Abstract:
According to aspects of the embodiments, there is provided methods of replenishing at least one consumable in a printer system having at least one channel with a lockout device and an indicator. The embodiments incorporate a solenoid latch on the channel, a channel closed switch and an attention light. When a consumable needs to be replaced, the user scans the new consumable label against a CRUM reader. If it is valid consumable for the printing system, the attention light above the low or empty channel is lit and its solenoid latch is released. The attention light and solenoid latch would be wired in parallel so that whenever the solenoid is energized to allow the channel to be opened, the attention light will illuminate.

Description:
BACKGROUND 
     Disclosed herein are methods to prevent the wrong consumable from being used in a printing device, and in particular to such methods for ensuring that the correct color toner cartridge is replaced in a printing device, as well as corresponding apparatus. 
     It is often desirable to control access to an ink barrel within a printing device in order to safeguard against accidental or unintended addition of ink. This is particularly the case where the wrong ink may be harmful to printing systems. The wrong color ink added to a barrel will contaminate the entire ink system inclusive of the barrel, melter, ink lines and the heads. If this mistake is made, there will be a service disaster. The printing system could be down for days and it could get very expensive in replacement parts. 
     The increase in the number of abilities and features of printers has resulted in tremendously complex electronic and mechanical designs. With more complex designs come more potential problems and more possibilities for operator error. For instance, with the advent of color copying and printing, it is possible for the operator to use the wrong color ink to refill one of the barrels, and unless some type of safe guard mechanism to prevent it is provided, this can have disastrous consequences. The operator can follow certain operational procedures to insure that the correct ink is inserted or introduced to the correct barrel. Unfortunately, even with all of the checks that are provided, it is still possible for the operator to make a serious mistake when refilling the printer with ink. Nothing prevents the operator from trying to fill a full or partially full barrel or toner hopper. The use of color ink like in color laser printer only helps to add another dimension to existing problems. For instance, an operator might not pay attention to the particular color, might simply grab the wrong color, or may even assume that because a particular color is empty, so too must be the black, cyan and yellow in their respective barrels. 
     For the reasons stated above, and for other reasons stated below which will become apparent to those skilled in the art upon reading and understanding the present specification, there is a need in the art for informing an operator that a consumable needs to be replenished and, in particularly, there is a need in the art for a lockout mechanism for controlling access to an ink barrel in a printing system. 
     SUMMARY 
     According to aspects of the embodiments, there is provided methods of replenishing at least one consumable in a printer system having at least one channel with a lockout device and an indicator. The embodiments incorporate a solenoid latch on the channel, a channel closed switch and an attention light. When a consumable needs to be replaced, the user scans the new consumable label against a CRUM reader. If it is valid consumable for the printing system, the attention light above the low or empty channel is lit and its solenoid latch is released. The attention light and solenoid latch would be wired in parallel so that whenever the solenoid is energized to allow the channel to be opened, the attention light will illuminate. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a simplified elevational view of a printing system with machine controller capable for ensuring that the correct consumable is replaced in a printing device in accordance to an embodiment; 
         FIG. 2  illustrates a block diagram of an electronic lockout device that may be used to ensure that the correct consumable is replaced in a printing device in accordance to an embodiment; 
         FIG. 3  is a perspective view of a container or bottle provided with a CRUM tag in accordance to an embodiment; 
         FIG. 4  is a view of the container, tag reader, cover, and lockout device for ensuring that the correct consumable is replaced in a printing system in accordance to an embodiment; 
         FIG. 5  is an illustration of a lockout element with solenoid to move the lockout element in accordance to an embodiment; 
         FIG. 6  illustrates a flowchart of a method for ensuring that the correct consumable is replaced in a printing system in accordance to an embodiment; and 
         FIG. 7  illustrates a flowchart of a procedure for the electronic lockout device in  FIG. 2  when the consumable can replenish a printing system in accordance to an embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Aspects of the embodiments disclosed herein relate to methods for replenishing at least one consumable in a printer system having at least one channel with a lockout device and an indicator, and corresponding apparatus and system. The disclosed embodiments comprise controller, latch mechanism, and attention light for notifying the operator which of the channel has been approved for receiving a consumable. 
     The disclosed embodiments include a printing system comprising at least one marking engine, each of the marking engines selectively receiving at least one consumable which is consumed during rendering of images by the marking engine; a cover with lockout device and indicator positioned on at least one marking engine, wherein the lockout device prevents the introduction of the consumable when in an inactive state and permits introduction of the consumable when in an active state; a reader to read an electronically-readable memory device that identifies the type of consumable in a container; and a controller coupled to the reader, to the lockout device, and to the indicator for controlling which of the least one marking engine can receive the consumable in the container; wherein the indicator when in an active state signals which of the marking engines is permitted to receive the consumable. 
