Paper Sorting Machine"
Serial No.: 897, 273, filed April 17, 1978;

3. "Feeding Mechanism for a Continuous Sorting Machine"
Serial No.: 897,274, filed April 17, 1978;

- 2 - 4. "Paper Sheet Deflecting System for Sorter Mecbanism"

[0002] Serial No.: 897,275, filed April 1978 Prior art paper distributors, sorters and/or collators have encountered many problems. One is that the large increase in the cost of labor and materials has made it more imperative that the available press or duplicator capacity be utilized to its fullest. In order for the maximum volume capability of a printing, duplicating, or copy making machine to be utilized, it is necessary that the sorter have the capacity to receive the printer or copy making machine output without undue loss of press or copy making machine time. Areas of lost time would be those accounted for by faulty or irregular transport of sheet copies and by failure of the controls to detect nonprogrammed occurrences such as sheets counted at entry to feeder but not counted in tower. Others would be paper sheets hanging up at deflector locations, stalling at the entrances to trays and overlapping to name a few of the irregularities.

[0003] Since there are different types of irregularities which can occur, it is important that the operator be able to locate the problem or irregularity area for quick clearing of the machine. Those skilled in the art will appreciate the savings in labor, time and money if the output of a printing or copying center is not impaired by long shutdowns to hunt for jams.

[0004] Among the prior art references which may be considered with respect to the features of this invention are the following: United States Patent Nos. 3,988,018; 3,527,406; 3,905,594. The devices covered by the above listed patents are considered to be nonanticipatory of the teachings of this invention.

Summary

[0005] Jam detection system for a continuous paper sorting machine, in which the receiver is comprised of at least two columns of inclined side-by-side stacks of paper storage trays with entrances for receiving paper sheets from a feeder. The receiver is mounted for lateral movement relative to the feeder mechanism, such that the tray entrances move past the feeder in a generally vertically plane. The feeder has an infeed conveyor from a press or duplicator which moves the sheets of paper to a deflector which directs the copies into a proof tray or on into the feeder. The sheets are then fed upwardly or downwardly onto an intermediate conveyor and from there to a reversible generally vertically disposed feeder conveyor.

[0006] Sensors are included in the sorting machine at predetermined locations as part of the control system and for jam detection. The jam detection system is designed to provide a visual readout code on the control panel for indicating the nature of and likely location of a paper jam.

Brief Description of Drawings

[0007] 

Figure 1 is a perspective outline view showing the general arrangement and organization of the sorter including both feeder- and distributor sections;

Figure 2 is a detailed view of the control panel for the machine, and

Figure 3 is a partial schematic and block diagram showing major subcircuit or component sections of the control system.

Description of the Preferred Embodiment

[0008] Referring now to the drawings and particularly to Figures 1 and 3, it will be seen that the sorter mechanism is generally designated by the number 10 and receives paper copies from a duplicator or press device generally designated by the number 12. A feeder section of the sorter is identified by the number 14 and a paper receiver mechanism is identified by the number 16 which moves laterally back and forth on a track structure 18. The feeder 14 includes a proof tray assembly 20 and a control panel box 22 as well as infeed conveyor 24 which feeds papers either to a downwardly inclined intermediate conveyor 26 or an upwardly inclined intermediate conveyor 28. A tower section generally designated by the number 30 supports a vertically disposed reversible feeder conveyor 32 together with tray deflectors and guides 34 and trays 36 in the receiver section 16. As can be seen, the tower section 30 is supported on a base section 38.

[0009] As can be seen by reference to Figure ;3, three sets of photoelectric sensors are provided, one being the light emitting diode and photo receiver sensor 40 at the entrance to the proof tray conveyor. A second light emitting diode and photo receiver 42 are previous to the junction of the up/down intermediate conveyors 26 and 28 with the inner end of infeed conveyor 24. Light emitting diode 44 and photo receiver 44 are disposed generally parailel to the face of the vertical up/down conveyor 32 and the deflector and guides 34. The control panel as seen in Figure 3 is provided with a vertical row of number or digit buttons 50 and a vertical row of selector buttons 52 corresponding to indicator lights 54 and the parameter indicia 56 also seen in vertically arranged rows on the face of the control console. Four sets of digital or numeric three place readout displays 58 are provided to correspond with the first four control parameter indices seen in respect of number 56. To the left of the control panel can be seen thumb switch 64 for a "count adjust" which anticipates the number of sheets which are in transit from the press or duplicator to the feeder after the press has been shut off. Thumb switch 62 allows the operator to select the number of copies for each master which will be directed into the proof tray 20. Finally the third thumb switch 64 allows the operator to tell the control systen the number of bins, that is modules of 100 trays, being used. A toggle switch 66 tells the control system which size trays are being used in the bin modules.

[0010] For the purpose of providing a better understanding of the jam detection system a brief description of the operation will now be set forth.

[0011] The sorter has the ability to store the parameters set forth as indicia by number 56. These parameters will define specifics for sorting from one to nine different jobs in sequence. Entry of the job parameters is accomplished by a series of depressions of the various function and digit keys 52 and 59 on the panel. The operator receives direction and readout information from the different numeric parameter displays and condition indicators on the panel.

[0012] The first parameter associated with each sorting job i₅ the "job" parameter which defines the job's position in the sequence of up to nine jobs which may be entered and stored in the machine's control memory. Jobs are executed in the same order in which they are entered.

[0013] The next parameter is the "first tray" parameter. This defines the position number or address of the tray which will receive the first sheet during sorting of a given job. Tray addresses may range from 0 to 600, with 0 denoting proof tray 20 shown in Figure 1.

[0014] The third parameter is "sets" and this defines the number of sets which will result from the sorting job. Sets values range from 1 to 600.

[0015] The fourth parameter is "pages" and this defines the number of pages (masters) in each set to be sorted during the job. "Pages" values range from 1 to the total number of sheets which can be fit into a maximum of two trays.

[0016] In order to enter parameters defining the jobs to be sorted, the operator must be sure that the system is in "enter" mode, signified by the fact that the "enter" indicator light 54 is lit. Once in the "enter" mode, the parameters for the various jobs must be entered in order of increasing job number. The four parameters for a given job must be sequentially entered in the order seen as the first four indicia, that is "job", "first tray", "sets," and "pages". A job will not be accepted for sorting unless the operator has successfully entered each of the four parameters for that job. After nine complete sets of job parameters have been entered, the system will automatically go to the "sort" mode. Next it will turn the "enter" indicator 54 off and the "sort" indicator 54 on, and wait for a sort execution command from the operator. If the operator wishes to run fewer than nine jobs, he will press "sort" following successful entry of the last parameter of the last job to be sorted, whereupon the system goes to "sort" mode.

[0017] The numeric values for "first tray", "sets" and "pages" parameters can be entered one digit at a time when their respective indicators are lit. When the display 58 holds the value desired for that parameter, the operator presses "enter" to record the parameter for the current job being specified.

[0018] Depressing the sort key causes the receiver conveyor to move into position for feeding paper into the first tray address.

Jam Detection Action

[0019] In the "sort" mode the system is continuously monitoring all events at the various sensors to see if sheets are making their way through the sorter without problem. Checks performed at the proof, up/ down. and tower sensors include counting each sheet that passes and measuring the amount of time each sheet is seen by each of the sensors. Whenever an irregularity in the flow of sheets (i.e. jam) is detected, the system suspends current sorting operation and takes the following action:

1. Cause press feed interrupt to stop the flow of sheets into the sorter.

2. De-entergize proof deflectors to send any residual sheets due to press run out to the proof tray.

3. Deactivate both sorter clutches.

4. Turn off sorter conveyor belts.

5. Turn off receiver conveyor motor, terminating any move in progress.

6. Turn on the "paper path" indicator lamp 54.

7. Display a number between 901 and 909 in the "first tray" display 58 which tells the operator by predetermined code the cause of the jam. Also, in the "sets" numeric display 58 the operator is told the number of sets remaining which are to be completed at the time the jam occurred.

[0020] At this point, the operator must take corrective action, the nature of which depends upon the jam condition being displayed in the first tray numeric display. It is then the operator's responsibility to remove all sheets from the conveyor and from the line of view of any of the sensors.

[0021] While in the jam mode, various panel keys may be pressed, resulting in the following actions:

(a) any key: pressing any key will cause the audio alarm to be turned off.

(b) stop/off: turn fans off.

(c) enter: returns the system to the job parameter entry mode causing any jobs previously held in memory to be not executed.

(d) paper path: first depression of this button 52 causes the receiver conveyor to move back to its home or zero switch to allow examination of the tower area. The second depression of this button causes the receiver conveyor to return to the position it was in when the jam occurred.

(e) continue: sorting may be resumed if all the sensors are found to be free of paper and when operator has removed all paper from sorter conveyor path. It must be noted that the receiver must be at its pre-jam position in order to resume sorting.

[0022] Upon successful jam recovery, the system resumes sorting by taking the following action:

(1) Turn off the "continue" and "paper path" indicator lamps 54.

(2) Re-display proper "first tray" for the job being sorted and redisplay the proper number of "sets" for that job.

(3) Turn on the conveyor belts and fans.

(4) After a one second delay, the controls activate the press feed.

(5) The system is returned to its pre-jam mode, either proof or sort.

Jam Identification Table

[0023] The control panel will display automatically one of the following nine jam conditions at the time a jam occurs to indicate the location and nature of the irregularity. The jam code number is displayed in the "1st Tray" numeric display 58.

Standard jam action requires that the operator do what is necessary in order to remove all sheets from the sorter conveyor belts; then restart sorting process by pressing CONTINUE.

Claims

1. In a continuous paper sorting machine having a feeder portion with an infeed conveyor leading from a press/duplicator mechanism and a proof tray there- above, and including upwardly and downwardly inclined intermediate conveyors at the inner end of said infeed conveyor and a generally vertical, reversible tower conveyor with paper deflector and guide means, said paper sorting machine also including a movable bin receiver section with vertical stacks of paper trays for receiving sheets of paper from said tower conveyer feeder portion, the jam detection improvements comprising:

1) first proof sensor means on said infeed conveyor,

2) second up/down sensor means near the inner end of said infeed conveyor,

3) third tower sensor means on said tower conveyor,

4) control means including a control panel having visual read-out means thereon for indicating by predetermined code the general nature and probable location of a paper jam in said sorting machine when such a jam occurs-

2. The jam detection improvements according to Claim 1 and in which said control'means, is able to sense, and display on said visual readout means a predetermined number of paper jam conditions in said sorting machine.

3. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a paper sheet was at said proof sensor for longer than a predetermined period.

4. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a paper sheet was at said down/ up sensor for longer than a predetermined period.

5. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a paper sheet was at said tower sensor for longer than a predetermined period.

6. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that paper sheets counts at said tower and said down/up sensors did not balance within predetermined time after last sheet cleared down/up sensor.

7. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that paper sheet counts at said tower and said down/up sensors differed by more than a predetermined number.

8. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that the machine was stopped by the operator depressing a stop/off switch.

9. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a paper sheet was detected at said down/up sensor which was not counted at said proof sensor.

10. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a paper sheet was detected at said tower sensor which was not counted at said proof sensor.

11. The jam detection improvements according to Claim 2 and in which a jam detect and display code condition shows that a zero or limit switch was tripped by said movable receiver at a time when it should not have been.

12. The jam detection improvements according to Claim 2 and in which while a jam condition is being displayed, said control means also displays the number of sets remaining to be completed at the time the jam condition occurred.

Drawing