[0001] The present invention relates to an improved system for providing recirculatory precollation
copying of sets of original document sheets for special conditions of small document
sets.
[0002] The exemplary copier and document recirculating and inverting apparatus disclosed
herein is also disclosed in US-A-4,278,344. An advantage of the present system is
that it may be used with that disclosed apparatus without substantial modification.
However, the present system is not limited to that apparatus or application and is
usable with various other recirculative document handlers and copiers.
[0003] As xerographic and other copiers increase in speed, and become more automatic, it
is increasingly important to provide higher speed yet more reliable and more automatic
handling of both the copy sheets and the original documents being copied, i.e. both
the output and input of the copier. However, the providing of recirculative document
copying for precollation copying, especially for duplex (two-sided) copies, greatly
complicates and increases the document sheet and copy sheet handling complexities.
[0004] The following terminology is generally used in the description herein. The term "sheet"
generally refers to conventional sized filmsy sheets of paper, plastics or other conventional
or typical individual image substrates (original or copy), and not to microfilm or
electronic images which are generally much easier to manipulate. However, the terms
"document" or "document paper" in the claims here, unless otherwise specified, may
also be read on encompassing laser-printed or otherwise electrically generated, stored
or rearranged images. The term "page" here generally refers to one side or "face"
of a sheet or the image thereof. A "simplex" document or copy sheet as one having
its page and image on only one side or face of the sheet, whereas a "duplex" document
or copy sheet has pages on both sides. The term "duplex copying" may be more specifically
defined into several different known copying modes. In "duplex/ duplex" copying, both
sides (both pages) of a duplex document sheet are copied onto both sides of a copy
sheet. In "duplex/simplex" copying, both sides of a duplex document are copied onto
one side of two successive copy sheets, In "simplex/duplex" copying, the two page
images of two successive simplex document sheets are copied onto the opposite sides
of a single copy sheet. In non-duplex copying, i.e. "simplex/ simplex" copying, one
side of each simplex document is copied onto one side of each copy sheet. In the printing
industry, as opposed to the copier industry, two-sided copying may be referred to
as "backing-up" rather than duplex copying. A commercially desirable precollation
document handling system should compatibly provide all of these copying modes, although
"duplex/simplex" need not be provided.
[0005] The present system particularly relates to a "simplex/duplex" precollation copying
system which is fully compatible, with the same apparatus, with all of the other said
copying systems.
[0006] "RDH" is an abbreviation for an automatic recirculating document handler, in which
document sheets are automatically fed from a stack, copied and returned thereto, normally
for a precollation copying system., The present system is particularly suited for
a precollation (multiply recirculated) document copying system, but is also compatible
with non-precollation copying with the same apparatus.
[0007] Precollation, or collation copying, as it is variably called, is a known desirable
feature for a copier, which provides a number of important advantages. In precollation
copying any desired number of precollated copy sets may be made by making a corresponding
number of recirculations of the original document set in collated order past the copier
imaging station and copying each document page only once each time it circulates past
the imaging station. The copies automatically exit the copier in precollated sets,
and thus do not require subsequent sorting in a sorter or collator. On-line finishing
and/or removal of completed copy sets may thus be provided while further copy sets
are being made from the subsequent circulations of the same document set.
[0008] However, a disadvantage of precollation copying systems is that the documents must
all be repeatedly circulated, and copied in a predetermined order, by a number of
circulations equivalent to the desired number of copy sets. Thus, increased document
handling is necessitated for a precollation copying system, as compared to a post-collation
copying system. Also, for duplex copying the copy sheets must normally also be recirculated
once in the copying path in coordination with the document set recirculation in order
to print images on both sides thereof. Therefore, maximizing document handling automation
and copying cycle efficiency is particularly important in precollation copying. If
the document handler cannot efficiently and rapidly circulate and copy documents in
coordination with copy sheets in the correct order, or must excessively strip documents
or copying cycles, the total copying time for completing all of the copy sets will
be increased. Also, minimizing the time delay from the initiation of copying until
the first copy set is completed is another important factor. This is known as "first
copy out time".
[0009] In contrast, in a post-collation copying system, plural copies are made at one time
from each document page and collated by being placed in separate sorter bins. The
document set need only normally be circulated or manually or semi-automatically fed
to the imaging station once and multiply copied to fill the bins of the copy sheet
sorter or collator with the corresponding number of copy sets. However, the number
of copy sets which can be made in one document circulation is limited by the number
of available bins. Also, a sorter adds space and complexity and is not well suited
for on-line finishing. However, post-collation copying and manual document placement
are desirable in certain copying situations to minimize document handling. Thus, it
is desirable that a precollation copying system be compatible with, and alternatively
usable for, post-collation copying as well.
[0010] Both forward serial order (1-to-N) and reverse order (N-to-1) precollation copying
of original documents is known for both simplex (one-sided) and duplex (two-sided)
ordinal documents and copies, as shown in the cited art. A recent 1-to-N or normal
forward serial order, and face-down stacking, document recirculation systems for precollation
simplex or duplex copying systems is disclosed in US-A-4,229,101. Another example
thereof is disclosed in US-A-4,234,180. However, in current products and said art,
N-to-1 (reverse order) document set circulation is conventional for systems feeding
from a stack of documents positioned (loaded) over a platen of a copier. In such conventional
systems the documents are loaded face-up and fed out from the bottom of the stack
and restacked on the top of the stack. The simplex documents are circulated by being
turned over, copied, turned over again, and returned back to the top of the stack
over the platen.
[0011] A major disadvantage of such N-to-1 or reverse document feeding and copying order
is that the copier controller does not know what document is being fed on the first
circulation, since the last page is fed first. Not knowing whether the number of documents
being fed is odd or even, and duplexing accordingly, has distinct disadvantages for
making duplex copies. If the number of original document pages is odd, the last duplex
copy sheet will be blank on one side. This problem has lead to simplex/duplex copying
with either precounting of the entire document set before copying in a non-copying
circulation and/ or selective use of a copy sheet inverter in the copy sheet path
and other disadvantages, as explained more fully in US-A-4,330,197, 4,278,344, and
4,166,614. That is, commercial RDH copying systems generally feed documents in backwards
or reverse page order, i.e. from the last or Nth page to the first page, as further
described hereinbelow. Thus for simplex/duplex copying a non-copying initial counting
circulation of simplex documents has been considered essential for such N-to-1 (reverse
page order) RDH systems. This is disclosed in US-A-4,330,197. This automatically determines
whether the Nth (first copied) document is odd or even, but increases first-copy-out-time.