     The disclosed embodiments further include a printing system wherein the lockout device has a lockout element that is positioned to prevent opening the cover at the at least one marking engine from being opened during an inactive state, and is movable to permit the consumable to enter when in the active state. 
     The disclosed embodiments further include a printing system wherein the lockout element comprises circuitry for supplying electrical current to move the lockout element to the permitting position when the lockout device is in the active state. 
     The disclosed embodiments further include a printing system wherein the lockout element has a distal end that is engageable with a barrel at the at least one marking engine to prevent substantial displacement of the container with the consumable into the barrel when the lockout element is in the inactive state. 
     The disclosed embodiments further include a printing system wherein upon placement of the lockout device into the activated state, the distal end of the lockout element is retracted to permit displacement of the consumable into the barrel. 
     The disclosed embodiments further include a printing system wherein the controller further performs disabling any future reading of the electronically-readable memory device on the container when the consumable in the container can replenish the printing system. 
     The disclosed embodiments further include a printing system wherein the controller having an associated memory for storing a replenishing condition, and wherein the controller is configured to send a signal to place the lockout device in the activated state only after the container has been identified to contain a consumable that can satisfy the replenishing condition. 
     The disclosed embodiments further include a method to replenish at least one consumable in a printer system having at least one channel with a lockout device and an indicator comprising a container with a consumable for the printer system, wherein the container has an electronically-readable memory device that identifies the type of consumable in the container; reading the electronically-readable memory device on the container to determine if the consumable in the container can replenish the printer system; and supplying electrical current to the lockout device and indicator to place a lockout device and an indicator in an active state when the consumable in the container can replenish the printer system, thereby permitting the transfer of the consumable through a channel with a lockout device and indicator in the active state; wherein the indicator when in an active state signals which of the at least one channel is permitted to receive the consumable in the container. 
     The disclosed embodiments further include an apparatus to control insertion of color inks into a printing system comprising at least one compartment to receive at least one of the color inks for the printing system, wherein each compartment has a bottle cradle operable to open and close and thereby restrict access to the compartment; an input device operable to receive input from a container with color ink for the printing system; and a controller coupled to the input device and to each bottle cradle and operable to control access to at least one compartment by receiving the input and comparing the input to stored information to generate one of a plurality of results to unlock and identify one of the compartments that can receive the color ink in the container. 
     Embodiments as disclosed herein may also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code means in the form of computer-executable instructions or data structures. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or combination thereof) to a computer, the computer properly views the connection as a computer-readable medium. Thus, any such connection is properly termed a computer-readable medium. Combinations of the above should also be included within the scope of the computer-readable media. 
     Computer-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, objects, components, and data structures, and the like that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described therein. 
     The computer-readable media store instructions that may be executed by a processor to perform various functions. For example, the computer-readable media may store instructions for ensuring that the correct consumable is replaced in a printing system by performing the methods illustrated in  FIG. 6  and  FIG. 7 . 
     The term “printing device” or “printing system” as used herein refers to a digital copier or printer, scanner, image printing machine, digital production press, document processing system, image reproduction machine, bookmaking machine, facsimile machine, multi-function machine, or the like and can include several marking engines, feed mechanism, scanning assembly as well as other print media processing units, such as paper feeders, finishers, and the like. “printing system” can handle sheets, webs, marking materials, and the like. A printing system can place marks on any surface, and the like and is any machine that reads marks on input sheets; or any combination of such machines. 
     The term “print media” generally refers to a usually flexible, sometimes curled, physical sheet of paper, plastic, or other suitable physical print media substrate for images, whether precut or web fed. 
     The term “container” includes any container in which something is packed for storage or transportation. It is contemplated that the container may include one or more: envelope, a wrapper, a pallet, a carton, a can, a jar, a tray, a trunk, a sleeve, a cargo container, and the like. 
     The term “bottle cradle” generally refers to a station at a compartment that houses a developer for a printing system. The bottle cradle control access to the compartment so as to prevent the material in the compartment from contamination or unauthorized depletion. 
     The term “marking engine” generally refers to a device for applying an image to print media. The exemplary printing system may include marking engines and a variety of other components, such as finishers, paper feeders, and the like, and may be embodied as a copier, printer, or a multifunction machine. 
     The term “consumable” refers to anything that is used or consumed by an imaging device during operations, such as print media, developer material, marking material, cleaning fluid, and the like. 
     The term “compartment” as used herein means a section or zone into which the developer of a particular color in a printing system has been divided or merely identified or labeled as such. Such compartments can be in fluid communication with another compartment of a printing system. For example, a compartment can be a container or barrel that can be partially or entirely physically separated from a second compartment, but comprises pipes or other means for fluid communication with a second compartment. 
       FIG. 1  is a simplified elevational view of a printing system  100  with machine controller capable for ensuring that the correct consumable is replaced in a printing device in accordance to an embodiment. 
     The illustrated printing system  100  is a direct-to-sheet, continuous-web, phase-change ink printer suitable for implementing aspects of the exemplary method. It is to be understood that other types of printers are contemplated. A very long (i.e., substantially continuous) web W of “substrate” (paper, plastic, or other printable material), supplied on a spool, is unwound as needed, propelled by a variety of motors (not shown). The web W moves through a printing station including a series of marking stations or print heads, each print head effectively extending across the width of the web and being able to place ink of one primary color directly (i.e., without use of an intermediate or offset member) onto the moving web, and an image processor (not shown) that sends image data to each print head. As is generally familiar, each of the four primary-color images placed on overlapping areas on the web W combine to form a full-color image, based on the image data sent to each print head. There may be multiple print heads for each primary color; the print heads can each be formed into a single linear array; the function of each color print head can be divided among multiple distinct print heads located at different locations along the process direction; or the print heads or portions thereof can be mounted movably in a direction transverse to the process direction P, such as for spot-color applications. In larger printing environment there could be for example sixteen (16) banks each containing four print heads per bank. In such a printing system there would be a total of 84 print heads. 
     The illustrated printing system  100  incorporates a media roll input  175 , media roll input adapter, multiple printing modules  170 , a media roll output adapter and a media roll output  180 . The printing system uses individual ink barrels  160 , one for each color, located in at or near the printing modules  170 . The ink barrels each have a lid  420  or bottle cradle  130  comprising an indicator light, slide valve, and solenoid latch on the slide valve as shown in  FIG. 2  and  FIG. 5 . Optionally the bottle cradle  130  could include a CRUM reader in communication with a controller. A container reader  110  contains a coupler that can read and/or write electronic data from the tag on container so that it could be processed by a control system  210 . The multiple print modules  170  includes processing components distributed over the printing system  100  and includes a marking engine controller (not shown) such as a CPU, associated with each marking engine (not shown), which includes actuators for controlling each of the subsystems, and an overall control system  210 , which communicates with the individual marking engine CPUs. The marking engine controller is linked to the system controller  210  and may be also linked to other known components, such as a memory, a marking cartridge platform, a marking driver, bottle cradle, a function switch, a self-diagnostic unit, all of which can be interconnected by a data/control bus. Details of controller function in a printing environment can be found, for example, in U.S. Pat. No. 7,665,817 to Falkins, the disclosure of which is hereby incorporated by reference in its entirety. 
     It should be noted that printing system  100 , shown in  FIG. 1 , is merely an example of a system to which the present technology may be advantageously applied. The present technology is not limited to this system and in fact, contemplates application to and implementation in any type of system in which multiple replaceable unit exist. Additional non-limiting examples of systems to which the present technology may be applied include xerographic or other photocopiers, paper handlers, document finishers, scanners, printers, fax machines, and the like. In addition, one of skill in the art would recognize that the present technology is not limited to implementation with programmable devices. Although, for simplicity, this document uses the term programmable device, it is to be understood that the present technology may be implemented relative to any type of software or firmware based processor, such as microcontrollers, microprocessors, computer systems, and the like, and that the term programmable device encompasses any such software or firmware based processor. 
       FIG. 2  illustrates a block diagram of an electronic lockout device  200  that may be used to ensure that the correct consumable is replaced in a printing device in accordance to an embodiment. The electronic lockout device consists of a controller  210 , a container reader  110 , a driver  235  circuitry for supplying electrical current to a latch solenoid  260  with light emitting device (LED)  270  combination, and a switch  240  such as an open/close switch at each cover. The function of the controller could be performed by machine controller as described in  FIG. 1 . As shown in  FIG. 2 , a separate controller could be employed provided that a processor  230  and a memory  220  are included to perform in combination the data processing. Processor  230  compares the input from container reader  110  to stored information, e.g. consumable type and quantity, to generate one of a plurality of results, e.g. open the slide valve or request another container, to unlock and identify one of the compartments that can receive the color ink in container  106 . 
     Processor  230  may include at least one conventional processor or microprocessor that interprets and executes instructions. The processor  230  may be a general purpose processor or a special purpose integrated circuit, such as an ASIC, and may include more than one processor section. Additionally, the controller  210  may include a plurality of processors  230 . 
     Memory  220  may be a random access memory (RAM) or another type of dynamic storage device that stores information and instructions for execution by processor  230 . Memory  220  may also include a read-only memory (ROM) which may include a conventional ROM device or another type of static storage device that stores static information and instructions for processor  230 . The memory  220  may be any memory device that stores data for use by controller  210 . 
     The controller  210  may perform functions in response to processor  230  by executing sequences of instructions or instruction sets contained in a computer-readable medium, such as, for example, memory  220 . Such instructions may be read into memory  220  from another computer-readable medium, such as a storage device, or from a separate device via a communication interface, or may be downloaded from an external source such as the Internet (not shown). The system may be a stand-alone system, such as a personal computer, or may be connected to a network such as an intranet, the Internet, and the like. Other elements may be included with the system  210  as needed. 
     The container reader  110  contains a coupler that can read and/or write electronic data from the tag on container  106 . The container reader  110  is any device that generates a modulated, electromagnetic carrier signal to be received by a tag, and receives data from the tag by detecting loading effects on the carrier signal. Similarly, a tag is any device that receives a modulated, electromagnetic carrier signal transmitted by a reader and superimposes data onto the carrier signal by load variation. 
     The processor receives an identification of the content in a container through container reader  110 , the processor using instructions and information from memory  220  then decides whether a latch solenoid for a compartment (Cover 1  . . . CoverN) should be energized thus allowing the content of the container to be received and used by a printing system. The compartments for each barrel is protected by a bottle cradle  250  that comprises an indicator light, slide valve, and solenoid latch on the slide valve for controlling access to the compartment. In the simplest case the instruction can be “IF” the content is ink “M” and a low or empty signal for ink “M” has been received “THEN” energized and illuminate, through driver  235 , the appropriate cover such as CoverN. Other function could be performed such as crediting pixels to the print head that receives the ink, disable the reading of the tag in the container, disable the reading of other tags until a reset signals like re-closing of the cover, and other functions that are well known to CRUM users in the printing arts. An open/closed switch  240  would signal processor  230  that the particular dump valve has been opened and closed by the operator. As noted above the consumables can be housed in compartments arranged in bottle cradle  250  of the printing system. 
       FIG. 3  is a perspective view of a container or bottle provided with a CRU tag in accordance to an embodiment.  FIG. 3  shows a cylindrical container or bottles  106  suitable for packaging a liquid product, such as ink, for example, wherein the container is provided with a tag  112 . In one case, the tag  112  is affixed to the side wall  120  of the container  106 , but it could also be affixed to a removable cap  116 . The cap  116  itself is of a conventional design having generally cylindrical side walls and a generally flat top surface. The tag  112  including its associated tag antenna  122  is affixed, imbedded or imprinted on the surface  120  of the of the container  106 . The ink container  106  is generally stored in a separate bottle within a printing machine or storage area along with its tag  112  that is generally affixed on the side wall  120  of the container  106 . The tag contains data relative to the ink product and can be ascertained using a reader. The tag  112  is an electronically-readable memory device, which is configured as a CRUM (Customer Replaceable Unit Monitor). The memory core in each CRUM (tag)  112  retains data relevant to the identification, function, color, and performance of the respective ink in the container  106 . Because it includes a non-volatile memory, the CRUM  112  can act as a “scratch pad” for retaining the data stored therein, which travels with the ink, even when the ink are not installed in the printing system  100 . If the controller  210  determines that the consumable in container  106  can replenish the printing system, the controller  210  communicates with the CRUM  112  affixed to the container  106 , via a coupler in container reader  110 , to disable the CRUM  112 , thereby preventing reuse of the CRUM  112  in another container. 
       FIG. 4  is a view of the ink barrel, tag reader, cover, and lockout device for ensuring that the correct consumable is replaced in a printing system in accordance to an embodiment. The compartments for each ink barrel  410  is protected by a bottle cradle that comprises an indicator light or LED  270 , slide valve or slide cover  450 , and solenoid latch on the slide valve for controlling access to the compartment. The illustrated embodiment includes a dedicated CRUM reader or container reader  110 . The container  106  with a tag is irradiated by the coupler in container reader  110  to ascertain the type of consumable therein. A light emitting device  270  such as an LED and a lockout/locking device such as a solenoid latch  260  are energized when the content in container  106  meets a predetermined criterion. The solenoid latch  260  consist of a solenoid coil  445  and distal element  440  that attaches to part of the barrel  410  or lid  420  to prevent entry into the barrel. If the consumable in the container  106  is the type that belongs in barrel  410  then a slide cover  450  on lid  420  is allowed to move and the content in container  106  is able to freely move or drop into barrel  410 . 
       FIG. 5  is an illustration of a lockout element with solenoid to move the lockout element in accordance to an embodiment. The lockout element comprises solenoid coil  445  and distal element  440 . A coil is provided to cause distal element  440  to retract when current is passed through solenoid coil  445 . An axis of movement  520  is shown for distal element  440 . The distal element  440 , as shown, moves in the “Y” coordinate of the axis of movement  520 . A spring  510  is held within solenoid coil to maintain distal element  440  in an extended position (outward movement) when not energized. In the extended position, distal element  440  engages a surface such as the cover or barrel to prevent the content of container  106  from being introduced into the barrel. In this way, no current is required by solenoid coil  445  to maintain distal element in the extended position. As such, receiving of outside particles from the canister or the ambient environment is prevented in the absence of any supplied power, i.e., when lockout device is in the inactive state. When electric current is supplied to solenoid coil  445 , the distal element  440  retracts (inward movement) to permit the cap  116  of container  106  to be inserted passed the cover of barrel  410  and to allow the consumable to enter or a metered amount to be dispensed where it may be used by the printing system. When the solenoid coil receives electrical energy the lockout device is in the active state and movement of the slide cover is possible. A switch  240  as described in  FIG. 2  which engages part of the cover. When the operator moves the slide cover  450  a short distance or open/closes the cover it is sensed by the controller. In some embodiments, the signal from an opening switch may be used to prevent operation of the reader and the opening of other covers. In some embodiments, the signal from a closing switch may be used to credit pixel counts and other functions and to disable any future reads of the tag on the container. 
       FIG. 6  illustrates a flowchart of method  600  for ensuring that the correct consumable is replaced in a printing system in accordance to an embodiment. Method  600  begins with a computing device like controller  210  or machine controller  36  listing for low consumable condition  610  for a printing system like printing system  100  (press) in  FIG. 1 . The listening continues until a low consumable condition such as an empty barrel or within a certain amount indicative of a lack of resources to perform a particular print job. In the case where the consumable is a developer like ink, the processing system, controller  210 , can ascertain using pixel credits from a memory in printing system  100  an indication as to the quantity of consumable needed to replenish a particular ink barrel. When a low consumable condition is found control is then pass to action  620 . In action  620 , the operator is notified of the low consumable condition. The notification includes the color and the location of the consumable that registered the low consumable conditioned. It should be understood that when only one barrel per color is used then a color will suffice as notification for both type and location. However, when multiple barrels of the same color are used then the operator is notified as to the position of the low consumable condition. 
     In action  630 , the tag on the container selected by the operator to replenish the low consumable condition is scanned using a reader like container reader  110 . As noted earlier the electronically-readable memory device (tag) on the container has information like the color and other identifiers. Control is then passed to action  640  for evaluation of the information in the tag relative to the low consumable condition. For example, the tag may indicate that the operator just scanned a yellow solid ink bottle with “X” liters of ink. The low consumable condition may have indicated that yellow solid ink bottle with “X” liters of ink was needed to replenish the printing system. Control is then passed to action  650  for further processing. 
       FIG. 7  illustrates a flowchart of a procedure for the electronic lockout device in  FIG. 2  when the consumable can replenish a printing system in accordance to an embodiment. In action  650  the computing device determines if the consumable in the container just scanned by the operator can replenish the printing system. If the computing device determines that the selected container has the ink needed for the printer based on the low solid ink condition then control is passed to action  670  for further processing. However, if the answer is “NO” because the color in the container does not match the low solid ink condition then action  660  causes the computing device to generate a message notifying the operator to select another container that can replenish the printing system. 
     In action  670 , the computing device energizes the solenoid latch and the attention light at the barrel of the low solid ink condition. The computing system then waits until the solid ink has been added to the printing system. In action  675  the controller listens for an open event and a close event as indicated by the open/close switch  240  described in  FIG. 2 . Control is then passed to action  680  and  690  for further processing. In action  680 , the tag on the container is disabled and information is added to the memory of the printing system. In action  690  control is returned to action  610  where the computing device listens for another low solid ink condition. 
     It will be appreciated that various 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.