Apparatus and method for detecting the travel direction of media in a media path in an image marking and fusing system

An apparatus (100) and method (500) that detects the travel direction of media in a media path in an image marking and fusing system is disclosed. The apparatus can include a media transport (110) configured to transport media. The apparatus can include a media marking engine (120) coupled to the media transport, the media marking engine configured to mark an image on media transported by the media transport to create unfused marked media (115). The apparatus can include a fusing member (130) coupled to the media transport, the fusing member having an axis of rotation (132), the fusing member configured to fuse the image on the media. The apparatus can include a media motion sensor (140) configured to sense travel information based on an unfused marked media travel direction (116) and configured to output a media motion sensor signal corresponding to the travel information. The apparatus can include a controller (150) coupled to the media motion sensor, the controller configured to output an alignment angle signal in response to receiving the media motion sensor signal, the alignment angle signal corresponding to an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction.

BACKGROUND

Disclosed herein is an apparatus and method that detects the travel direction of media in a media path in an image marking and fusing system that marks images onto print media substrates and fuses or fixes marked images onto the print media substrates.

Presently, in a typical electrophotographic printing process, a photoconductive member in a media marking engine is charged to a substantially uniform potential to sensitize a surface of the photoconductive member. The charged portion of the photoconductive member is exposed to a light image of an original document being reproduced. Exposure of the charged photoconductive member selectively dissipates the charges on the photoconductive member in irradiated areas. This process records an electrostatic latent image on the photoconductive member corresponding to informational areas contained within the original document. After the electrostatic latent image is recorded on the photoconductive member, the latent image is developed by bringing a developer material into contact with the photoconductive member. Generally, the developer material comprises toner particles adhering triboelectrically to carrier granules. The toner particles are attracted from the carrier granules to the latent image forming a toner powder image on the photoconductive member. The toner powder image is then transferred from the photoconductive member to media to generate unfused marked media. The media can include paper, a transparency, a substrate, or any other media.

After the media marking engine marks the media with the toner powder image, a fuser heats the toner particles to fuse the toner powder image to the media. While the fuser may take many forms, where heat or combination heat-pressure fusers are currently most common. One combination heat-pressure fuser includes a heat fusing roll in physical contact with a pressure roll. These rolls cooperate to form a fusing nip through which the unfused marked media passes. As the media passes through the rolls, heat and pressure fuses the powder image to the media.

Unfortunately, the unfused marked media may not travel in a media path at a desired angle from the media marking engine to the fuser. This can cause problems, such as edge wear, which is a critical problem in roll and belt fusing systems, such as in viton over silicone systems, Teflon over silicone systems, and other fusing systems. Edge wear can be the result of roller surface properties, the nature of media paper edges, the misalignment of media sheets as they pass through a fusing nip, and other properties. For example, shear stress is placed upon roller surfaces and paper surfaces when the surfaces conform around the edge of the media when it is in the fusing nip. Furthermore, if the media is not perfectly square to the rotation of the roll surface, a cutting or wiping action will occur. The cutting action exacerbates the wear of the roller surface and causes a resulting differential gloss and color differential on the media.

As a further example, in most conventional printing systems, the fuser is located in a machine frame on pins or slides that affect alignment control between the fuser roll axis and a machine paper path. In the fixed pinned system the misalignment between media motion and fuser roll axis is usually consistent, which results in more wear on one end of the fuser roll then the other. This is generally thought to be the side with the cutting motion. In slide systems the wear can be at either end depending upon the float of the system.

Furthermore, since the travel path of the media is dependent upon the skew adjustment performed at paper registration prior to marking, subsequent contact, transfer, stripping and transport alignments during marking and prior to fusing result in skew of the media travel direction. The skew of the media travel direction causes resulting issues of edge wear, cutting, wiping, gloss differential, and color differential mentioned above. These issues are especially problematic because current systems cannot detect the travel direction of unfused marked media.

