Sheet processing system, sheet processor and abnormal-transportation correction method

The sheet processing system includes: an image forming unit forming an image on a sheet; a sheet stack unit that lowers along a moving route, as more sheets are stacked on the sheet stack unit, the sheets each having an image formed by the image forming unit and being transported through a first route; a processing unit provided in a housing, and applying processing to a sheet having an image formed by the image forming unit, the sheet being transported through a second route; a cover member provided so that a part of the housing is openable, partially reaching a position in the moving route when the part is opened, and allowing a user to operate the processing unit by opening the part; and a moving unit moving the sheet stack unit to a position where the sheet stack unit does not interfere with the cover member, upon abnormal transportation.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on and claims priority under 35 USC §119 from Japanese Patent Application No. 2008-189399 filed Jul. 23, 2008.

BACKGROUND

1. Technical Field

The present invention relates to a sheet processing system for applying processing to a sheet, a sheet processor, and an abnormal-transportation correction method.

2. Related Art

A finisher including an exit tray elevation unit for facilitating jam processing has been proposed.

SUMMARY

According to an aspect of the present invention, there is provided a sheet processing system including: an image forming unit that forms an image on a sheet; a sheet stack unit that lowers along a moving route set in advance, as more sheets are stacked on the sheet stack unit, the sheets each having an image formed thereon by the image forming unit, the sheets being transported through a first transporting route; a processing unit that is provided in a housing, and that applies processing to a sheet having an image formed thereon by the image forming unit, the sheet being transported through a second transporting route; a cover member that is provided so that a part of the housing is openable, that partially reaches a position in the moving route when the part of the housing is opened, and that allows a user to operate the processing unit by opening the part of the housing; and a moving unit that moves the sheet stack unit to a position where the sheet stack unit does not interfere with the cover member, upon occurrence of an abnormality in transportation of a sheet.

DETAILED DESCRIPTION

FIG. 1is an entire configuration of a paper sheet processing system1to which the exemplary embodiment is applied. The paper sheet processing system1shown inFIG. 1includes, for example, an image forming apparatus2, such as a printer and a copy machine, which forms an image by electrophotography, and a paper sheet processor3that applies post-processing to a paper sheet (an example of a sheet) on which, for example, a toner image has been formed by the image forming apparatus2.

Here, the image forming apparatus2includes an image forming apparatus main body2A, and a user interface (UI) that displays information to an operator (a user) and receives an instruction (an input) from the operator, the UI being formed of, for example, a liquid crystal display. Additionally, the image forming apparatus2includes, inside the image forming apparatus main body2A, an image forming portion (not shown in the figure) that forms, for example, a toner image on a paper sheet. The image forming apparatus2further includes a paper sheet transporting mechanism (not shown in the figure) that includes a drive source such as a motor, and transports a paper sheet to the image forming portion, and transports (outputs), to the paper sheet processor3, a paper sheet on which an image has been formed in the image forming portion. Furthermore, the image forming apparatus2includes a controller2C that controls the image forming portion in the image forming apparatus main body2A, the paper sheet transporting mechanism, the UI and the like.

On the other hand, the paper sheet processor3includes a transporting apparatus10that further transports, to the downstream side, a paper sheet outputted from the image forming apparatus2, and a slip-sheet supplying apparatus20that supplies a slip sheet such as a cardboard or a windowed paper sheet to a paper sheet transported by this transporting apparatus10. Additionally, the paper sheet processor3includes a folding apparatus30that applies folding processing, such as twice inward folding (C-folding), twice outward folding (Z-folding), or the like, to the paper sheet transported by the transporting apparatus10, and a first post-processing apparatus40that, while being provided in the downstream side of the folding apparatus30, applies punching, end binding, or center binding to a paper sheet. Furthermore, the paper sheet processor3further includes a second post-processing apparatus50that is provided to the downstream side of the first post-processing apparatus40, and applies additional post-processing to a bundle of center-folded and center-bound paper sheets (a book form). Additionally, the paper sheet processor3includes a drive motor and the like that drives portions and units included in the transporting apparatus10, the slip-sheet supplying apparatus20, the folding apparatus30, the first post-processing apparatus40and the second post-processing apparatus50.

Additionally, the paper sheet processor3has a controller100that is provided so as to be communicable with the controller2C in the image forming apparatus2, and controls an entirety of the paper sheet processor3. Note that, although a position in which the controller100is installed is not particularly an issue, the controller100is provided in the first post-processing apparatus40in the present exemplary embodiment.

Here, by use ofFIG. 2, the first post-processing apparatus40and the second post-processing apparatus50will be described in detail.FIG. 2is an enlarged view showing the first post-processing apparatus40and the second post-processing apparatus50.

The first post-processing apparatus40includes: an apparatus main body41formed substantially into a rectangular parallelepiped shape; a punching unit42that applies punching to a paper sheet; and an end binder43that binds an end of a paper sheet bundle by using a staple. Additionally, the first post-processing apparatus40includes a center-binding unit44that center-folds and center-binds a paper sheet bundle to produce a double-page spread booklet. Note that, in each of the first and second post-processing apparatuses40and50, a paper sheet transporting route is configured to branch into two transporting routes after passing through the punching unit42. Then, while one of the two transporting routes (a first transporting route) is configured to reach an end-bound paper sheet stack unit45(described later), the other (a second transporting route) is configured to reach the second post-processing apparatus50.

Additionally, the first post-processing apparatus40includes the plate-like end-bound paper sheet stack unit45which is provided so as to be movable on the transporting route along a vertical direction while being provided so as to project from a side face of the apparatus main body41, and on which bundles of end-bound paper sheets are stacked. This end-bound paper sheet stack unit45, which functions as a sheet stack unit, is arranged in a slanted state so that one side thereof more distant from the apparatus main body41may be positioned higher than the other side closer to the apparatus main body41. Furthermore, the first post-processing apparatus40includes an upper stack unit46which is provided on an upper portion of the apparatus main body41and on which paper sheets to which no processing is applied by the first post-processing apparatus40or paper sheets to which only punching has been applied in the punching unit42are stacked.

Additionally, the first post-processing apparatus40includes: a motor M used for moving the end-bound paper sheet stack unit45in an up or down direction; and a moving mechanism (not shown in the figure) that includes an endless belt and the like, and moves the end-bound paper sheet stack unit45in the up or down direction by using drive force from the motor M. Furthermore, the first post-processing apparatus40includes a presence/absence detecting sensor S1that detects presence or absence of a paper sheet on the end-bound paper sheet stack unit45. Additionally, the first post-processing apparatus40includes plural position detecting sensors S2which are provided along the up and down direction, and detect a position of the end-bound paper sheet stack unit45in the up and down direction.

Furthermore, the first post-processing apparatus40includes a paper sheet detecting sensor S3that detects paper sheets stacked on the end-bound paper sheet stack unit45. Note that, in the present exemplary embodiment, a position of the end-bound paper sheet stack unit45is controlled by the controller100on the basis of an output from the sheet detecting sensor S3so that the uppermost one of the paper sheets on the end-bound paper sheet stack unit45may be positioned lower than a later-described opening411. Additionally, in the present exemplary embodiment, a position of the end-bound paper sheet stack unit45is controlled by the controller100on the basis of an output from the sheet detecting sensor S3so that the uppermost one of the paper sheets on the end-bound paper sheet stack unit45may maintain a constant position. For this reason, in the present exemplary embodiment, the end-bound paper sheet stack unit45lowers as more paper sheets are stacked thereon.

The end binder43includes: a compiler431collecting and receiving plural paper sheets; and exit rolls432being a pair of rolls that output a paper sheet toward the compiler431. Additionally, the end binder43includes a main paddle and a sub paddle (which are not shown in the figure) that rotate so as to push a rear end of a paper sheet toward an end guide of the compiler431. Furthermore, the end binder43includes an ejection roll433that transports to the end-bound paper sheet stack unit45, through the opening411formed in the apparatus main body41, a bundle of paper sheets accumulated in the compiler431. Furthermore, the end binder43includes an end-binding stapler435used for binding an end of a bundle of paper sheets contained in the compiler431.

The center-binding unit44includes: an accumulating portion441that, when a center-folded and center-bound booklet is produced, accumulates the required number of paper sheets on which images have been formed; discharging rolls442that output a paper sheet to the accumulating portion441; and an end guide443that moves along the accumulating portion441so as to determine center-binding and center-folding positions. Additionally, although illustration of the following is omitted, the center binding unit44includes: a paddle that rotates so as to align, toward the end guide443, paper sheets to be accumulated on the accumulating portion441; a pair of aligning plates that slide so as to align, in a width direction of the paper sheets, the paper sheets to be accumulated on the accumulating portion441. Furthermore, the center-binding unit44includes a stapler444that center-binds a bundle of paper sheets accumulated on the accumulating portion441.

Furthermore, the center-binding unit44includes: a folding knife445that moves so as to project from an upper side to a lower side of the accumulating portion441for the purpose of folding, at the center-binding position, a bundle of paper sheets having been center-bound by the stapler444; folding rolls446formed of a pair of rolls that sandwich a bundle of paper sheets having started to be folded by the folding knife445; and a transporting roll (not shown in the figure) that transports, to the second post-processing apparatus50, a bundle of paper sheets sandwiched by the folding rolls446.

When a center-folded and center-bound booklet is produced in the first post-processing apparatus40, the discharging rolls442of the center-binding unit44sequentially discharges transported paper sheets into the accumulating portion441. At this time, the end guide443moves and stops, for example, so that central parts of the paper sheets may be positioned at a stapling position where the paper sheets are stapled by the stapler444. Then, the predetermined number of paper sheets is accumulated on the accumulating portion441, and thereafter, the central parts, for example, of the paper sheets are bound by the stapler444. Subsequently, a bundle of the center-bound paper sheets is moved by an upward movement of the end guide443so that a folded part thereof (for example, the center parts of the paper sheets) may coincide with a tip position of the folding knife445.

Then, after the folded part of a bundle of the paper sheets moves to the tip position of the folding knife445, the folding knife445is pushed out in a downward direction from the above. Then, a tip of the folding knife445is pushed out into a part below an opening of the accumulating portion441, whereby the paper sheet bundle is pushed down from a containing face of the accumulating portion441, and comes to be sandwiched by the folding rolls446. Thereafter, the paper sheet bundle whose center has been bound by the stapler444and folded by the folding knife445and the folding rolls446is transported to the second post-processing apparatus50by a transporting roll (not shown in the figure).

The second post-processing apparatus50includes an apparatus main body (a housing)50A formed substantially into a rectangular parallelepiped shape. Additionally, the second post-processing apparatus50includes a first cover member50B and a second cover member50C. Each of the first and second cover portions50B and50C covers an opening formed in an upper portion of the apparatus main body50A, and opens this upper portion by being provided so as to have an end portion thereof joined to an upper portion of the apparatus main body50A and so as to be openable and closable with this end portion serving as a supporting point. Here, in the second post-processing apparatus50in the present exemplary embodiment, there is a possibility that an abnormality in sheet transportation, such as a jam (a paper sheet jam), may occur in the paper-sheet bundle transporting route, a later-described cutting unit55or the like.

In such a case, the paper-sheet bundle transporting route, the cutting unit55or the like in the second post-processing apparatus50becomes accessible by opening the first and second cover members50B and50C. In an additional remark, various members provided to the paper-sheet bundle transporting route, the cutting unit55and the like become operable by opening the first and second cover members50B and50C. Thereby, a jam becomes removable. Note that the first cover member50B in the present exemplary embodiment is provided below the end-bound paper sheet stack unit45in the first post-processing apparatus40. The first cover member50B is provided so that a part thereof (an end portion opposite to the end portion in which the supporting point is provided) may reach a position in the moving route of the end-bound paper sheet stack unit45when the first cover member50B is opened.

Additionally, the second post-processing apparatus50includes members and units, which are described below, inside the apparatus main body50A. To begin with, the second post-processing apparatus50includes: a transporting unit51that transports a booklet (a paper sheet bundle) whose center has been bound and folded and that adjusts positional misalignment of the booklet. Additionally, the second post-processing apparatus50includes: a clamp member53that holds a front end portion (a center-folded/center-bound portion) of the booklet by sandwiching the front end portion; and a pressing roll member54that moves while pressing the front end portion of the booklet, and thereby flattens the front end portion.

Additionally, the second post-processing apparatus50includes: a cutting unit (a trimmer unit)55(one example of a processing unit) that performs cutting processing so as to trim a rear end portion (a spread portion) of a booklet; a feeding roll56that feeds the booklet into an inside of the cutting unit55; and a cut position setting unit57that moves while sandwiching and holding the booklet so as to determine a cut position of the rear end portion of the booklet. Additionally, the second post-processing apparatus50includes: a cutting wastage receiving unit58that receives cutting wastage from the booklet cut by the cutting unit55; and a booklet transporting roll59that transports the booklet whose rear end portion has been cut by the cutting unit55. Furthermore, the second post-processing apparatus50includes, along a transporting route of paper sheets (a booklet), plural jam detecting sensors S4that detect a jam of a booklet (a paper sheet bundle) (FIG. 2shows only one of the jam detecting sensors S4). Furthermore, the second post-processing apparatus50includes a booklet stack unit60that accumulates bound booklets, and booklets fed from the booklet transporting roll59are accumulated in the booklet stack unit60while being sequentially transported one by one.

Incidentally, in the present exemplary embodiment, as has been described above, when a jam occurs in the second post-processing apparatus50, the jam becomes removable by opening the first cover member50B and the second cover member50C. Additionally, in the present exemplary embodiment, as has been mentioned above, the end-bound paper sheet stack unit45lowers as more end-bounded paper sheet bundles are stacked on the end-bound paper sheet stack unit45. Furthermore, the first cover member50B is provided below the end-bound paper sheet stack unit45of the first post-processing apparatus40, and is provided so that a part thereof may reach a position in the moving route of the end-bound paper sheet stack unit45. For this reason, when a jam occurs in the second post-processing apparatus50, if the end-bound paper sheet stack unit45is positioned at a lower part (in a lowered state), the end-bound paper sheet stack unit45and the first cover member50B interfere with each other, which hinders the first cover member50B from being sufficiently opened. As a result, removal of a jam becomes difficult. Consequently, in the present exemplary embodiment, the following processing is applied in which the end-bound paper sheet stack unit45is elevated to a position where the end-bound paper sheet stack unit45does not interfere with the first cover member50B.

Here, interference between the end-bound paper sheet stack unit45and the first cover member50B becomes avoidable if the second post-processing apparatus50is provided so as to be separated from the first post-processing apparatus40. In this case, however, an occupied area (an installation area) of the paper sheet processor3becomes large. Consequently, in the present exemplary embodiment, the second post-processing apparatus50is arranged near the first post-processing apparatus40. This arrangement allows the occupied area of the paper sheet processor3to be small. That is, this arrangement allows the paper sheet processor3to be more space saving.

Note that, as the end-bound paper sheet stack unit45is arranged in the slanted state as mentioned above, paper sheets on the end-bound paper sheet stack unit45are stacked in a state of leaning against the apparatus main body41. If the end-bound paper sheet stack unit45is elevated in this state, the paper sheets on the end-bound paper sheet stack unit45may possibly enter the opening411in the apparatus main body41or be caught by the opening411, whereby there is a risk of having the paper sheets in a jumbled stacked state, or a risk of damaging the paper sheets. For this reason, in the present exemplary embodiment, on condition that paper sheets on the end-bound paper sheet stack unit45have been removed, elevation of the end-bound paper sheet stack unit45is executed. Then, the present exemplary embodiment is configured so that occurrence of a jam or necessity of jam removal may be displayed on the UI (refer toFIG. 1) after the elevation of the end-bound paper sheet stack unit45is executed.

Here,FIG. 3is a block diagram for explaining a functional configuration of the controller100in the paper sheet processor3. Note thatFIG. 3shows only a functional configuration with respect to jam removal.

As shown in this figure, the controller100in the present exemplary embodiment includes a jam detector101, a paper sheet transportation controller102, a transmitter103, and a paper sheet stack controller104.

The jam detector101detects occurrence of a jam in the second post-processing apparatus50on the basis of outputs from the jam detecting sensors S4. Additionally, the jam detector101outputs a detection result on jam occurrence to the paper sheet transportation controller102, the transmitter103, and the paper sheet stack controller104.

The paper sheet transportation controller102controls a drive motor (not shown in the figure) or the like, thereby controlling transportation of paper sheets (paper sheet bundles) in the paper sheet processor3.

The transmitter (a transmitting unit)103transmits predetermined information to the image forming apparatus2after receiving a detection result in the jam detector101, and information from the paper sheet stack controller104.

The paper sheet stack controller104identifies a position of the end-bound paper sheet stack unit45on the basis of outputs from the position detecting sensors S2. Additionally, the paper sheet stack controller104determines whether or not the end-bound paper sheet stack unit45is in a lowered state, that is, the end-bound paper sheet stack unit45is positioned lower than a predetermined position. Furthermore, on the basis of outputs from the presence/absence detecting sensor S1, the paper sheet stack controller104, which functions as one example of a detecting unit, determines whether or not paper sheets on the end-bound paper sheet stack unit45have been removed. Additionally, the paper sheet stack controller104, which functions as one example of a moving unit, drives the motor M, thereby elevating and lowering the end-bound paper sheet stack unit45.

Here,FIG. 4is a block diagram for explaining a functional configuration of the controller2C in the image forming apparatus2. Note that this drawing also shows only a functional configuration with respect to the jam removal.

As shown in this drawing, the controller2C in the present exemplary embodiment includes a receiver201, a jam detector202, a paper sheet transportation controller203and a UI controller204.

The receiver201receives information transmitted from the controller100in the paper sheet processor3, and outputs this information to the jam detector202and the UI controller204.

The jam detector202detects occurrence of a jam in the second post-processing apparatus50on the basis of the information outputted from the receiver201.

The paper sheet transportation controller203controls the paper sheet transporting mechanism in the image forming apparatus2, thereby executing and stopping paper sheet transportation inside the image forming apparatus2.

The UI controller204, which functions as one example of a display, controls the UI, thereby displaying information on the UI, and erasing (clearing) displayed information.

Note that each of the above-mentioned controller100and controller2C includes a central processing unit (CPU), a read only memory (ROM) and a random access memory (RAM) in practice.

Thereby, the above functions are realized by causing the CPU to execute processing while exchanging data with the RAM in accordance with a program stored in the ROM.

Next, processing performed by the controller100and processing performed by the controller2C in a case where a jam occurs in the paper sheet processor3will be described more specifically.

FIG. 5is a flowchart showing one example of a procedure of the processing performed by the controller100in the paper sheet processor3.

As shown inFIG. 5, the jam detector101in the controller100monitors outputs from the jam detecting sensors S4, and determines whether or not a jam of paper sheets (a paper sheet bundle) has occurred in the transporting route and the like in the second post-processing apparatus50(step101). Note that, if it is determined that a jam has not occurred, the processing returns to step101. Then, if it is determined in step101that a jam has occurred, the transmitter103notifies the image forming apparatus2that a jam has occurred in the paper sheet processor3(step102). Subsequently, the paper sheet transportation controller102stops the drive motor (not shown in the figure) and the like, thereby stopping transportation of paper sheets (step103). Thereafter, the paper sheet stack controller104identifies a position of the end-bound paper sheet stack unit45on the basis of outputs from the position detecting sensors S2(step104).

Subsequently, the paper sheet stack controller104determines whether or not the end-bound paper sheet stack unit45is in the lowered state (step105). In more detailed description, the paper sheet stack controller104determines, on the basis of outputs from the position detecting sensors S2, whether or not the end-bound paper sheet stack unit45is positioned lower than the predetermined position. Note that, if it is determined in step105that the end-bound paper sheet stack unit45is not in the lowered state, that is, if the end-bound paper sheet stack unit45is positioned sufficiently high to the extent allowing the first cover member50B to be opened, the processing is finished.

On the other hand, if it is determined in step105that the end-bound paper sheet stack unit45is in the lowered state, the transmitter103transmits, to the image forming apparatus2, a removal request for paper sheets stacked on the end-bound paper sheet stack unit45(step106). Thereby, in the present exemplary embodiment, a removal instruction for paper sheets stacked on the end-bound paper sheet stack unit45is displayed on the UI in the image forming apparatus2(details of the display will be described later). Note that the present exemplary embodiment employs a configuration in which the removal request for paper sheets is thus transmitted to the image forming apparatus2, but may employ instead, for example, another configuration in which the end-bound paper sheet stack unit45transmits, to the image forming apparatus2, a notification that the end-bound paper sheet stack unit45is in the lowered state.

Subsequently, on the basis of outputs from the presence/absence detecting sensor S1, the paper sheet stack controller104determines whether or not paper sheets on the end-bound paper sheet stack unit45have been removed (step107). Note that, if it is determined that paper sheets on the end-bound paper sheet stack unit45have not been removed in the step107, processing of step107is executed again. On the other hand, if it is determined that paper sheets on the end-bound paper sheet stack unit45have been removed, the paper sheet stack controller104drives the motor M, thereby elevating the end-bound paper sheet stack unit45(step108). Then, on the basis of outputs from the position detecting sensors S2, the paper sheet stack controller104determines whether or not the end-bound paper sheet stack unit45has reached a predetermined elevated position (step109). Note that, if the end-bound paper sheet stack unit45has not yet reached the predetermined elevated position, the paper sheet stack controller104further elevates the end-bound paper sheet stack unit45(step108). On the other hand, if it is determined in step109that the end-bound paper sheet stack unit45has reached the predetermined elevated position, the transmitter103transmits, to the image forming apparatus2, a request for cancellation of the above-mentioned removal instruction displayed on the UI (step110), and the processing is finished.

Next, the processing performed by the controller2C in the image forming apparatus2will be described.

FIG. 6is a flowchart showing one example of a procedure of the processing performed by the controller2C in the image forming apparatus2.

First of all, the jam detector202in the controller2C determines, on the basis of information transmitted from the paper sheet processor3side and received by the receiver201, whether or not a jam has occurred in the paper sheet processor3(step201). Then, if it is determined in step201that a jam has occurred, the paper sheet transportation controller203controls the paper sheet transporting mechanism in the image forming apparatus2and the like, thereby stopping paper sheet transportation and the like inside the image forming apparatus2(step202).

Thereafter, the controller2C determines whether or not the receiver201has received, from the paper sheet processor3, the removal request for paper sheets stacked on the end-bound paper sheet stack unit45(step203). Note that, if the receiver201has not received the removal request within a predetermined time period, the processing proceeds to step207. On the other hand, if it is determined in step203that the receiver201has received the removal request, the UI controller204displays, on the UI, a removal instruction (a removal request) for paper sheets on the end-bound paper sheet stack unit45(step204). This allows the operator to be urged to remove paper sheets on the end-bound paper sheet stack unit45, and the operator having seen the UI removes the paper sheets on the end-bound paper sheet stack unit45.

Subsequently, when the receiver201receives a request for cancellation of the removal instruction (step205), the UI controller204clears the removal instruction for paper sheets displayed in step204on the UI (step206), the request being transmitted from the transmitter103of the paper sheet processor3. Thereafter, the UI controller204displays, on the UI, an indication that a jam has occurred in the paper sheet processor3(step207), and the processing is finished.