[0012] Such precount cycles and/or selective use of a copy sheet inverter adversely affect
the system reliability by requiring extra handling of the document set and running
the copy sheets past additional deflector fingers and in and out of an inverter, with
extra or different handling and timing. In addition, for a large document set the
precount cycle may decrease the perceived productivity of the system by cycling the
document handler without imaging the originals at the beginning of copying when it
is most noticeable and when there is no copy sheet output finishing or handling to
occupy the operator's time. For a larger document set there is a corresponding increase
in first copy out time for simplex/duplex copying using a pre-count circulation.
[0013] Not knowing whether a document set being fed is an odd or even page number on the
first circulation particularly complicates the simplex/ duplex operation of a copier
when it is desired to use letter-head, binder edged, prepunched, marginal, or other
special copy sheets which require a particular face or orientation of the copy sheet
to be printed or bound. For example, with letterhead paper, for duplex copying page
1 must be printed on the letterhead side, not the obverse side. Using paper with ring
or spiral binder holes, the odd document pages should be copied so that the holes
are on the left-hand side of the page and the even document pages should be copied
so that the holes are on their right. If the copier finisher has a stapler positioned
for one corner, the copy sheets should be placed in the finisher automatically in
the correct orientation for stapling in the correct corners.
[0014] However, N-to-1 document recirculation has been commercially utilized in spite of
these disadvantages because it is suitable and conventional for a "racetrack" or over-platen
loop circulation path, in which the documents are recirculated to and from a document
stack, located over the copier platen, as shown in the cited references. Simplex documents
are fed from one edge of the stack to the same side or edge of the platen underneath
the stack and back from the opposite edge of the platen to the opposite edge of the
stack, and therefore may be stream fed unidirectionally over the platen, feeding one
document on while the prior one is feeding off. The document path has a 180° loop
turn at each side of the platen which is generally a short path. With such a shorter
and unidirectional "racetrack" loop path length, document transport speeds can be
lower and two or three sheet document set handling with less skipped copy cycles can
be achieved more easily than with most non-racetrack systems.
[0015] By way of further background as to known difficulties in integrating precollation
document recirculation with duplex copying, in a properly collated set of duplex copy
sheets the odd pages 1, 3, 5, etc., should normally appear on the first or front faces
or sides, and only the next higher page number even pages 2, 4, 6, etc., should normally
be on the respective second or back sides. The order of copying the document pages
and the order of presenting the copy sheets to the images thereof must be coordinated
to maintain proper page order for collation. Also, the number of duplex sheets will
always be less than the number of pages on those duplex sheets. In contrast, in a
set of simplex document or copy sheets, the number of the sheet will typically also
correspond to the page number. Thus, an odd number of simplex sheets will normally
also have a corresponding odd number of page images. However, a set of duplex sheets,
regardless of the sheet count, may have an odd or even number of pages. If there is
an odd number of pages in the set of duplex sheets, the reverse side of the last sheet
will normally be blank (empty). Other difficulties involved in efficient duplexing
systems and sequences, which are compatible with both simplex and duplex systems,
are discussed in the art cited herein and other duplexing art.
[0016] Of interest as relating to improved simplex/ duplex precollation system efficiency
is US-A-4,116,558. That system is also described in other above-cited patents. This
patent teaches a more efficient RDH system for making duplex precollated copy sets
compatible with simplex copying and usable with the present invention, in which all
of the simplex documents may be recirculatively copied on all but the first and last
copying circulations, and in which alternate simplex documents are copied on the first
and last circulations (by circulating all documents but not exposing alternate ones)
to form and remove a duplex copy buffer set, but with copying of all simplex documents
on all other circulations (with alternate feeding of clean or buffer set copy sheets
to the photoreceptor for imaging alternate pages on opposite sides thereof and to
maintain a buffer set until the last copying circulation).
[0017] Some examples of fuller details of preferable recirculating document handlers are
disclosed in US-A-4.,335,954, 4,270,746 and 4,076,408. US-A-4,078,787 is noted as
to copying a single simplex document in an RDH without any circulation (since single
page copy sets cannot, of course, be collated). Also of interest is US-A-4,093,372
teaching an RDH copying system which switches from a precollation to a post-collation
mode of copying automatically in response to operator selection of a preset (larger)
number of desired copy sets.
[0018] By way of further background, another recent example of a duplex or simplex document
recirculation precollation copying system is disclosed in Disclosure Number 16332,
pp. 49-52, of the November 1977 issue of "Research Disclosure", published by Industrial
Opportunities, Ltd., Homewell, Havant, Hampshire, U
:K. and its equivalent disclosure in GB-A-2,000,749.
[0019] The anonymous Disclosure Number 19015 published February 1980 in "Research Disclosure"
is of interest as merely suggesting that when duplex original documents are being
copied onto duplex copy sheets in a ("immediate duplex") system where the duplex documents
must be immediately inverted each time for copying opposite sides in immediate sequence,
that the consequent copying speed loss can be compensated for to some extent by making
two consecutive copies of the same original each time. However it requires two copy
receiver trays.
[0020] Further by way of background, it is known that non-precollation duplex copying (for
either duplex/duplex or simplex/duplex copying) may be done by first making in the
copier processor a "buffer set" comprising a plurality of simplexed copy sheets (printed
only on their first sides). The buffer set sheets are temporarily stored, preferably
in a duplex buffer tray, and then fed back through the same copying processor for
a second pass printing of the proper opposite page on their opposite sides. Such systems
may be referred to as sequential or dual pass duplexing systems, and are used, for
example, in the Xerox 4000 (without an RDH) and in the Xerox 9400 copiers. Examples
of such systems for handling the copy sheets being duplexed are shown in US-A-3,615,129,
and 3,645,615. In such non-precollation duplexing systems all the sheets in the buffer
set are normally identical copies of the same, single, document page.
[0021] In contrast, for precollation duplex copying the buffer set copies are not identical.
Each buffer set has one copy of each different document page, and thus there order
and orientation must be maintained and coordinated with the document pages to be printed
on their opposite sides. As noted in the above-cited US-A-4,278,344 the references
teaches that two buffer sets may be provided in the special situation of bidirectional
copying where copies are made in two different orders (1-to-N then N-to-1) in a special
document feeder and copier. These cited references are US-A-4,116,558 and 4,172,655.
Also noted in that regard is US-A-4,210,319. These are different (different order)
buffer sets, as are those in IBM Technical Disclosure Bulletin Vol. 22, No. 7. pp,
2657-2659, Dec. 1979.
[0022] Examples of various other patents teaching conventional document handlers and also
control systems therefor, including document path switches and counters, are US-A-4,054,380;
4,062,061; 4,076,408; 4,078,787; 4,099,860; 4,125,325; 4,132,401; 4,144,550; 4,158,500;
4,176,945; 4,179,215; 4,229,101; 4,278,344 and 4,284,270. Conventional simple software
instructions in a copier's conventional microprocessor logic circuitry and software
of document handler and copier control functions and logic, as taught by the above
and other patents and various commercial copiers, are well known and preferred. However,
it will be appreciated that the document handling functions and controls described
herein may be alternatively conventionally incorporated into a copier utilizing any
other suitable or known simple software or hard wired logic systems, switch controllers,
etc. Such software for functions described herein may vary depending on the particular
microprocessor or microcomputer system utilized, of course, but will be already available
to or readily programmable by those skilled in the art without experimentation from
the description provided herein.
[0023] The control of all of the exemplary sheet handling systems disclosed herein may be
accomplished by conventionally activating them by signals from the controller in response
to simple programmed commands and switch inputs from the copier console selected by
the operator, such as selecting the number of copies, selecting simplex or duplex
copying, selecting whether the documents are simplex or duplex, etc. These signals
may conventionally actuate conventional electrical solenoid or cam- controlled sheet
deflector fingers and drive motors or their clutches in the selected steps or sequences
as programmed. Conventional sheet path sensors or switches and bail bars, connected
to the controller, may be utilized for counting and keeping track of the positions
of documents and copy sheets, as is well known in the art, and taught in the above
and other patents and products. Known precollation copying systems utilize such conventional
microprocessor control circuitry and connecting switches for counting the number of
document sheets as they are recirculated, counting the number of completed document
set circulations, and thereby controlling the operation of the document and copy sheet
feeders and inverters, etc.
[0024] The present invention overcomes or reduces various of the above-discussed problems.
[0025] Accordingly the present invention describes a copying method which is as claimed
in the appended claims.
[0026] Further features which may be provided by the method disclosed herein, individually
or in combinations, include those wherein, if the number of copy sets made is greater
than two, all of the documents are copied in all intermediate document copying circulations
(other than the first two and the last two copying circulations) to maintain two buffer
sets during the intermediate circulations by concurrently rebuilding and depleting
the two buffer sets. The present invention will now be described by way of example
with reference to the accompanying drawings, in which
Fig. 1 is a schematic side view of an exemplary copier and an exemplary recirculating
document handler therefor with which the present invention may be practised and
Fig. 2 shows schematic document and copy sheet paths for exemplary efficient N-to-1
order simplex/duplex copying on the apparatus of Fig. 1 for precollation copying for
a 3-page (3-sheet) simplex document set.
[0027] Referring first to the exemplary xerographic copier 10 shown particularly in Figure
1 and its exemplary automatic document feeding unit 20, it will be appreciated that
various other alternative recirculating document feeding units and copiers may be
utilized with the present invention, including various ones disclosed in the above-cited
references.
[0028] In the exemplary N-to-1 order recirculating document handler (RDH) 20 disclosed here,
individual original document sheets are sequentially fed from a stack of document
sheets placed by the operator face-up in normal forward collated order in the document
stacking and holding tray 22, i.e. with page 1 on the top of the stack. Document sheets
are fed from the bottom of the stack seriatim to the imaging station 23, which is
the conventional copying platen of the copier 10, to be conventionally imaged onto
a photoreceptor 12 for the production of copies in a generally conventional xerographic
manner. The documents are stacked initially, and also restacked automatically during
each circulation, in the tray 22 over the platen 23. The document handler 20 has conventional
switches or other sensors such as 24 for sensing and counting the individual documents
fed from the tray 22, i.e. counting the number of document sheets circulated. A conventional
resettable bail or finger drops to indicate through its associated set counter switch
or sensor 26 the completion of each circulation of the complete document set, by sensing
that all the documents have been fed out from under it, and then is automatically
reset on the top of the stack before the next circulation. The document feeder 20
is adapted to feed the documents, which may be various conventional sizes and weights
of sheets of paper or plastics displaying information indicia to be copied on one
or both sides, e.g. printed or typed letters, drawings, prints, photographs, etc.
A bottom feeder 28 feeds the bottommost document sheet, on demand by the controller,
from the stack through one of two selected feed paths described below to a platen
transport 30 which moves the document into a registration position, against a registration
gate 32, over the copier platen 23, where the side of the document facing the platen
23 is copied.
[0029] In this document feeder 20 each document is selectably inverted or not inverted as
it is fed from the tray 22 to the imaging station 23 through one of two paths selectable
by the controller. Thus, this is accomplished here before the document is copied.
The two paths here are provided by a selectably reversible sheet drive roller (inverting
roller) 40 and a selectable position gate or deflector 60 in the document path. Each
document sheet is fed initially from tray 22 around the outside of the roller 40.
If the document path is continued around roller 40, it is fed invertedly through a
first (simplex document) path 54 onto the platen 23.
[0030] The decision gate 60 in the document path here is adjacent the entrance to roller
40 and comprises pivotable, normally-raised, deflector fingers which may be lowered
after the trail edge of the document has passed this gate. (Switch 24 or another switch
can sense the trail edge and start a count of sufficient time for it to pass). Subsequent
actuation of the gate 60, together with coordinated reversal of the roller 40, causes
the further recirculatory movement of the document to reverse and pass through a second
and different transport path 58 to the platen for copying. In the art this is called
an "inverter" even though the document is not inverted at this point, as described
below. The second transport path 58 provides no sheet inversion between the stack
and the platen, whereas the first transport path 54 inverts the document sheet (once)
between the stack and the platen. The path 58 provides for duplex document inversion,
for copying both sides of the duplex document set as described in detail in US-A--4,278,344.
[0031] In the inverter operation for path 58, the reversal of the roller 40 causes the documents
to go only partially around the roller 40 and then be reversed in direction and fed
directly back through the gate 60. The now deflecting down gate 60 (as shown in its
solid line position in Figure 1) deflects the document into the path 58 which feeds
directly onto the platen 23. Thus, in this non-inverting path 58, the documents arrive
at the platen with the same orientation as their original orientation in tray 22.
[0032] In contrast, the first inverting transport path 54 transports the documents unidirectionally
and without reversal fully around the roller 40 onto the platen 26. Thus, the orientation
or facing on the copy platen 23 of documents fed through the simplex path 54 is inverted
from the previous orientation of those documents in the tray 22.
[0033] It may be seen that the return path of the documents to the tray 22 from the platen
after they are copied is always the same here, regardless of which of the two initial
paths 54 or 58 is used. This document return path has one sheet inversion, provided
by feeding the documents around a second, but non-reversing, inverting roller document
feeding system 42, which also returns the documents to restack on the top of the stack
in tray 22.
[0034] Thus, in the total circulation path from the bottom of the tray 22 back to the top
thereof, with the selection of the transport path 54 the documents are inverted twice
around both rollers 40 and 42, whereas with the selection of the tranport path 58
the documents are inverted only once. Therefore, it may be seen that the reversal
or non-reversal of the roller 40 and the coordinate actuation or non-actuation of
the selector gate 60 therewith during a document set circulation determines whether
that set of documents will be recirculated with a total of one or two inversions in
that circulation. (In either case, since the documents can be continuously restacked
simultaneously with continuous feeding by the feeder 28, continuous multiple recirculations
can be provided for precollation copying). With two total path inversions per circulation
(i.e. utilizing the path 54), there is effectively no inversion per circulation. Thus,
the documents will be restacked in the tray 22 in their same original orientation,
and the same sides of the documents will be exposed in the next circulation. In contrast,
with only one total path inversion per circulation (using the path 58) the documents
will be restacked in the tray 22 inverted from their previous orientation. Thus, the
apparatus of path 58 is referred to as the "inverter" because its total circulation
path effect is inversion, even though its local effect is actually non-inversion as
noted above.
[0035] In the method of precollation copying of a set of plural (multipage) simplex document
sheets disclosed herein, the document sheets are presented to the imaging station
23 of the copier 10 in N-to-1 or conventional reverse serial page order. They are
multiply recirculated between the stacked set of the document sheets and the imaging
station, and copied only once on one side per circulation at the imaging station,
by feeding the document sheets seriatim from the bottom of the stack to one side of
said imaging station and then returning the document sheets from the opposite side
of said imaging station to the top of said same stack, in a recirculatory loop path,
in said multiple circulations. The set of simplex document sheets are stacked in proper
page order, face-up, with the first page on the bottom of the stack, in the stacking
position 22 overlying the imaging station 23.
[0036] As noted, in the systems disclosed in US-A-4,116,558, 4,278,344 for making duplex
copies from simplex document sheets in a desired manner, in the first copying circulation
and the last copying circulation of the set of document sheets only every alternate
document sheet is copied at the imaging station to fill and deplete a buffer set,
respectively, but in all other circulations all documents are copied, with alternate
feeding from a main copy tray and the duplex copy tray. A final non-copying document
circulation may be provided to recollate the document set in its tray.
[0037] In the system here, no hardware changes are required and improved efficiency but
fully compatible precollation copying may be provided with this same disclosed document
handler, same copier, and same imaging station and same stacking of the document sheets
merely by applying a different selectable software program to the copier programmer
under the special conditions and inputs described herein to provide a different process
of copying or not copying selected document pages onto selected copy sheets.
[0038] The operation of inverter mechanisms utilizing a sheet reversal path can increase
reliability problems, particularly if it must be frequently used for multiple recirculations
of a document set or used for many of the copy sheets. The present system does not
require the use of the duplex document transport path 58 for simplex documents, nor
does it require frequent use of a copy sheet inverter e.g. 116. The use of any inverting
path is normally much less than the total number of copy sets made with this system.
Furthermore, this system is fully.compatible with duplex document recirculation without
increasing the number of inverter operations for the duplex documents either.
[0039] The exemplary copier 10 processor and its controller 100 will now be described in
further detail. The copier 10 conventionally includes a xerographic photoreceptor
belt 12 and the xerographic stations acting thereon for respectively charging 13,
exposing 14, developing 15, driving 16 and cleaning 17. The copier 10 is adapted to
provide duplex or simplex precollated copy sets from either duplex or simplex original
documents copied from the same RDH 20. Two separate copy sheets trays 106 and 107
are provided for feeding clean copy sheets selectably from either one. They are known
as main tray 106 and auxiliary tray 107. The control of all sheet feeding is, conventionally,
by the machine controller 100.
[0040] The controller 100 is preferably a known programmable microprocessor, exemplified
by the art cited above, which conventionally also controls all of the other machine
steps and functions described herein including the operation of the document feeder,
the document and copy sheet gates, the feeder drives, etc. As further disclosed in
those references, the controller 100 also conventionally provides for storage and
comparison of the counts of the copy sheets, the number of documents recirculated
in a document set, the number of copy sets selected by the operator through the switches
thereon, time delays, jam correction control, etc.
[0041] The copy sheets are fed from a selected one of the trays 106 or 107 to the xerographic
transfer station 112 for the conventional transfer of the xerographic toner image
of a document, page to the first side of the clean copy sheet. The copy sheets here
are then fed by a vacuum transport to a roll fuser 114 for the fusing of the toner
image thereon. From the fuser, the copy sheets are fed onto a gate or fingers 118
which functions as an inverter selector. Depending on the position of the gate 118
the copy sheets will either be deflected into a sheet inverter 116 or bypass the inverter
116 and be fed directly on to a second decision gate 120. Those copy sheets which
bypass the inverter 116 (path I') turn a 90° corner in the sheet path before reaching
the gate 120, which inverts the copy sheets into a face-up orientation, so that the
image side which has just been transferred and fused is face-up at this point. If
the inverter path 116 is selected the opposite is true (the last printed face is face-down
at this point).
[0042] The second decision gate 120 then either deflects the sheets directly into an output
tray 122 or deflects the sheets into a transport path which carries them on without
further inversion to a third decision gate 124. This third gate 124 either passes
the sheets directly on without inversion into the output path 128 of the copier, or
deflects the sheets into a duplex inverting roller transport 126. The inverting transport
126 inverts and then stacks copy sheets to be duplexed in a duplex tray 108 when the
gate 124 so directs.
[0043] The duplex tray 108 provides intermediate or buffer storage for those copy sheets
which have been printed on one side and on which it is desired to print an image subsequently
on the opposite side thereof, i.e. the sheets being duplexed. Because of the sheet
inverting by the roller 126, these buffer set copy sheets are stacked into the duplex
tray 108 face-down. They are stacked in this duplex tray 108 on top of one another
in the order in which they were copied.
[0044] For the completion of duplex copying, the previously-simplexed copy sheets in the
tray 108 are fed seriatim by its bottom feeder 109 from the duplex tray back to the
transfer station 112 for the imaging of their second or opposite side page image,
through basically the same copy sheet path (paper path) as is provided for the clean
(blank) sheets from the trays 106 or 107. It may be seen that this copy sheet feed
path here between the duplex tray 108 feeder 109 and the transfer station 112 has
an inherent inversion which inverts the copy sheets once. However, because of the
inverting roller 126 having previously stacked these buffer sheets printed face-down
in the tray 108, they are presented to the photoreceptor 12 at the transfer station
112 in the proper orientation, i.e. with their blank or opposite sides facing the
photoreceptor 12 to receive the second side image. This is referred to as the "second
pass" for the buffer set copies being duplexed. The now duplexed copy sheets are then
fed out through the same output path through the fuser 114 past the inverter 116 to
be stacked in tray 122 or fed out past the gate 124 into the output path 128.
[0045] The output path 128 transports finished copy sheets (simplex or duplex) either to
another output tray as shown in Fig. 2 or, preferably, to a finishing station where
the completed precollated copy sets may be separated and finished by on-line stapling,
stitching, glueing, binding, and/ or off-set stacking (shown in Fig. 2).
[0046] If alternative non-precollated output is provided, as by using the RDH 20 in a semiautomatic
stream feeding mode utilizing only platen transport 30, or alternative manual document
placement, then the output path 128 may connect to a sorter. The sorter can have an
inherent sheet path inversion if alternative 1-to-N order document placement is used.
[0047] It is desirable to minimize the operation of the copy sheet output inverter 116,
in order to simplify and shorten the paper path and increase its reliability. Its
use also depends on the inherent inversions provided within the paper path of the
copier. The exemplary conventional inverter 116 here operates by the gate 118 deflecting
a copy sheet face-down into the first or lower nip of the illustrated three roll inverter,
which drives the sheet into the inverter chute. The copy sheet's movement is then
reversed within the inverter chute by known or suitable sheet reversing means, e.g.,
further rollers, or resilient rebound members, and the copy sheet is then reversed
and driven out of the inverter 116 through the second or upper nip of the same three
roll inverter directly toward the gate 120. The convex shape of the inverter chute
acting on the beam strength of the sheet causes the sheet trail edge to flip up toward
this second nip. The copy sheet output from the inverter 116 to the gate 120 here
is thereby last-printed-face-down. Note that the inverter 116 here is positioned at
a corner of an otherwise inherent 90° paper path inversion as described above. However,
any other suitable sheet inverter may be utilized, and may be provided at different
positions in the copy sheet output path. Examples of similar or substitutable sheet
inverters are disclosed in US-A-2,901,246; 3,337,213; 3,416,791; 3,523,687; 3,856,295;
and 4,044,285.
[0048] By way of further background, as to the difficulties in copy sheet output orientation
and order for precollation, for which the inverter 116 may be utilized, there are
several known problems and solutions in maintaining the proper collation of the copy
sheets in the output tray or finisher, particularly with reproducing machines which
must do both simplexing and duplexing, as discussed in the US-A-4,278,344 and elsewhere.
Fig. 2 illustrates proper collated output copy sheet stacking, i.e. face-up for N-to-1
page order copying. Collated duplex copying output presents particular output collation
difficulties and requirements, depending on which side is printed last, etc. As noted
above, a lower and odd, document page number must be on one side of a duplex copy
sheet and the next higher, and even, document page number must be on the opposite
side of that copy sheet; so that in each set of copies the outputted duplex copies
as picked up by the operator are in the proper page order 1/2; 3/4; 5/6; etc., even
though copied in the reverse page order. Providing properly collated output without
normally using an inverter is made more difficult for duplex copies by the fact that
the total overall copy sheet path for the copies being duplexed is typically different,
i.e., contains more inversions, than the overall copy path for copy sheets which are
only being simplexed, since it is necessary to turn the duplex copy sheets over to
present their opposite sides for their second copying pass. In the particular duplex
sheet path herein each sheet to be duplexed is inverted once at the duplex tray input
126, a second time in the return path to the transfer station 112, and a third time
in the path from the transfer station 112 to the output 128, to exit last-printed-face-up.
Thus, if the second sides printed are the odd sides, as N-to-1 output may be stacked
with these last-printed odd sides facing up as in Fig. 2 without using inverter 116.
It is desirable to have commonality, i.e., to utilize the same sheet feeding path
to the maximum extent possible for both duplex and simplex copies, and thus normally
to avoid using a selectable output inverter for either.
[0049] In the N-to-1 simplex/duplex document copying sequence shown in Fig. 2, the next
higher and even numbered pages are properly printed on the second side of the duplex
copy sheets in their second pass through the transfer station 112 here. That is, page
2 is printed on the opposite side of page 1. With N-to-1 copying and an "odd" page
buffer set, the last-printed page in each set is always page two printed on the back
of the page one sheet and this last duplex copy sheet is exited with page two down.
[0050] The inverter 116 path is illustrated in Fig. 2 as an alternative in dashed lines.
However, as otherwise discussed herein, it is normally bypassed (path I') here by
gate 118. This same path I' in Fig. 2, normally avoiding the inverter 116, is also
used for simplex copies, which is an important advantage.
[0051] By way of further background, there is an additional problem in the situation where
there is an odd rather than even number of simplex document pages to be copied onto
a duplex copy set. With an odd number of document pages the Nth or first-copied page
of the set of duplex copies made therefrom in N-to-1 order is really a simplex copy.
That is, the bottom copy sheet in each copy set will have an image on only one side
(of the odd Nth page) and a blank reverse side. It is undesirable to run this Nth
page only copy sheet through the transfer station a second time for the pseudo-printing
of a blank image on the reverse side thereof simply to obtain an additional inversion
of that sheet to maintain output collation, since this wastes processing time and
also can cause undesirable background contamination of the blank reverse side of this
sheet. This can be avoided by printing the Nth page on a clean sheet from tray 106
or 107 and directly outputting the Nth duplexed copy sheet immediately after its first
side is printed rather than feeding it from or into the duplex tray 108. This normally
results in this particular copy sheet having a different number of inversions, as
discussed, but this particular sheet can then be inverted by the inverter 116, if
needed.
[0052] However, to treat an odd Nth duplex copy page differently in this manner, or to know
whether the first duplex buffer set in tray 108 comprises odd or even pages (essential
to maintaining output collation) it must be known in advance whether there are an
odd or even number of simplex documents. If the documents were being copied in foward
serial order, i.e. 1-to-N, this would not be a problem. The Nth copy sheet page will
need to be fed and copied only after the last (Nth) document in the set has been counted,
and the bail switch 26 actuated, which determines whether or not N is an odd number.
[0053] However, as here, when the simplex documents are copied in reverse serial order (N-to-1)
the first document fed is page N and the first (Nth) duplex copy sheet will be the
one requiring special duplex processing, i.e., having a blank reverse side when N
is odd. Since this Nth copy sheet is fed first it is not known whether the Nth document
page is odd or even until after the documents have all been counted in the first document
set circulation, which reduces the efficiency of the system.
[0054] Pre-printed, e.g. letterhead, copy sheets present a special problem. They cannot
have a first even page printed on the front (pre-printed) side. That is, page 1 must
be on the letterhead side and properly oriented with the pre-printing orientation.
This is an additional complication for duplex copies. For said simplex/duplex copying,
by loading letterhead or other special paper face-up, in the trays 106 and 107 and
copying odd page documents on the first pass, the odd pages will be properly printed
on the front or letterhead sides of the letterhead copy sheets here, since the copy
paper path here contains one inversion between trays 106 and 107 and the transfer
station 112. Then on the next circulation these duplex copy sheets will have even
pages properly printed on their reverse sides.
[0055] However, for edge oriented pre-punched binder holes and certain other special papers
even the above may not provide proper (common) sheet orientation of an odd Nth page
duplex copy sheet. There can be additionally provided a "special paper" or the like
operator button 200 on the copier console for the controller 100. The controller can
then be programmed to detect the coincidence of signals from (1) the "special paper"
button being pressed and (2) "simplex documents" and (3) "duplex" buttons also having
been pressed. Upon detection of all of these conditions the controller 100 can direct
special processing.
[0056] A duplex/duplex copying system, compatible with the simplex/duplex system disclosed
herein, can be provided as disclosed in the above-cited US-A-4,278,344. Briefly, the
duplex documents may also be loaded face-up and copied in N-to-1 order. The duplexing
system disclosed therein is to copy only one side of each duplex document sheet in
each circulation, storing the buffer set copies thereof in the duplex tray 108, then
inverting the duplex document sheets during a circulation, and copying all of the
opposite sides of all the document sheets onto the opposite sides of the buffer set
copy sheets fed back from the duplex tray 108. The controller 100 is instructed by
its software to provide this copying sequence in response to the "duplex document"
switch on its console or in the RDH unit having been actuated by the operator. Since
duplex/ simplex copying is not provided here, this same duplex document switch can
also automatically select the duplex copy mode.
[0057] Thus, this simplex/duplex system here is fully compatible with the special duplex/duplex
system disclosed in the above-cited US-A-4,278,344, in which the inverter (40, 60)
path 58 is only utilized intermittently between successions of plural copying circulations
of the duplex documents, i.e. in which plural buffer sets are placed in the duplex
tray 108 and the document inverter operation path 58 is utilized only during single
document circulations at the beginning or end of a succession of circulations, after
the document set has been circulated by a number of times (not exceeding the sheet
capacity of the tray 108) thereby significantly reducing the number of circulations
requiring the operation of the document inverter, except for very large document sets.
Thus, for an example of a four-sheet and seven page duplex document set, and a 100
sheet capacity duplex tray 108, the four duplex documents could be circulated 25 times
through path 54 at the beginning of copying to form 25 four-sheet buffer sets in the
tray 108. These four copy sheets would respectively bear pages 7, 5, 3, 1. Then on
the 26th document circulation the duplex document set would be circulated once through
the path 58. Then the document set would be circulated again through the path 54 for
the next 24 circulations. In circulations 26 through 50 here, the pages 6, 4, 2, blank
would be printed in that order 25 times on the back of the buffer set sheets fed from
the duplex tray 108 until all 25 duplex copy sets have been printed and exited. Then
the sequence would repeat until the requested number of copies were completed. (Assuming
that more than 25 copy sets had been requested by the operator through the appropriate
switch selection in the controller 100).
[0059] Referring now to the special copying sequences for small document sets shown in the
Tables I-V, they provide higher efficiency with reduced document circulations and/or
reduced total copying time compared to the above-described normal simplex/duplex precollation
copying method. First the special case in Table I of precollation simplex/duplex copying
of a simplex document set of only two sheets (two pages) will be discussed, then the
three-page document set situation is shown in Table II, etc. There is disclosed in
each table a unique document copying sequence or mode of operation for improved efficiency
in that special case, with reduced skipped pitches or cycles. Note that there is actually
five individual tables forming Table I, showing the respective document and copy sequencing
for runs of "One", "Two", "Three", "Four" and "Fourteen" requested copy sets. The
other tables are similarly organized.
[0060] In all of the Tables I-V the horizontal lines labelled "Doc. on Platen" indicate
which of the document pages is on the platen at that point in time (e.g. 1 or 2 in
Table I). In the "Paper Feed" lines the symbol "m" designates a clean copy sheet fed
from either the main or auxiliary sheet feeder (trays 106 or 107), while "d" designates
a buffer set copy sheet fed from the duplex feeder (tray 108). In the "Flash" lines
the "X" indicates a flash exposure in that pitch (vertical column) of the document
page shown vertically thereabove in the "Doc. on Platen" line onto the copy sheet
shown thereabove in the "Paper Feed" line. In all of the three horizontal lines for
each set number each asterisk designates one skipped pitch or cycle there, i.e. a
time delay.
[0061] Note that the repeated "Machine Pitch/Cycle" numbers 1 through 9 and 10 (ten pitches)
in the top line of each table are each a preset time period corresponding to one sheet
path space or pitch and are each equated to one document cycle, i.e. one document
feed or one pause in document feeding. This pitch or cycle count is repeated at each
10 pitches here merely for tabulation space convenience (to use only single digits).
The number of circulations of the entire document set is the number of repetitions
of all the document page numbers in the "Doc. on Platen" lines (reading across). This
is also illustrated in the "Doc. Circ." line, which, however, is shown only for the
highest set number shown in each table, e.g. only for the 14 page document example
in Table I. Also for clarity the "Buffer Set" line is shown only for the last example
in each table, to illustrate the formation and depletion of plural buffer sets of
the copy sheets for that one case.
[0062] Note that, as previously discussed, in each Table I-V this operation assumes in each
case an N-to-1 (reverse order) unidirectional copying system with an initial non-copying
circulation of the document set in which the number of simplex documents is counted
to determine the number of document pages and whether the Nth document page is even
or odd. Thus for example, in Table I in all cases there is no "Paper Feed" and no
"Flash" for (under) the first "Doc. on Platen" circulation "21".
[0063] In Table I the first copy is made (of page 1) only on the 4th pitch, which is at
the end of the second document set circulation. Then, on the 4th up to 14th pitch,
up to 14 plural identical copies are made of page 1, corresponding to the number of
copy sets being made, rather than circulating the documents, contrary to conventional
precollation copying, to form up to 14 plural buffer sets consisting only of page
1's. For more than 14 requested copy sets the pattern is repeated rather than increasing
the size of the buffer set beyond 14 sheets.
[0064] A brief verbal description of the operation illustrated in Table I (from right to
left) is as follows:
Step 1: (Pitches 1 and 2) Make a first non-copying circulation of both document sheets
(pages 2 and 1) to make a set count determination that there are only two sheets in
the simplex document set, and therefore that the second document sheet (page 1) is
the odd page, without a paper feed or flash.
Step 2: (Pitches 3 and 4) On the second document circulation (the first copying circulation)
the odd page (page 1) is stopped on the platen and without any further document circulation
is copied by the number of times in immediate succession (up to 14) equal to the desired
total number of copy sets, making these plural copies on clean sheets fed from a main
tray and placed after copying in the duplex tray (i.e. one copy of page 1 for one
set, two copies of page 1 for two sets, etc. up to 14 copies of page 1 for 14 sets).
(Note that this is not normal precollation copying, which would be to circulate the
documents and make only one page 1 copy in each circulation.)
Step 3: Then feed the next (other) document (page 2) to the platen, and after an appropriate
variable pause (in pitches) (to allow the first buffer copy cycled through the proper
path to reach its proper position for duplexing) copy this document page 2 in direct
immediate succession without circulation the same number of times as in step 3 onto
the other sides of the buffer copy sheets fed from the duplex tray (only). The length
of the document recirculation and copying pause is a function of the length of the
paper path of the particular copier processor from transfer station 112 to buffer
tray 108 and the number of buffer sheets being made. For 14 or more sets there need
only be a single (as shown) or no pitch pause i.e. up to 100% efficiency. Further,
there are (desirably) only three document circulations in all cases for up to 14 copy
sets.
Step 4: (Occasional) If more than 14 copy sets are requested, the number of copies
made in steps 3 and 4 is limited to 14 (so as not to exceed the capacity of the duplex
tray) and there is a further document set circulation with a repetition of steps 3
and 4 to complete the desired total number of sets. That is, the sequence shown in
Table I, last example, is repeated, as indicated. Step 5: Complete the last (second)
document circulation without further copying simply to return page 1 to the document
input tray.
[0065] As an alternative to the system of Table I (a variation) if the controller logic
system could respond in time to the end of set signal from sensor 28 one of the following
more efficient alternatives may be used instead:
A. Begin making the selected plural copies of page 1 (step 2 above) at the end of
the first document set circulation rather than the second document set circulation.
Note that the end of set finger 26 in the document tray has already dropped to indicate
the completion of document counting by switch 26 before page 1 has been ejected from
the platen, since page 1 was the last document fed out from under the set counter
finger.
B. Alternatively, copy page 2 first rather than page 1 in the second set circulation
(i.e. reverse steps 2 and 3 above) (noting that for this two-page original document
set that the duplex set copies thereof have only a single sheet in each set, and therefore
their output orientation could be either face-up or face-down) (i.e. with a single
sheet output set, no output collation is required). However, odd page first copying
may be required for letterhead, edge binder hole or other output or copy sheet restraints
even for single sheet two-page output sets.
[0066] Turning now to Table 11, the respective higher efficiency operations are shown for
runs of one, two, three, four, five and six precollated copy sets from the special
case of a set of three original simplex document sheets being recirculated. This desired
sequence is similar but even more complicated. For one to four copy sets the first
two steps are basically the same as the above-described first two steps, i.e. holding
page 1 on the platen for up to four copies in a row thereof. However there is the
additional step of copying document page 3 onto a main tray sheet before page 2 is
copied each time. But for four or more sets the number of copies made of page 1 in
sequence in the second circulation (step 2) does not exceed four here. This has been
found to provide a more efficient (less pitches required) copying sequence for this
processor, but may vary somewhat for other processors, e.g. may be three copies of
page 1 (or 2) for a different processor. After the second document circulation, the
documents are recirculated and all copied only once per circulation for normal intermediate
build/deplete cycles of the buffer set. Then on the final copying circulations, the
processor skips copying of page 1 for the number of copies previously made thereof
on the first copying circulation to deplete the plural buffer sets (which, as in Table
I, consists only of plural identical copies of page 1).
[0067] The example shown schematically in Fig. 2 of the drawing is for said three-page original
document set system of Table II. The Fig. 2 example shows three completed copy sets
in the output tray at the right-hand side of Fig. 2 and a full buffer tray 108 set
of four sheets, i.e. a running situation in which the operator has requested four
or more copy sets and only three have been completed at the point in time illustrated.
At the end of the last requested copy set the duplex tray 108 would be empty, having
been depleted as shown in the Table II.
[0068] Table III illustrates the algorithm for a four-document sheet simplex document set.
Examples in Table III are provided for one, two and four copy set runs of the four
document sheets. For only the four-set example, additional lines are shown for the
document set circulations and buffer sets. In this special case of four documents
the most efficient buffer comprises two buffer sets (each here containing copies of
pages 1 and 3). That is, the complete (full) buffer set in the duplex tray is a stack
of four sheets copied on their downward facing sides with pages 3, 1; 3, 1. These
two buffer sets are initially formed on the second and third document set circulations,
and depleted out on the last and next-to-last document circulations. Note that there
are no plural consecutive copies of any document page, and that the individual buffer
sheets are not identical or interchangeable, but the two complete buffer sets are.
[0069] Tables IV and V are respectively for the cases of five-document and six-document
sets. They are processed similarly to the four-document set of Table III. However,
the Table IV case with five documents has an odd Nth page requiring special processing
as in Table II.
[0070] Referring to Tables II and IV, it is important to note, as described previously,
that in an N-to-1 order copying system where odd pages are buffered, as in all cases
here, that for all of the odd-numbered document sets (regardless of size), the last
page of the copy set (e.g. page 3 in Table II or page 5 in Table IV) is copied first,
but preferably not buffered, i.e. the Nth odd page is copied first and onto a clean
sheet fed directly from the main or auxiliary copy tray and fed directly to the output.
Therefore in Table II the buffer set consists only of copies of page 1 (not 3). Likewise
in Table IV the buffer set duplex tray 108 contains only copies of pages 3 and 1 (not
5). However, it should be noted that in another (alternative) system, the even pages
may be buffered rather than the odd pages.
[0071] In Table II, all the buffer pages are identical copies of only page 1 in this special
(three-page original) case, the same as in the two-original case of Table I. Thus
it has been discovered that for the special case of only two or three originals, plural
buffer pages may be accumulated and their copying order and feeding out order is not
critical i.e. it is immaterial which of the identical page 1 bearing copy sheets fed
into the duplex tray 108 is fed out with this system. That is, the order of sheets
in the buffer need not be maintained. This feature is advantageously utilized here
by switching to a special copying mode of operation maximizing productivity for two
or three-page original sets. In this special higher productivity mode of Tables I
and II, rather than copy each document page only once per circulation, as conventionally
considered necessary for precollation copying (to provide collated output sets), the
first page, which is the second and last-fed document sheet, is copied a plural number
of times in succession, dependent on the number of copy sets being made in the first
copying circulation (i.e. the first document circulation after the initial non-copying
counting circulation) to make up a plural sheet buffer of an equal number of said
page 1 copies. Then on the last copying circulation or circulations for the last copy
set this plural sheet buffer is depleted (emptied out) by plurally copying the other
sides thereof (with equal plural copies of page 2).
[0072] As noted, for the two-original set of Table I this above-described special system
is utilized for up to 14 consecutive copies to form a 14-sheet buffer set, then repeated.
However, that break point number is a function of the paper path lengths and the duplex
tray capacity of the particular processor example, and will vary. In this processor
example there are slightly more than nine pitches of paper path length to the duplex
tray in copying the first sides. Thus there are nine asterisks (a nine-pitch pause)
in the "ONE" set example of Table I between the second and third circulations. For
a shorter paper path the maximum efficiency system (elimination of any skipped pitches)
may be reached with less plural copies (a smaller buffer set). For job recovery, a
smaller buffer set is desirable, since there are less sheets to throw away and/or
recycle in the event of a jam.
[0073] Likewise in Table II, the maximum number of plural copies of page 1 placed in the
buffer tray in the second (first copying) document circulation (pitches 6 through
9) is four ("1111") for this processor example. However, this could be three or even
two for a shorter paper path.
[0074] All the disclosed algorithms are designed to maximize efficiency by keeping the paper
path full most of the time and eliminating dead pitches (document copying pauses)
as much as possible. However, for the Table III-V special cases, the system builds
two plural sheet buffer sets when the number of originals is determined to be four,
five or six. When the number of originals counted in the document set is greater than
nine, it changes its mode to the conventional single buffer set algorithm. In contrast,
in the special cases where the document set is determined to consist of only two or
three sheets the plural buffer sets (normally more than two and up to 14, or four,
respectively) are made while stopping the document circulations to make buffer sets
which are plural identical copies of only one document, and to reduce document circulations,
especially for only two documents. In all cases other than two documents, once the
buffer sets are initially built they are simultaneously rebuilt and depleted during
intermediate circulations until the last copy set, when the buffer sets are all fully
depleted, as previously described. In all cases the subsequent buffer set(s) are made
during the time while the first buffer set is in the duplex paper path loop completing
its travel, thereby improving efficiency by reducing copying delays.
[0075] It will be noted in the Table III-V systems, having two buffer sets, that there will
be one less intermediate (build and deplete) document recirculation than normal which
would appear to reduce efficiency perse (i.e. there are four cycles of only alternate
document copying rather than the usual two). However, overall efficiency is higher.
In, for example, Table III, with two requested copy sets, there are two buffer sets
of odd pages only (3, 1; 3, 1) formed and stored during the second and third document
set circulations and then depleted during the fourth and fifth circulations, (by copying
only even page documents) to form the two precollated four-page and two-copy-sheet
duplex output copy sets 1/2, 3/4; 1/2, 3/4. There are no intermediate copying recirculations
here until there are three or more requested copy sets. In the four-set example of
Table III, the forth and fifth circulations are providing two intermediate (build/deplete
buffer) copying circulations.
[0076] The disclosed copier and document handler unit can automatically handle a wide latitude
of original document sets with a minimum of operator interaction. In a typical job,
the operator need only drop the set of documents to be copied into the open loading
tray 22 on top of the RDH 20, program the desired number of copies to be made in the
controller 100 switches, indicate if duplex documents rather than simplex have been
loaded (by pressing a button connected to the controller 100), and then initiating
the copying run sequence by pressing the conventional "start print" button on the
controller. There may, of course, be some adjustment of side and rear guides in the
tray 22 for different sizes of documents. Except for jam clearance, there would normally
be no other operator interaction required with the copier or document handler to provide
precollated output sets.