Thus, there is a need for apparatus and method that detects the travel direction of media in a media path in an image marking and fusing system.

SUMMARY

An apparatus and method that detects the travel direction of media in a media path in an image marking and fusing system is disclosed. The apparatus can include a media transport configured to transport media. The apparatus can include a media marking engine coupled to the media transport, the media marking engine configured to mark an image on media transported by the media transport to create unfused marked media. The apparatus can include a fusing member coupled to the media transport, the fusing member having an axis of rotation, the fusing member configured to fuse the image on the media. The apparatus can include a media motion sensor configured to sense travel information based on an unfused marked media travel direction and configured to output a media motion sensor signal corresponding to the travel information. The apparatus can include a controller coupled to the media motion sensor, the controller configured to output an alignment angle signal in response to receiving the media motion sensor signal, the alignment angle signal corresponding to an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction.

DETAILED DESCRIPTION

The embodiments include an apparatus for detecting the travel direction of media in a media path. The apparatus can include a media transport configured to transport media. The apparatus can include a media marking engine coupled to the media transport, the media marking engine configured to mark an image on media transported by the media transport to create unfused marked media. The apparatus can include a fusing member coupled to the media transport, the fusing member having an axis of rotation, the fusing member configured to fuse the image on the media. The apparatus can include a media motion sensor configured to sense travel information based on an unfused marked media travel direction and configured to output a media motion sensor signal corresponding to the travel information. The apparatus can include a controller coupled to the media motion sensor, the controller configured to output an alignment angle signal in response to receiving the media motion sensor signal, the alignment angle signal corresponding to an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction.

The embodiments further include an apparatus for detecting the travel direction of media in a media path. The apparatus can include a media transport configured to transport media in a travel direction substantially along a y-axis. The apparatus can include a media marking engine coupled to the media transport, the media marking engine configured to mark an image on media transported by the media transport to create unfused marked media. The apparatus can include a fusing member coupled to the media transport, the fusing member having an axis of rotation substantially parallel to an x-axis perpendicular to the y-axis, the fusing member including a rotating cylinder, the fusing member configured to fuse the image on the media. The apparatus can include a media motion sensor configured to sense x-axis and y-axis travel information of unfused marked media and configured to output a media motion sensor signal corresponding to the x-axis and y-axis travel information of the unfused marked media. The apparatus can include a controller coupled to the media motion sensor, the controller configured to adjust an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction based on the media motion sensor signal.

The embodiments further include method for detecting the travel direction of media in an apparatus having a media transport, a media marking engine, and a fusing member having an axis of rotation, the apparatus also including a media motion sensor and a controller. The method can include transporting media in the media transport and marking, with the media marking engine, an image on the media transported in the media transport to create unfused marked media. The method can include sensing, using the media motion sensor, travel information of the unfused marked media. The method can include sending a media motion sensor signal to the controller, the media motion sensor signal corresponding to the unfused marked media travel information. The method can include outputting, with the controller, an alignment angle signal in response to receiving the media motion sensor signal, the alignment angle signal corresponding to an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction. The method can include fusing, using the fusing member, the image on the media.

FIG. 1is an exemplary illustration of an apparatus100. The apparatus100may be a printer, a multifunction media device, a xerographic machine, or any other device that transports and fuses an image onto media. The apparatus100can include a media transport110, a media marking engine120coupled to the media transport110, a fusing member130coupled to the media transport110, a media motion sensor140, and a controller150coupled to the media motion sensor140. Portions of the controller150operation can be contained in one element or can be distributed throughout the apparatus100. The fusing member130can have an axis of rotation132, a first end134, and a second end135. The fusing member130can include or be part of a fusing assembly131. The fusing member130can be coupled to a pivot point111coupled to the fusing member first end134. The apparatus100can also include a prime mover160coupled to the fusing member130and coupled to the controller150. The prime mover160can be coupled to the fusing member second end135.

In operation, the media transport110can be configured to transport media. The media marking engine120can be configured to mark an image on media transported by the media transport110to create unfused marked media115. The media marking engine120can mark the media using xerographic marking, ink jet marking, liquid ink marking, or other marking. For example, a toner powder image can be transferred from a photoconductive belt or roll to the media. Unfused marked media115can be media marked with an image by the media marking engine120that has not yet been fused by the fusing member130. The unfused marked media115may include the unfused image along with an image that has previously been fused in a separate process.

The fusing member130can be configured to fuse the image on the media. The fusing member130can fuse, dry, and/or fix an image on the marked media. For example, the fusing member130can permanently affix a transferred toner powder image onto the media. The fusing member130can be a fusing roll, a fusing belt, or other fusing member. For example, a fusing belt can be wrapped around one or more rotating cylinders. The fusing belt can have an axis of rotation based on an arc that the belt creates around the rotating cylinders. Because the unfused marked media travel direction116may not be exactly perpendicular to the fusing member axis or rotation132, the axis of rotation132may only be substantially perpendicular the unfused marked media travel direction116.

The media motion sensor140can be configured to sense travel information based on an unfused marked media travel direction116and can be configured to output a media motion sensor signal corresponding to the travel information. The controller150can be configured to output an alignment angle signal in response to receiving the media motion sensor signal. The alignment angle signal can correspond to an alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116. The alignment angle signal can correspond to the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116because it can be based on the media motion sensor signal. For example, the controller150can use the media motion sensor signal to determine the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116. The alignment angle signal can include alignment angle information, can include a control signal used to control elements of the apparatus100, or can include other information or signals relating an alignment angle. The alignment angle signal is defined to be a signal that corresponds to the alignment angle in that the alignment angle signal is any signal that can be used to display information regarding an angle between the fusing member and the unfused marked media travel direction and/or used to adjust an angle between the fusing member and the unfused marked media travel direction.

For example, the controller150can output the alignment angle signal to provide information regarding the media motion sensor signal to an operator who can manually align the fusing member130with the unfused marked media travel direction116based on the media motion sensor signal. The operator can manually align the fusing member130with unfused marked media travel direction116by manually adjusting a position of the fusing member130, by manually adjusting elements of the apparatus100that affect the unfused marked media travel direction116, or by making other adjustments to the apparatus100. For example, the controller150can output alignment information corresponding to an angle between the fusing member axis of rotation132and the unfused marked media travel direction116. The alignment information can be displayed to an operator who can use it to manually adjust the fusing member130or the unfused marked media travel direction116to make the fusing member axis of rotation132more perpendicular to the unfused marked media travel direction116and parallel with a media sheet leading edge. The operator can also use the alignment information to adjust the fusing member130or the unfused marked media travel direction116to make the alignment angle closer to a desired angle. The operator can make manual adjustments during a manufacturing process of the apparatus100, during field setup of the apparatus100, during maintenance of the apparatus100, or at any other useful time.

According to a related embodiment, the apparatus100can include a media transport110configured to transport media in a travel direction substantially along a y-axis101. The media travel direction can be substantially along the y-axis101because the travel direction of the media may not be exactly parallel with the y-axis101. For example, the unfused marked media travel direction116may be at an angle to the y-axis101. The apparatus100can include a media marking engine120coupled to the media transport110. The media marking engine120can be configured to mark an image on media transported by the media transport110to create unfused marked media115. The apparatus100can include a fusing member130coupled to the media transport110. The fusing member130can have an axis of rotation132substantially parallel to an x-axis102perpendicular to the y-axis101. The axis of rotation132can be substantially parallel to the x-axis102perpendicular to the y-axis101because the axis of rotation132may not be exactly parallel to the x-axis102. The fusing member130can be or can include a rotating cylinder. The fusing member130can be configured to fuse the image on the media. The apparatus100can include a media motion sensor140configured to sense x-axis and y-axis travel information corresponding to an unfused marked media travel direction116and configured to output a media motion sensor signal corresponding to the x-axis and y-axis travel information.

The apparatus100can include a controller150coupled to the media motion sensor140. The controller150can be configured to adjust an alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116based on the media motion sensor signal. The controller150can be configured to adjust the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116closer to a desired angle. The controller150can be configured to adjust the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116more of a right angle. The controller150can be configured to adjust the angle between the fusing member axis of rotation132and the unfused marked media travel direction116to make the angle between the fusing member axis of rotation132and the unfused marked media travel direction116closer to a desired angle that reduces wear on the fusing member130.

For example, the unfused marked media115can travel in a travel direction116at a slight angle to the y-axis101. The controller150can be configured to align fusing member130operation with the unfused marked media travel direction116based on the media motion sensor signal by adjusting the fusing member axis of rotation132to be more perpendicular to the unfused marked media travel direction116or by adjusting the unfused marked media travel direction116to be more perpendicular to the fusing member axis of rotation132. The controller150can also make the alignment angle more of a desired angle to minimize wear on the fusing member130, to adjust the unfused marked media115so a more desirable edge than another edge of the unfused marked media115passes through a desirable location of the fusing member130, to bias the unfused marked media115to adjust media wear of the fusing member130, to distribute media wear over a wider band of the fusing member130, or to make the angle more desirable for any other purpose.

The apparatus100can include prime mover160coupled to the fusing member130and coupled to the controller150. The controller150can be configured to control the prime mover160to adjust the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116based on the media motion sensor signal. A prime mover can be a primary source of movement of the fusing member130, such as an air cylinder, a drive motor and lead screw, a gear motor, a cam motor, a linear solenoid, or any other source of movement that can move the fusing member130.

FIG. 2is an exemplary illustration of the apparatus100according to a related embodiment. An unfused marked media travel direction116can be at an alignment angle117from an axis118perpendicular to the fusing member axis of rotation132. The unfused marked media travel direction116can also be at an alignment angle from the fusing member axis of rotation132. For example, the alignment angle117can be relative based on a relative point of reference. To elaborate, the alignment angle117can be an angle between the unfused marked media travel direction116and an axis118perpendicular to the fusing member axis of rotation132, can be an angle between the unfused marked media travel direction116and the fusing member axis of rotation132, can be an angle relative to the x-axis102or the y-axis101, can be an angle between the unfused marked media travel direction116and the fusing member direction of operation139, or can be any other angle relative to an unfused marked media travel direction116and a fusing member axis of rotation132. The unfused marked media travel direction116and the alignment angle117may be exaggerated for purposes of illustration. For example, the alignment angle117may be closer to an angle of the y-axis101, closer to the axis118perpendicular to the axis of rotation132, and/or closer to an angle of the fusing member direction of operation139.

The controller150can be configured to output an alignment angle signal to adjust the alignment angle117between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle117closer to a desired angle. The controller150can also be configured to adjust the alignment angle117between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle117more of a right angle. The controller150can also be configured to adjust the alignment angle117between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle closer to a desired angle that reduces wear on the fusing member130.

For example, the unfused marked media115can travel in a travel direction116at an alignment angle117in the media transport110. The controller150can be configured to adjust the alignment angle117based on the media motion sensor signal by adjusting the fusing member axis of rotation132to be more perpendicular to the unfused marked media travel direction116or by adjusting the unfused marked media travel direction116to be more perpendicular to the fusing member axis of rotation132. The controller150can also make the alignment angle117more of a desired angle to minimize wear on the fusing member130, to adjust the unfused marked media115so a more desirable edge than another edge of the unfused marked media115passes through a desirable location of the fusing member130, to bias the unfused marked media115to adjust media wear of the fusing member130, to distribute media wear over a wider band of the fusing member130, or to make the alignment angle117more desirable for any other purpose.

As a further example, the controller150may determine, based on the media motion sensor signal that the unfused marked media travel direction116is at an angle from an axis118perpendicular to the fusing member axis of rotation132. The controller150can then align the unfused marked media travel direction117with the axis118perpendicular to the fusing member axis of rotation132by reducing or increasing the angle between the unfused marked media travel direction116and the axis118perpendicular to the fusing member axis of rotation132.

FIG. 3is an exemplary illustration of the apparatus100according to a related embodiment. The controller150can be configured to control the prime mover160using the alignment angle signal to adjust an alignment angle119between the fusing member axis of rotation132and the unfused marked media travel direction116to make the alignment angle119closer to a desired angle. The fusing member130can also be adjusted, moved, or pivoted in any other manner. For example, a pivot point can be in the center of the fusing member130and the controller150can control the prime mover160to adjust an alignment angle119of the fusing member axis of rotation132relative to the unfused marked media travel direction116. The controller150can also adjust, move, or pivot the fusing member130in any other manner useful for adjusting a fusing member130. The unfused marked media travel direction116and the amount of adjustment of the fusing member130may be exaggerated for purposes of illustration and elements of the apparatus100are not necessarily drawn to scale.

FIG. 4is an exemplary illustration of the apparatus100according to a related embodiment. The apparatus100can include a pressure member137coupled to the fusing member130at a fusing nip138where the unfused marked media115can pass through the fusing nip138. The pressure member137can be a roll, a belt, or any other pressure member that provides a pressure on media in contact with a heated surface of the fusing member130. For example, a pressure roll can be cammed against the fusing member130to provide pressure to fix a toner powder image to media. The controller150can be configured to control a prime mover (not shown) to align operation of the fusing member130and the pressure member137with the unfused marked media travel direction116.

The controller150can be configured to compare a media motion sensor signal corresponding to the unfused marked media travel direction116prior to the unfused marked media115reaching the fusing nip138with a media motion sensor signal corresponding to a media travel direction after the media enters the fusing nip138. The controller150can be configured to output the alignment angle signal based on comparing the media motion sensor signal corresponding to the unfused marked media travel direction116prior to the unfused marked media115reaching the fusing nip with the media motion sensor signal corresponding to the media travel direction after the media enters the fusing nip.

The media motion sensor140can be located relative to the fusing member axis of rotation132. One media motion sensor140can be used to detect a travel direction of a front area401of the unfused marked media115prior to the unfused marked media115entering the nip138and used to detect a travel direction of a back area402of the same unfused marked media115as or after the media has entered nip138. Also, two or more sensors can be used to detect a travel direction of media before and after the media enters the nip138where at least one first sensor can be located before the nip138and at least one second sensor (not shown) can be located after the nip138. The controller150can compare a media motion sensor signal prior to the unfused marked media115reaching the fusing nip138with a media motion sensor signal after fused media enters or exits the fusing nip138to determine if a media travel direction has changed or is changing as the media has exited the fusing nip138, while the media is in the fusing nip138, or after the media has exited the fusing nip138.

The controller150can also be configured output the alignment angle signal to adjust, after media marking, skew of the unfused marked media115relative to the fusing member axis of rotation132. For example, a media registration process can use nip wheels and other elements to adjust media sheets to desired positions for accurate transportation, marking, fusing, output, and other registration purposes. The controller150can adjust skew of media after media registration or after both media registration and marking. The controller150can adjust the skew of the media by adjusting elements of the media transport110that affect the skew of the media, by adjusting the media itself, of by making other adjustments that affect the skew of media.

The media motion sensor140can include an optical transmitter142configured to transmit light146at the unfused marked media115. The media motion sensor140can include an optical receiver144configured to receive light146transmitted by the optical transmitter142reflected off the unfused marked media115. The media motion sensor140can include a sensor controller148configured to translate light146received by the optical receiver144into motion of the unfused marked media115and configured to output the media motion sensor signal based on the motion of the unfused marked media115. The optical transmitter142can be a light emitting diode, an infrared transmitter, a laser, a laser interferometer, a dual-laser configuration, or any other useful optical transmitter. The optical receiver144can be a camera, a light sensor, a complimentary metal-oxide semiconductor sensor, a photodiode sensor, or any other useful optical receiver. The media motion sensor140may include other elements useful for detecting the motion of media. For example, the media motion sensor140may include a ball that can contact the media. The ball may be located on a side of the media opposite from the marked side of the media. The sensor controller can detect ball movement and can translate the ball movement into motion of the media. According to another example, an optical transmitter and an optical receiver can be used to detect ball movement when a ball that contacts the media.

The apparatus100can include a fusing member adjustment module170coupled to the controller150. The controller150can be configured to provide the alignment angle signal to the fusing member adjustment module170and the fusing member adjustment module170can be configured to adjust the fusing member to adjust the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116based on the alignment angle signal. The apparatus100can include a media travel adjustment module172coupled to the controller150. The controller150can be configured to provide the alignment angle signal to the media travel adjustment module172and the media travel adjustment module172can be configured to adjust media travel to adjust an angle between the fusing member axis of rotation132and an unfused marked media travel direction116based on the alignment angle signal. The apparatus100can include a display174coupled to the controller150. The controller150can be configured to provide the alignment angle signal to the display174and the display174can be configured to display information regarding the alignment angle between the fusing member axis of rotation132and the unfused marked media travel direction116based on the alignment angle signal.

FIG. 5illustrates an exemplary flowchart500of a method for detecting the travel direction of media in an apparatus having a media transport, a media marking engine, and a fusing member having an axis of rotation, the apparatus also including a media motion sensor and a controller. The method can be performed during manufacturing, during setup of the apparatus, during maintenance of the apparatus, during normal apparatus operation, or at any other useful time. The method starts at510. At520, media is transported in the media transport. At530, an image is marked, using the media marking engine, on the media transported in the media transport to create unfused marked media. At540, travel information of the unfused marked media is sensed using the media motion sensor. At550, a media motion sensor signal is sent from the media motion sensor to the controller, where the media motion sensor signal corresponds to the unfused marked media travel information. At560, the controller outputs an alignment angle signal in response to receiving the media motion sensor signal. The alignment angle signal can correspond to an alignment angle between the fusing member axis of rotation and the unfused marked media travel direction. At570, the fusing member fuses the image on the media. At580, the method ends.

FIG. 6illustrates an exemplary flowchart600of a method for detecting the travel direction of media in an apparatus. Elements of the flowchart600can be used with the flowchart500. The method starts at610. At620, travel information of unfused marked media prior to the unfused marked media reaching the fusing member is sensed to generate a corresponding media motion sensor signal. At630, travel information the media after the media contacts the fusing member is sensed to generate a corresponding media motion sensor signal. At640, a media motion sensor signal corresponding to the unfused marked media prior to the unfused marked media reaching the fusing member is compared with a media motion sensor signal corresponding to the media after the media contacts the fusing member. At650an alignment angle signal regarding an alignment angle between the fusing member axis of rotation and a media travel direction is output based on comparing the media motion sensor signal corresponding to the unfused marked media prior to the unfused marked media reaching the fusing member with the media motion sensor signal corresponding to the media after the media contacts the fusing member. At660, an angle between the fusing member axis of rotation and the media travel direction is adjusted based on the alignment angle signal to make the angle between the fusing member axis of rotation and the media travel direction closer to a desired angle. The angle can be adjusted by adjusting an orientation of the fusing member, by adjusting the media travel direction, by adjusting both the orientation of the fusing member and the media travel direction, or by adjusting other elements of the apparatus. At670, the method ends.

FIG. 7illustrates an exemplary printing apparatus700, such as the apparatus100. As used herein, the term “printing apparatus” encompasses any apparatus, such as a digital copier, bookmaking machine, multifunction machine, or other printing device that performs a print outputting function for any purpose. The printing apparatus700can be used to produce prints from various media, such as coated, uncoated, previously marked, plain paper sheets, or other media. The media can have various sizes and weights. In some embodiments, the printing apparatus700can have a modular construction. As shown, the printing apparatus700can include at least one media feeder module702, a printer module706adjacent the media feeder module702, an inverter module714adjacent the printer module706, and at least one stacker module716adjacent the inverter module714.

In the printing apparatus700, the media feeder module702can be adapted to feed media704having various sizes, widths, lengths, and weights to the printer module706. In the printer module706, which can include the marking engine120, toner is transferred from an arrangement of developer stations710to a charged photoreceptor roll or belt707to form toner images on the photoreceptor roll or belt707. The toner images are transferred to the media704fed through a paper path, such as the media transport110. The media704are advanced through a fuser712, which can include the fusing member130, adapted to fuse the toner images on the media704. The inverter module714manipulates the media704exiting the printer module706by either passing the media704through to the stacker module716, or by inverting and returning the media704to the printer module706. In the stacker module716, the printed media704are loaded onto stacker carts717to form stacks720.

Embodiments can minimize the misalignment between a media motion and/or travel direction and the fuser roll axis to minimize the cutting and or wiping action of the media as it passes through the fuser nip. Embodiments can include a motion sensor, feeding both x-axis and y-axis media travel information, a prime mover that adjusts the fuser alignment to the media, and a control system to control the position of the fuser based upon the sensor signal and to control the ability to align the fuser to media travel motion.

Some embodiments can fix a fuser assembly at one end and provide a prime mover to adjust the opposite end of the fuser assembly so the fuser roll axis can be moved relative to a media alignment direction. These embodiments can make the fuser steerable and the axis of the fuser roller can be adjusted to achieve perpendicularly with the media path.

According to some embodiments, the use of an optical paper motion sensor can provide the true vector of paper motion. Both y-axis process direction velocity and x-axis cross-process direction velocity can be supplied and then used to calculate the travel angle of the media. Travel angle information can be fed back to a fuser location adjuster, which can adjust the fuser roll axis to square it to the media travel direction prior to the media arrival at the fuser nip. This process can correct the paper angle relative to the fuser.

According to some embodiments, the sensor can be used as a field set up tool, to determine the angle and the fuser can be manually adjusted to achieve better alignment. Also, the media travel direction prior to entering the nip can be compared with the media travel direction after media is in the nip and the fuser position can be adjusted to minimize the shift in direction due to misalignment.

Some embodiments can compensate for the skew induced by an anti-wrinkle flair built into a fuser system where the pressure roller is larger on the ends then in the middle. Such anti-wrinkle compensation can lead to the fuser passing media sheets through at the edges faster than in the center, which can stretch out the sheets to prevent wrinkle in moisture damaged sheets. However, since the sheet is edge registered, having too much anti-wrinkle flair on narrow media can lead to problems on wide sheets with a non-uniform velocity profile within the nip, where the flair is reduced at the non-registered end from the ideal except for the widest sheets. The non-uniform flair can lead to skewing of the sheets in the nip when narrow media is passed. This can also increase the edge wear damage of the fuser roll. Embodiments can adjust the amount of skew compensation based upon media width. For example, for wide media, full correction can be made. For narrower media, a compromise angle can be used to compensate for the anti-wrinkle skew induced in the travel path.

While this disclosure has been described with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. For example, various components of the embodiments may be interchanged, added, or substituted in the other embodiments. Also, all of the elements of each figure are not necessary for operation of the embodiments. For example, one of ordinary skill in the art of the embodiments would be enabled to make and use the teachings of the disclosure by simply employing the elements of the independent claims. Accordingly, the preferred embodiments of the disclosure as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure.