Abstract:
A printing system for printing images onto copy sheets and tab stock includes a media registration transport for transporting a media sheet along a path. The printing system further includes a sensing system having a plurality of sensors positioned in line and orthogonal to the feed direction of the sheet path for detecting a leading edge of the media sheet. A control system provides for detecting signals at the times when each of the plurality of sensors are occluded and a control algorithm compares every one of the sensor signals with each other of the sensor signals. The system then identifies at least one pair of sensor signals having inconsistent readings with the other of sensor signals and, determines the presence of a tab on the leading edge based on the inconsistent sensor signal readings and calculates sheet skew based on the other sensor signals.

Description:
BACKGROUND  
       [0001]     The present exemplary embodiments relate to a printer apparatus or the like, and more particularly, to printing on tab stock, i.e., heavy weight media or sheets having an irregular, protruding portion on one edge thereof, with such a printer.  
         [0002]     Duplex printing of tab stock requires feeding the tab stock with the tab edge leading from through the registration transport. This requirement is incompatible with machines using stalled roll deskew registration as shown, for example in U.S. Pat. Nos. 3,949,979 and 4,128,327. No provision is made in the systems of these patents for providing deskew of tab stock.  
         [0003]     Other existing printing products can print tabs in duplex mode by using an edge registration system, i.e. the sheets are biased against their top or bottom edge using a cross-roll or other edge registration system.  
         [0004]     While still other systems are limited to printing tab sheets in simplex mode only; such as, for example where two sensors are used to detect lead edge skew and an electronic (or differential drive) mechanism is used to deskew the sheets. If the tabbed sheets were inverted for printing on side two, the tab would be on the leading edge of the sheet which would create problems when the lead edge passed the two skew sensors. Also, since only two point sensors are used, and they must be located to detect the smallest size media handled by the system, the accuracy of the skew reading is compromised when the larger baseline media is being used.  
         [0005]     Accordingly, disclosed herein is a printer including a registration media sensing system that can handle tabbed sheets, even with the tab leading (on the leading edge). The system makes use of multiple sensors, for example point sensors, to detect the presence of a tab and to determine the lead edge skew of the sheet.  
         [0006]     The disclosed apparatus may be readily operated and controlled in a conventional manner with known or conventional copier or printer control systems, operated as taught herein. Some additional examples of various prior art copiers with document handlers and control systems therefore, including sheet detecting switches, sensors, etc., are disclosed in U.S. Pat. Nos. 4,054,380; 4,062,061; 4,076,408; 4,078,787; 4,099,860; 4,125,325; 4,132,401; 4,144,550; 4,158,500; 4,176,945; 4,179,215; 4,229,101; 4,278,344; and 4,475,156. It is well known in general and preferable to program and execute such control functions and logic with known software instructions for known microprocessors. This is taught by the above and other patents and various commercial copiers. Such software may of course vary depending on the particular function and the particular software system and the particular microprocessor or microcomputer system being utilized, but will be available to or readily programmable by those skilled in the applicable arts without undue experimentation from either verbal functional descriptions, such as those provided herein, or prior knowledge of those functions which are conventional, together with general knowledge in the software and computer arts. Controls may alternatively be provided utilizing various other known or suitable hard-wired logic or switching systems.  
         [0007]     As shown in the above-cited art, the control of exemplary document and copy sheet handling systems in copiers or printers may be accomplished by conventionally actuating them by signals from the copier controller directly or indirectly in response to simple programmed commands and from selected actuation or non-actuation of conventional copier switch inputs by the copier operator, such as switches selecting the number of copies to be made in that run, selecting simplex or duplex copying, selecting whether the documents are simplex or duplex, selecting a copy sheet supply tray, etc. The operator inputs and controls, and machine internal controls or limits, may be coordinated and/or made interactive with operator displays and “prompts” or instructions; e.g., U.S. Pat. No. 4,332,464 issued Jun. 1, 1982 regarding the Xerox Corporation “5700” printer. The resultant controller signals may conventionally actuate various conventional electrical solenoid or cam-control led sheet deflector fingers, motors or clutches in the copier in the selected steps or sequences as programmed. Conventional sheet path sensors, switches and bail bars, connected to the controller, may be utilized for sensing and timing the positions of documents and copy sheets, as is well known in the art, and taught in the above and other patents and products. Known copying systems utilize such conventional microprocessor control circuitry with such connecting switches and sensors for counting and comparing the numbers of document and copy sheets as they are fed and circulated, keeping track of their general positions, counting the number of completed document set circulations and completed copies, etc. and thereby controlling the operation of the document and copy sheet feeders and inverters, etc.  
         [0008]     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.  
         [0009]     Various of the above-mentioned and further features and advantages will be apparent from the specific apparatus and its operation described in the example(s) below, as well as the claims. Thus, the present exemplary embodiments will be better understood from this description of an embodiment thereof, including the drawing figures.  
       BRIEF SUMMARY  
       [0010]     In one aspect, a printing system is provided for printing images onto copy sheets and tab stock including a media registration transport for transporting a media sheet along a path. The printing system further provides a sensing system having a plurality of sensors positioned in line and orthogonal to the feed direction of the sheet path for detecting a leading edge of the media sheet. A control system provides for detecting signals at the times when each of the plurality of sensors are occluded and a control algorithm compares each one of the sensor signals with each other of the sensor signals. The system then identifies at least one pair of sensor signals having inconsistent readings with the other of sensor signals and, determines the presence of a tab on the leading edge based on the inconsistent sensor signal readings.  
         [0011]     In another aspect, a method of printing is employed including transporting a media sheet along a media registration transport path. The method of printing provides for detecting a leading edge of the media sheet including a sensing system with a plurality of sensors positioned in line and orthogonal to the feed direction of the sheet path adapted to detect signals at the times when at least three of the plurality of sensors are occluded by the leading edge. Each one of the sensor signals can then be compared with each other of the sensor signals in order to identify at least one pair of sensor signals having inconsistent readings with the other of sensor signals. The method thus determines the presence of a tab on the leading edge based on the inconsistent sensor signal readings.  
         [0012]     In yet another aspect, a printing system is provided comprising a media registration transport for transporting a media sheet along a path and a sensing system including a plurality of sensors positioned in line and orthogonal to the feed direction of the sheet path for detecting a leading edge of the media sheet. The system further comprises a control system for detecting trip times when at least three of the plurality of sensors are occluded including a control algorithm for comparing each one of the sensor signals with each other of the sensor signals. The system identifies at least one pair of sensor signals having inconsistent readings with the other of sensor signals and then determines the presence of a tab on the leading edge based on the inconsistent sensor signal readings.  
         [0013]     In still yet another aspect, a printing system is provided comprising a media registration transport for transporting a tabbed media sheet along a sheet path and a sensing system including a plurality of sensors positioned substantially in line and orthogonal to a feed direction of the sheet path for detecting a leading edge of the tabbed media sheet. The system further comprises a control system for detecting trip times when each of the plurality of sensors are occluded including a control algorithm having knowledge of a location of a tab on the tabbed media sheet to determine which sensor signals are to be ignored when calculating sheet skew based on the trip times of the plurality of sensors.  
         [0014]     And still further, a printing system is provide comprising a media registration transport for transporting a media sheet having a tab along a path and a sensing system including a plurality of sensors positioned substantially in line and orthogonal to the feed direction of the sheet path for detecting a leading edge of the media sheet. The system further comprises a control system for detecting trip times when each of the plurality of sensors are occluded including a control algorithm having knowledge of the location and width of the tab on the media sheet and using a correction factor to compensate for the width of the tab when calculating sheet skew based on the trip times of the plurality of sensors. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  shows an exemplary compiler/finisher/set stacker system in a modular unit connected to the output of an exemplary xerographic printer;  
         [0016]      FIG. 2  is a partial plan view of the subject system of the present exemplary embodiments showing in line sensors for sensing tab stock and sheet skew; and,  
         [0017]      FIG. 3  is an example control algorithm utilizing a four (4) point sensor model. 
     
    
     DETAILED DESCRIPTION  
       [0018]     Describing now in further detail the exemplary embodiment with reference to the  FIG. 1 , there is shown a duplex printer reproducing machine  10  by way of one example of an apparatus in which the particular disclosed apparatus of the present exemplary embodiments may be utilized.  FIG. 1  shows a schematic front elevational view of one example of a subject finishing system, station, or module  12  incorporating an exemplary sheet compiling station or system  40 , an (optional) finisher example of a conventional set stapler (not illustrated), and an exemplary compiled sets stacking tray system  42 . The finishing system  12  is shown here in  FIG. 1  directly adjacent to (or integral) an exemplary high-speed, high-volume document creating apparatus  10 , such as, for example, the xerographic printer shown here, from which a series of printed sheets with image reproductions thereon may be directly fed seriatim to the finishing system  12  for production of desired sets of these printed sheets, normally collated sets.  
         [0019]     Referring further to the  FIG. 1  printer  10 , as in other xerographic machines, and as is well known, an electronic document or an electronic or optical image of an original document or set of documents to be reproduced may be projected or scanned onto a charged surface  13  of a photoreceptor belt  18  to form an electrostatic latent image. Optionally, a document handler  20  may be provided to scan at a scanning station  22  paper documents  11  fed from a tray  19  to a tray  23 . The latent image is developed with developing material to form a toner image corresponding to the latent image. The toner image is then electrostatically transferred to a final print media material, such as paper sheets  15 , to which it may be permanently fixed by a fusing device  16 . The machine operator may enter the desired printing and finishing instructions through the control panel  17 , or, with a job ticket, an electronic print job description from a remote source, or otherwise.  
         [0020]     The belt photoreceptor  18  here is mounted on a set of rollers  26 . At least one of the rollers is driven to move the photoreceptor in the direction indicated by arrow  21  past the various other known xerographic processing stations, here a charging station  28 , imaging station  24  (for a raster scan laser system  25 ), developing station  30 , and transfer station  32 . A sheet  15  is fed from a selected paper tray supply  33  to a sheet transport  34  for travel to the transfer station  32 . Transfer of the toner image to the sheet is effected and the sheet is stripped from the photoreceptor and conveyed to a fusing station  36  having fusing device  16  where the toner image is fused to the sheet. The sheet  15  is then transported by a sheet output transport  37  to the finishing station  12  where plural sheets  15  may be accumulated to be compiled into superposed sets of sheets and optionally fastened together (finished) by being stapled, bound, or the like.  
         [0021]     In order to ensure that the sheets fed from feed module  20  are accurately aligned with the image on the photoreceptor  32 , a sheet registration transport  100  is located just upstream of the photoreceptor image transfer point. Transport  100  may consist of independently driven rollers  110  and  112  which can be used to deskew and optionally laterally shift the media, and a set of pre-registration transport drive nips  150  and  160  that can open or release to allow the sheets to be deskewed or laterally shifted by drive rolls  110  and  112 .  
         [0022]     The following terms regarding the example here are hereby defined. “UI” is the User Interface, in this case the interactive CRT, or liquid crystal or other operator control console display panel and touch area or switch inputs connected to the system controller. It may also be called a UIT or User Interface Terminal. This is where document handling, or finisher or other machine functions or modes are programmed in by the operator. The disclosed system can be used to determine, for example which of the five document handling modes (Recirculating Document Handler (RDH), (Semi-Automatic Document Handler (SADH), Computer Forms Feeder (CFF), Platen, and Book copying) the operator is trying to use for scanning. E.g., document scanning in Book Mode or CFF Mode are “selected” by the operator at the UIT in this example. ESS is the Electronic Sub-System or system control. IIT is the Image Input Terminal, also called a scanner in this example, but it does more than just image scan here. (Another term for this is EFE or Electronic Front End). IOT is the Image Output Terminal, which writes or prints (with a laser beam) the marks on the (copy) paper. DH is the overall Document Handler, or feeder, also referred to hereinbelow as the “UDH” or universal document handler with both an RDH document stacking tray input and a SADH/CFF document input into which either computer form web (usually fan-fold) feeding (CFF) or large or other individual documents may be loaded and fed.  
         [0023]     As shown in  FIG. 1 , the printer machine  10  and its original document presentation system may be like that disclosed in Xerox Corporation U.S. Pat. No. 6,819,906, issued Nov. 16, 2004 to Herrmann et al. An electronic document imaging system, and a laser scanning system imaging a photoreceptor, may be provided as shown here and in the above cross-referenced applications. Alternatively this may be a conventional optical imaging system. As discussed above, operator inputs and controls and machine internal controls and operator displays and “prompts” or instructions are provided in a controller with displays. The document handler may also be like that in Xerox Corporation U.S. Pat. No. 4,579,444, and the finisher may also be like that shown and described in Xerox Corporation U.S. Pat. No. 4,782,363.  
         [0024]     Referring now to  FIG. 2 , a sheet S is advanced along ingress paper path P 1  which may be any surface over which paper sheets will be passed, into the pair of nip roll pairs  110  and  112 , each respectively comprising driving rollers and idler rollers which frictionally engage sheet S therebetween. The driving and idler rollers are generally provided with an elastomer or plastic surface suitable for substantially non-slipping engagement of sheets passed therebetween. Driving rollers are respectively supported for controllable rotating driving motion on roller shafts  114  and  116 . The shafts  114 ,  116  can be supported at both ends by frame mounted bearings and driven by separate motors (not illustrated). Drive rollers  110  and  112  can be used to deskew or laterally register the sheet S as it is transported along path P 1 , however it should be appreciated that many alternate sheet registration mechanisms can be used in conjunction with the proposed sensing and control scheme.  
         [0025]     Paper path P 1  can be provided with a series of sensors  130 ,  132 ,  134 ,  136 . The sensors can be suitably spaced substantially on a line L arranged generally perpendicularly to the path of paper sheet travel (x-or process direction) along paper path P 1 . In one embodiment the spacing of sensors  130  and  136  can be approximately equidistant from a paper path centerline C. Similarly, the spacing of sensors  132  and  134  can be approximately equidistant from a paper path centerline C, albeit different than spacing  130  and  136 . It will be appreciated that the positioning of the sensors  130 ,  132 ,  134 ,  136  allow detection of a tab T by one of the sensors prior to the other sensors detecting a skew of a leading edge E. Sensors  130 ,  132 ,  134 ,  136  may be comprised of reflective optical sensors which will produce a signal upon occlusion by paper sheets or the like. Other dimensions and positions of the sensors and nip roll pairs with respect to each other are possible. The above description and  FIG. 3  are given as examples only.  
         [0026]     As sheet S enters the deskewing arrangement and is advanced through nip roll pairs  110 ,  112 , the tab T will occlude one of the sensors and the lead edge E will occlude the other sensors. Which sensor is occluded first depends on the location of the tab T. The order in which the other sensors are occluded depends on the direction of skew of the sheet S, and it is entirely possible that the sheet S will occlude a second, third, fourth, etc. sensor substantially simultaneously, thereby indicating no skew in the sheet. In either event, on occlusion, the sensors  130 ,  132 ,  134 ,  136  pass a signal to a controller system as will be described.  
         [0027]     As shown in  FIG. 2 , the leading edge E of the media sheet S encounters sensors  130 ,  132 ,  134 , and  136  positioned in line L downstream of the retard nip. In one example, four sensors are used. After a sheet crosses the sensors, a signal or time stamp from each sensor can be determined. Each sensor signal can be compared with every other signal to determine a skew of the media sheet. By comparing these time stamp signals it can be determined if a tab T has crossed the path of one of the sensors and the input or time stamp values from that sensor can be ignored. The skew of the sheet can then be determined using the remaining or ‘non-ignored’ sensor signals. This can be done in several ways. For example the two farthest apart non-ignored sensors can be used. Alternatively, the average skew from the non-ignored sensor pairs can be used. These methods can yield improved skew measurement accuracy over a conventional narrowly-spaced two sensor system.  
         [0028]     There are many options for how the signal from the sensors can be used to determine the presence of a tab T and the skew of a sheet. Referring to  FIGS. 3 and 4 , one example is to calculate the skew, and compare the signals (i.e. paired comparisons) between sensors  130 / 132 ,  130 / 134 ,  130 / 136 ,  132 / 134 ,  132 / 136 , and  134 / 136 . If the tab T occluded sensor  134 , for example, then the skew from signals  130 / 132 ,  130 / 136 , and  132 / 136  would roughly match, or indicate a skew within a predetermined threshold. On the other hand, the varied, inconsistent, or exaggerated skews from signals  130 / 134 ,  132 / 134 , and  134 / 136  would each be quite different from, less than, or greater than, the predetermined threshold (i.e. close to zero). In one exemplary embodiment, the skew angle defined by sensors  130 / 132 ,  130 / 136 , and  132 / 136  will result in generally the same angle, i.e. angle a. In contrast, the skew angle defined by sensors  130 / 134  will be greater than a. The skew angle defined by sensors  132 / 134  will be much greater than a. And the skew angle defined by sensors  134 / 136  will be much less than a. In this example, the signals involving sensor  134  would be ignored and the sheet skew could then be determined using the time stamps or signal from sensors  130 / 136 , i.e. the farthest apart non-ignored sensor signals. Alternatively, the skew can be determined by averaging the time stamps or signals from sensors  130 / 132 ,  130 / 136 , and  132 / 136 , i.e. all of the non-ignored sensor signals. This calculation could be a straight average of the remaining skew calculations, a weighted average (giving a greater weight to the skew calculated using the farthest apart sensor pair, for example) or another averaging technique.  
         [0029]     Using the configuration described above, the multiple point sensors can also be calibrated using non-tabbed reference sheets to correct for any misalignment of the sensors. In this manner, the multiple sensors can also be used to improve the accuracy of the lead edge skew measurement, even when non-tabbed sheets are being registered. Since the straightness of the lead edge of any given piece of media, and the position of sheet within the baffle, can affect the trip point of a sensor, using three (3) or more sensors to detect the lead edge and averaging the results will yield a more accurate skew measurement than using two (2) sensors.  
         [0030]     It is to be appreciated that the number of point sensors that can be used to perform this function can be less than four, for example three (3), if the amount of incoming skew is limited. For example, if three sensors are in place,  130 ,  134 ,  136 , with sensor  134  now located along the path centerline C, and a tab occludes sensor  134 , then large and inconsistent skew values will be detected when comparing  130 / 134  and  134 / 136 . The signal comparison of  130 / 136  gives a skew value closer to zero or the predetermined threshold. In this case, the algorithm can ignore signal comparisons  130 / 134  and  134 / 136 .  
         [0031]     Alternatively, the system can have precise knowledge of each tabbed sheet (i.e. the exact location of the tab T), as is the case when printing onto the tabs themselves, then again only three sensors can be used, even with large amounts of input skew. For this algorithm, the known location of the tab T results in a known or identified occlusion of one of the sensors. The resultant associated signal can then be ignored from that sensor. The skew is then determined based on the comparison of the two non-ignored sensors.  
         [0032]     Further, knowledge of the location of a tab could result from running a simplex side of a sheet and detecting the location of a tab T of a trailing edge by one of the sensors (not illustrated). After inverting, the location and timing offset (error) of the detected tab T can be correspondingly imposed onto the lead edge skew measurement on the same said one sensor when the tabbed sheet is being run on a duplex side.  
         [0033]     In addition, if the length of the tab was known, then two (2) sensors can be used by adding an appropriate correction factor to one of the signals. It should also be appreciated that a system similar to that shown in  FIG. 2  can be arranged having an array sensor instead of the multiple point sensors. The signal from the array sensor can be used to determine if a tabbed sheet was present by determining a sudden shift in observed lateral position, and if so, ignoring the portion of the signal caused by the tab and determine the lead edge skew of the sheet using trip time data from the non-tabbed portion of the sheet&#39;s leading edge. As described above, sensors  130 ,  132 ,  134 ,  136  provide control signals to the control system to provide sensing information. Operation of the driving rollers can be controlled from the sensing information. Additionally, the controller can drive stepper motors in accordance with the required movement and rotational velocity of the driving rollers (not illustrated). In one typical example, stepper motors can be driven in a halfstep mode, although full step or microstep modes of operation could be used. Motor revolutions can thus be divided into a large number of halfsteps, each halfstep providing an exact increment of rotation movement of the motor shafts, and thus the driving rollers. In accordance with this scheme, a pair of motor driver boards (not shown) provide a pulse train to incrementally drive the motors.  
         [0034]     With reference to  FIGS. 2 and 3 , the deskew process will now be described more specifically. Sheet S having an unknown amount of skew angle a (not illustrated) enters the nip roll pairs and is driven non-differentially thereby, at a constant velocity Vo. As it is advanced, lead edge E passes by and occludes sensors  130 ,  132 ,  134 ,  136 . For the purpose of the deskew process, it will be assumed that tab T occludes sensor  134  and sensor  136  is occluded by lead edge E first. If the two farthest apart sensors are being used to determine skew, sensor  136  provides an occlusion signal to the controller, whereby, the controller commences counting the halfsteps generated by motor driver boards as sheet S is driven non-differentially through the nips by the motors, past sensor  136 , and recording the number of halfsteps counted until sensor  130  also indicates occlusion by sheet lead edge E. As there is assumed to be a linear relationship between the number of motor halfsteps counted and travel by the sheet lead edge E, it can be seen that: 
 
 N=D/K   (1) 
 
 where, 
 
 N=number of motor halfsteps; 
 
 K=a constant equal to the advancement of the driving roller surface for each motor halfstep; and 
 
 D=the difference distance traveled by the portion of the sheet which originally occluded  136  until  130  is occluded. 
 
         [0035]     Thus, it can also be seen that 
 
 a =tan−1( D/Sx )  (2) 
 
 or for small angles 
 
 a=D/Sx   (3) 
 
 where, 
 
 a=the random skew angle of a sheet entering the nips; and Sx=distance between sensors  130  and  136 . 
 
         [0036]     Because K and Sx are constants for a particular registration subsystem, a sufficient measure of the skew angle of the sheet as it enters the registration and deskewing arrangement is simply N, the number of motor halfsteps taken between occlusion of sensor  136  and sensor  130 , while the motors are driven non-differentially. It should be appreciated that instead of counting the number of half steps driven by the motors, the controller could associate a time stamp with each sensor trip event and the distance D could then be calculated based on the average velocity and time difference between two sensor trip events (i.e. trip times). That is, D=V*(Tsenor 136 −Tsensor 130 ), and so forth for each sensor pair.  
         [0037]     With the skew angle a of the sheet known, the sheet is rotated in a selected direction, for example clockwise, looking down on  FIG. 2  to compensate for the skew angle a. This rotation can be accomplished simultaneously with continuing advancement along paper path P 1 . It is to be appreciated that when the sheet first enters the nips, both motors are operating at substantially similar speed to drive the sheet non-differentially at a velocity Vo, at T 1 , sensor  136  is occluded by lead edge E of sheet S, while at T 2 , sensor  130  is similarly occluded. In accordance with the detected random skew angle a of the sheet, one of the motors can be driven at an increased velocity V 2  while another one of the motors can be driven at a decreased velocity V 1 .  
         [0038]     It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. In addition, the claims can encompass embodiments in hardware, software, or a combination thereof.