Low manual effort system for removably mounting paper handling modules to reproduction machines

A system and method for manually removably locking a paper handling module to a reproduction apparatus with greatly reduced manual force, wherein the reproduction apparatus and the paper handling module have respective sheet feed openings which are operatively aligned for sheet feeding therebetween when the module is so locked to the reproduction apparatus in a locking position, and wherein the paper handling module has a weight which is undesirable for manual lifting into the locking position. The module is supported on an integral module transporting system to be freely movable in any horizontal direction into an initial docking position closely adjacent to the reproduction apparatus. Then, slightly vertically lifting at least one side of the module with only a small vertical manual lifting force while most of the weight of the module is lifted with an automatic weight lifting system, moving the module towards the locking position, and then removing the small vertical manual lifting force from the module, to drop and lock the module to the reproduction apparatus. The automatic weight lifting may be provided by vertically movably spring loading at least one side of the module on the module transporting system.

Reproduction apparatus, such as xerographic or other printers, copiers, 
and/or multi-function devices, commonly have modular paper handling 
accessory units which need to be removably connected to the reproduction 
apparatus in a secure manner which provides operative connections 
therewith. In particular, to provide the sheet feed opening of the 
removable module operatively aligned with the appropriate sheet feed 
opening of the reproduction apparatus, so that copy or document sheets may 
be fed therebetween. Yet, many such modules can be quite heavy, especially 
sheet finishing units and/or sorters or stackers. 
Disclosed in the embodiments herein is an improved system for such 
operative connection between a reproduction apparatus and one or more such 
paper handling accessory modules, with improved locking and unlocking 
therebetween with substantially reduced manual force or effort. 
The disclosed system does not require previously used mounting rails and/or 
installer hydraulic or pneumatic lifters or pallets to support and lift 
the weight of the module as it is being docked with and secured to the 
reproduction apparatus. That is, it is desirable to reduce or eliminate 
the amount of lifting and carrying equipment required for installing 
accessory modules on reproduction apparatus. It also overcomes problems 
where the reproduction apparatus and/or the module are on uneven floor 
surfaces, common in customer sites, such as where the module or the 
reproduction apparatus are on carpeted versus uncarpeted areas, or the 
like. 
Modules allow adding on additional customer features to previously 
installed printers or copiers, and allow offering different reproduction 
systems customer options for the same basic printer or copier. The use of 
removable and/or substitutable paper handling module units provides 
greater flexibility in customer options of paper feeders and/or paper 
output finishing and/or stacking systems such as sheet folders, stitchers, 
staplers, book binders, etc. Other auxiliary modules which are known to be 
desirable add-on features include high-capacity alternate sheet feeders 
for the input of additional and/or alternate size copy sheets to the 
reproduction apparatus. Furthermore, the use of removable modules allows 
the basic reproduction apparatus itself to be smaller and lighter, with a 
smaller floor size or footprint, and thus easier to move and install. 
Ideally, the modules themselves should be easily installable and removable 
by the tech rep and/or installer, or even the operator or customer. 
As indicated, such modules can be heavy. Yet, it is desirable not to 
require a large manual effort for module installation, or any force which 
cannot be easily and safely done by ordinary men and women, not just 
strong professional riggers or movers. Yet, as indicated above, it is also 
important that any such paper handling module be properly vertically and 
horizontally aligned in a proper mounting and locking position with 
respect to the reproduction apparatus, so that the existing sheet input or 
output path openings and baffles of the reproduction apparatus are 
properly aligned with the sheet openings and baffles of the module for the 
uninterrupted and jam free feeding of the flimsy paper or other such 
reproduction sheets therebetween. This mating position of the two units 
must be maintained, and must be reestablished every time the two units are 
separated and then redocked and reconnected. 
Another important desirable feature is to allow the paper handling module 
unit and the reproduction apparatus to be easily connected and 
disconnected even in the limited space or cramped quarters of many office 
and other copying areas. Many of the present paper handling accessory 
module units for reproduction apparatus require substantial lateral free 
space between the end of the reproduction apparatus and a wall or other 
obstruction because the module can only be separated from the reproduction 
apparatus by moving in one direction on rails or tracks extending away 
from that end of the reproduction apparatus. Thus, it is desirable to 
allow a module to be initially moved toward the reproduction apparatus and 
docked therewith from either the front or side of the reproduction 
apparatus, and to be separated and removed from the reproduction apparatus 
in either direction as well. This allows the overall dimensions of the 
combined reproduction apparatus and module to be installable in spaces 
only slightly greater in dimension that the total dimensions of both. The 
disclosed system does not have said disadvantages of requiring a mounting 
track or rail system restricting separation movement to the direction away 
from the end of the reproduction apparatus, and does not require a large 
movement distance for mounting or removal. 
Another advantage of the disclosed embodiments is that a desirably small 
floor space module too narrow to be safely stable as an unsecured 
free-standing module may be utilized, by being safely secured to a large 
reproduction apparatus, for insuring lateral or tipping stability. The 
present system can provide this without applying a large cantilever, 
bending or tipping force to the reproduction apparatus or its frames. 
Although one example of a sheet handling output module for stacking and/or 
finishing sets or jobs of copy output sheets is illustrated herein, it 
will be appreciated that the present system of interconnection of sheet 
handling modules to reproduction apparatus is widely applicable to a wide 
variety of different sheet handling modules with the same basic advantages 
of greatly reduced installation manual effort, etc. Specifically, with the 
advantage that the installing person need never lift more than a small 
percentage of the total weight of the paper handling module accessory, 
even when, due to unevenness of the floor, the module and reproduction 
apparatus are initially at different and/or uneven levels. E.g., such as 
where the processor is on a carpeted area but the add-on module unit will 
not be, or vice versa, Furthermore, because the subject mounting system 
provides correct alignment of the respective sheet input and output paths 
of the module and reproduction apparatus, there is no requirement for an 
interface transport or module transitioning the paper path between the 
reproduction apparatus and the output device, for example that shown in 
Xerox Corporation U.S. Pat. No. 5,326,093 issued Jul. 6, 1994 to Thomas E. 
Sollitt. 
The particular illustrated disk type invader stacker and stapler finisher 
unit per se shown in the exemplary module embodiments herein is similar to 
that disclosed in more detail in Xerox Corporation U.S. Pat. No. 5,409,202 
issued Apr. 25, 1995 to the same Raymond A. Naramore, et al and thus need 
not be described herein in any detail. 
Of particular interest for module movements, interchangeable color toner 
developer unit transport cads for printers with uneven floor alignment 
compensation are shown in Xerox Corporation U.S. Pat. No. 5,144,369 issued 
Sep. 1, 1992 to Lawrence R. Benedict, et al. However, as may be seen, that 
patent has a much more complicated foot pedal lifting system for leveling 
the developer unit with machine rails on which the developer unit is slid 
into the machine, or out of the machine. This is not a paper handling 
accessory module mounting system and is self-evidently considerably more 
complex than the disclosed system. 
The disclosed embodiments provide the securing advantages of a simple "hang 
on" connection module without the usual disadvantages of putting a 
cantilevered load of the entire weight of the module on the frames of the 
reproduction apparatus. Furthermore, because only a small portion of the 
weight of the module is carried by the reproduction apparatus, the "hang 
on" mounting and/or locking system may comprise a simple mounting hook 
system such as disclosed hereinbelow, and the module can even latch with 
relatively thin or lightweight frame or cover members of the reproduction 
apparatus and/or the module. Also, the present system does not require any 
person to support the weight of the module, even as the module is being 
"hung on" to the side of the reproduction apparatus. Also, the module may 
be rolled about easily in any direction, even on uneven floors, without 
having to carry or lift the module. 
In fact, as shown in these embodiments, the mounting modification of the 
printing apparatus may consist of something as simple as mounting slots or 
apertures in the existing sheet metal or plastic side or end wall of the 
reproduction apparatus, and simple correspondingly spaced hooks of 
appropriate configuration on the module unit which are easily and 
intuitively mounted through said apertures while the weight of the module 
is substantially automatically supported and/or lifted by the system 
disclosed herein. 
It may be seen that a low cost, simple, and universal or widely useable 
docking and mounting system for various add-on modules for reproduction 
apparatus is disclosed herein. 
A specific feature of the specific embodiment disclosed herein is to 
provide, in a reproduction system for generating printed sheets with a 
reproduction apparatus and providing for docking and operatively 
connecting and disconnecting one or more selected paper handling modules 
of substantial weight to said reproduction apparatus, wherein said 
reproduction apparatus and said paper handling module have respective 
sheet feed openings, which respective sheet feed openings are operatively 
aligned for sheet feeding therebetween when a said selected paper handling 
module is operatively connected to said reproduction apparatus; a system 
for said docking and removably operatively connecting and disconnecting a 
selected said paper handling module accessory unit to said reproduction 
apparatus with greatly reduced manual movement force irrespective of the 
weight of said module, including a locking system positively securing said 
module to said reproduction apparatus in a locking position with said 
sheet feed opening of said module sufficiently operatively vertically 
aligned with said sheet feed opening of said reproduction apparatus for 
sheet feeding opening of said reproduction apparatus for sheet feeding 
therebetween, wherein said paper handling module accessory unit has a 
transporting system allowing said module to be freely manually movable in 
any horizontal direction for both frontal and lateral horizontal movement 
relative to said reproduction apparatus into a docking position therewith 
while supporting the weight of said module, and said paper handling module 
accessory unit has a low-force vertical docking position adjustment system 
providing for low force manual vertical movement of said module relative 
to said reproduction apparatus from said docking position into said 
locking position, after said module is initially horizontally docked with 
said reproduction apparatus, and said vertical docking position adjustment 
system includes a weight supporting system for automatically supporting a 
major portion of the weight of said module in said manual vertical 
movement of said module into said locking position, for said greatly 
reduced manual movement force. 
Further specific features disclosed herein, individually or in combination, 
include those wherein said vertical docking position adjustment system and 
its said weight supporting system comprises a spring loaded vertically 
movable separation system between said module transporting system and said 
module; and/or wherein said module transporting system comprises plural 
castored wheels mounted under said module, and wherein said vertical 
docking position adjustment system and its said weight supporting system 
comprises a vertically movable wheel mounting system with module weight 
supporting springs vertically acting to provide low force vertical 
movement of said module relative to said castored wheels; and/or wherein 
said locking system for securing said module to said reproduction 
apparatus in said locking position is latched by first vertically lifting 
said module slightly above said initial docking position, with said weight 
lifting system and a small added manual vertical force, and moving said 
module against said reproduction apparatus, and then releasing said small 
manual vertical force to allow said module to drop into said locking 
position and latch.; and/or wherein said locking system for securing said 
module to said reproduction apparatus in said locking position comprises 
mounting hooks and hook retainers positioned so that when said module is 
vertically lifted slightly above said initial docking and said locking 
position said mounting hooks may be inserted into said hook retainers, and 
so that said mounting hooks latch said module to said reproduction 
apparatus on said hook retainers by automatic downward movement of said 
module when said module is released; and/or wherein said weight supporting 
system automatically lifts all but a minor portion of the weight of said 
module in said vertical movement of said module into said locking 
position; and/or wherein said paper handling module is a finishing unit 
for binding and stacking sets of printed sheets from said reproduction 
apparatus; and/or wherein said module transporting system comprises plural 
castored wheels mounted under said module, and wherein said vertical 
docking position adjustment system weight supporting system provides low 
force vertical movement of said module relative to said castored wheels 
with module weight supporting springs which are spring mounting at least 
one side of said module relative to said castored wheels; and/or wherein a 
removable spring locking system normally removably locks said module 
weight supporting springs; and/or an improved method for manually 
removably locking a paper handling module to a reproduction apparatus in a 
locking position, wherein said reproduction apparatus and said paper 
handling module have respective sheet feed openings, which respective 
sheet feed openings are operatively aligned for sheet feeding therebetween 
when said module is so locked to said reproduction apparatus in said 
locking position, and wherein said paper handling module has a weight 
which is undesirable for manual lifting into said locking position; 
comprising an improved system for said locking of said module to said 
reproduction apparatus with greatly reduced manual force, by. supporting 
said module on an integral module transporting system on which said module 
is freely movable in any horizontal direction relative to said 
reproduction apparatus, moving said module on said module transporting 
system into an initial docking position closely adjacent to said 
reproduction apparatus while supporting the weight of said module on said 
transporting system, then slightly vertically lifting at least one side of 
said module with only a small vertical manual lifting force applied to 
said module while most of the weight of said module is lifted with an 
automatic weight lifting system; moving said module towards said locking 
position with said reproduction apparatus while so lifting said module, 
and then removing said small vertical manual lifting force from said 
module, to lock said module to said reproduction apparatus with said 
respective sheet feed openings operatively aligned for sheet feeding 
therebetween; and/or wherein said automatic weight lifting is provided by 
vertically spring loading at least one side of said module on said module 
transporting system with a spring loading system that supports all but a 
minor portion of the weight of said module throughout said slight vertical 
lifting of said module with said small vertical manual lifting force; 
and/or wherein said module automatically drops slightly into said locking 
position when said small vertical manual lifting force is removed, to 
automatically latch said module to said reproduction apparatus; and/or 
wherein said module is hooked onto said reproduction apparatus in said 
locking position by hooking mounting hooks on said module onto hook 
retainers in said reproduction apparatus; and/or wherein said module is so 
movable on plural castored wheels mounted under said module providing said 
module transporting system; and/or wherein said module is unlocked from 
said reproduction apparatus with only a small manual force much less than 
said weight of said module by reversing the above steps; and/or wherein 
said module is initially tilted away from said reproduction apparatus on 
said module transporting system in said initial docking position and moved 
towards said reproduction apparatus before said step of slightly 
vertically lifting said module; and/or wherein a pair of lower hooks on 
said module are engaged in lower hook retainers on said reproduction 
apparatus in said initial tilting step, and then a pair of upper hooks on 
said reproduction apparatus are engaged in upper hook retainers in a 
second tilting step in coordination with said slight vertical lifting 
step. 
As to specific components of the subject apparatus, or alternatives 
therefor, it will be appreciated that, as is normally the case, some such 
components are known per se in other apparatus or applications which may 
be additionally or alternatively used herein, including those from art 
cited herein. All references cited in this specification, and their 
references, are incorporated by reference herein where appropriate for 
appropriate teachings of additional or alternative details, features, 
and/or technical background. What is well known to those skilled in the 
art need not be described here.

Describing now in further detail the exemplary embodiments with reference 
to the Figures, there is schematically shown a reproduction machine 10, by 
way of one example of a printer or copier with physical sheet input and 
output, for which paper handling modules such as 20 may be readily 
operatively connected, disconnected and/or interchanged in accordance with 
the present system, with little manual effort. 
Shown in the Figures is the right-hand side or end of the exemplary 
reproduction apparatus 10 with a sheet output path therefrom indicated by 
the arrow and output rollers and baffles through which printed sheets exit 
the reproduction apparatus 10 through an end wall 15. Both the 
reproduction apparatus 10 and the module 20 are mounted on a conventional 
floor or other such support surface 11, which, as shown here, is uneven. 
This floor 11 unevenness is illustrated in FIGS. 1 and 6 by carpeting 
shown underlying the mounting wheels 14 of the reproduction apparatus 10 
and an uncarpeted area under most of the module 20, merely for purposes of 
illustrating one of the advantages of the present system. 
As will be further described herein, the end wall 15 of the reproduction 
apparatus 10 has a pair of upper mounting apertures 16 and a pair of lower 
mounting apertures 17. FIG. 9 shows one example in end view thereof. It 
may be seen that the upper portion of the apertures 16 or 17 may be 
enlarged like a keyhole, as shown in FIG. 9, for ease of initial docking 
and mounting of the module 20 thereto, with the sides of this enlarged 
upper portion smoothly tapering downwardly to the actual locking slots. 
These slots may be slightly wider on one side than the other, e.g., 3.5 mm 
wide on one side versus 7.5 mm wide on the other side, as between the 
respective pairs 16 and 17 of such mounting aperture slots. This also aids 
in initial alignment for locking. 
Turning now to the exemplary module 20, as indicated this is merely one 
example of numerous possible input or output sheet handling accessory 
units which may employ the docking and locking system disclosed herein. 
This particular module 20 example includes a sheet output stacking system 
21, here comprising a sheet input path selector gate 22 which can direct 
incoming sheets either to an upper stacking tray 23 or to a lower stacking 
tray 24 via a disk inverter/stacker 25 (of a known type, as indicated 
above with reference to a previous patent thereon). As disclosed therein, 
this inverter/stacker 25 may include an integral set stapler and offset 
system for stapling and offsetting output sets of print jobs. However, the 
module 20 is not limited to any particular sheet handling, finishing or 
output system. 
Turning now to the transporting, docking, and mounting system of the module 
20, the module 20 has a mounting base 26 and mounting cups 27 secured 
thereto. In the embodiment of FIG. 1-5, all four mounting cups 27 have 
vertical movement spring castor units 30, as will be described. However, 
in the embodiment of FIGS. 6-8, the two inboard mounting cups 27 or other 
such mounting arrangements have alternative unsprung module castor units 
50 which rigidly mount these castor wheels to the mounting base 26 without 
providing for relative vertical movement. However, even with this 
alternative 50 example, the outboard mounting of the module 20 (at the 
side opposite from the reproduction apparatus 10) comprises a pair of the 
sprung castor units 30. 
Each of the sprung castor units 30 comprises a conventional wheel 32 and 
castor 33 arrangement providing for freely pivotable wheeling of the 
module 20 unit, and therefore free movement of the module 20 on any 
horizontal axis on all four wheels, as do the unsprung module castor units 
50. However, in the sprung castor units 30, the castor wheel assembly is 
mounted on an elongated vertical shaft 34 surrounded by an elongated coil 
spring 35, as best illustrated in FIGS. 2 and 3. As shown in FIG. 2, for 
transporting and movement of the module 20 prior to its locking or 
latching to the reproduction apparatus 10, the spring 35 is held 
compressed by a retaining pin 36 such as a standard "hitch pin". This 
holds the spring 35 fully down, and holds the shaft 34 all of the way up, 
to essentially prevent any spring action and help maintain stability of 
the module 20 during such initial transport. The retaining pin 36 is 
removably secured in a pin hole 37 in the shaft 34. 
Turning now to the module 20 latching or locking system, this is provided 
here by a mounting hook system 40 on the module 20, comprising a pair of 
upper hooks 42 designed to mate with and engage the pair of upper mounting 
apertures 16 in the reproduction apparatus 10, and a pair of lower hooks 
44 designed to engage the pair of lower mounting apertures 17 in the 
reproduction apparatus 10, as will be described. 
In either of the two embodiments described herein, the module may be freely 
wheeled into a docking position from either the front and/or the side of 
the reproduction apparatus 10 with the full weight of the module 20 being 
supported on the four castor wheels under the four corners of the module 
20. The module 20 is riding at all times on the mounting base 26 to which 
these castor wheels are mounted through the mounting cups 27. 
Once the module 20 is in position closely adjacent to the reproduction 
apparatus 10 at the side of the reproduction apparatus 10 in which the 
sheet output thereof is to feed sheets into the sheet input side of the 
module 20, the module 20 mounting hooks 42 and 44 are roughly laterally 
aligned with the apertures 16 and 17 in the end wall 15 of the 
reproduction apparatus 10. To this end, the horizontal spacing of the 
respective hooks and their apertures is substantially the same. However, 
in order to provide complete alignment and locking, it will be described 
below how to lift at least that side of the module containing the hooks 42 
and 44 up above the bottom of the slots of said mounting apertures, and 
then to move the hooks downwardly slightly until the end of the hooks are 
on the inside of the end wall 15 below the bottom of the aperture slots, 
to positively engage the module 20 to the end wall 15, at least in the 
upper aperture 16. This is to provide positive "hang on" or "hook on" 
mounting of the module to the end wall of the reproduction apparatus 10. 
As indicated above, with the present system, it is not necessary, as it is 
in conventional "hang on" mounting systems, to lift the entire weight of 
the module 20. In fact, with the present system, only a small portion of 
the total weight of the module 20 need ever be lifted by the installer, 
and installation can be done easily by one person even if the module 20 is 
too heavy for a normal person to lift. Exemplary mounting movements or 
techniques are schematically illustrated for the two respective 
embodiments in FIG. 5 and FIG. 8. As may be seen in FIG. 5, by releasing 
all four retaining pins 36 for all four sprung castor units 30, the module 
20 is now supported by the four springs 35. The spring force of the 
springs 35 is designed to have a total lifting force such that most, but 
not all, of the weight of the module 20 is supported thereon even when the 
module is lifted. The hooks 42 and 44 at this point are still slightly 
below the level needed for locking the hooks into the mounting apertures 
16 and 17. Thus, as shown in FIG. 5 by the phantom positions and movement 
arrows, a slight manual lifting force, e.g., as little as from 9 to 20 
pounds, can be applied to a handle or other grip point on the module on 
the front and/or back side of the module 20 while moving the module 20 
against the reproduction apparatus 10. The spring factor of the springs 35 
and their movement of the shaft 34 of the sprung castor unit 30 is such as 
to maintain most of the weight of the module on these castor units 30 
while this docking movement is made by the operator. This allows the hooks 
to enter and mate with the mounting apertures. Then, the installer, by 
simply releasing the slight vertical force being applied, allows the 
module 20 to settle back down on its spring mounting until the base of the 
hooks engage the base of the mounting slots to securely latch the module 
20 to the reproduction apparatus 10. Due to the preset positions of the 
mounting hooks and the apertures, that latching automatically fully aligns 
the sheet output of the reproduction apparatus with the sheet input of the 
module. By inserting the bottom hooks first, lateral alignment is 
confirmed and held while the top hooks are being inserted in the top 
apertures. 
As shown in FIG. 8, the other embodiment only has spring mounted castor 
units under the outboard side of the module, the side away from the 
reproduction apparatus 10 and thus opposite from the side of the module 20 
with the mounting hooks. In the mounting arrangement illustrated 
schematically in FIG. 8, the previously described mounting procedure may 
be varied by first, before removing the retaining pins 36, tilting on 
those outboard castors and moving forward the module 20 as otherwise 
described above, to lift the bottom hooks 44 enough to insert into the 
lower mounting apertures 17 with a slight vertical lifting and tilting 
force. Then, by releasing that manual force, the lower hooks 44 latch onto 
the lower mounting apertures 17. At that point, the hitch pins 36 may be 
removed from the outboard spring castor units 30. That automatically lifts 
and tilts forward the module slightly with the force of these springs 35. 
Then, by grasping the right or front side illustrated handle and lifting 
it with a slight manual force and pushing the top of the unit module 
forward with a slight force, the top hooks 40 (which are now already 
laterally aligned by the bottom hooks) are moved into the upper mounting 
apertures 16. Then, by releasing the lifting movement on the module 20, 
the module 20 automatically drops, with a small force, with the hooks 
sliding down over the bottom of the aperture slots to latch and lock the 
module unit 20 to the reproduction apparatus 10. If desired, an additional 
safety screw or other locking may be provided to prevent inadvertent 
unlatching of the unit by unauthorized tampering. 
Note that in either of the two described mounting systems only a small 
portion of the weight of the module 20 is actually hanging on the end wall 
15 of the reproduction apparatus 10 and that most of the weight is carried 
by the sprung and/or unsprung castor units under the module 20. 
Furthermore, this mounting and support arrangement is not substantially 
affected by differences in the floor level between the reproduction 
apparatus 10 in the module 20, as long as it is within the operating range 
of vertical movement of the springs 35 and shaft 34. 
It will be appreciated that unlatching, dismounting and removal of the 
module 20 for repair or substitution may be done simply by reversing the 
above steps. That is, slightly lifting the module 20 and tilting it 
slightly away from the reproduction apparatus 10 to remove the mounting 
hooks from the mounting apertures, and then rolling the module away from 
the reproduction apparatus 10. For further movement, it is desirable to 
press down on the module 20 to compress the springs 35 and to put the 
retaining pins 36 back into the pin holes 37 in the shafts 34 to stabilize 
the unit for rolling it away on the wheels 32. This compression of the 
springs 35 can be done for the outboard springs while the lower hooks 44 
are still retained in the lower mounting apertures 17 by tilting the unit 
downwardly at that point. 
Various alternative shapes and dimensions for the hooks and mounting 
apertures may be provided. The exemplary mounting apertures shown 
particularly in FIG. 9 may be for example approximately 40 mm in vertical 
dimensions for the top apertures 16 and 54 mm for the lower mounting 
apertures 17. The particular hooks and apertures illustrated are of low 
cost and simple manufacture in sheet metal, but it will be appreciated 
that numerous other configurations may be used. 
While the embodiments disclosed herein are preferred, it will be 
appreciated from this teaching that various alternatives, modifications, 
variations or improvements therein may be made by those skilled in the 
art, which are intended to be encompassed by the following claims: