Abstract:
A solid ink stick loader verifies position and orientation of an ink stick prior to an ink stick identification operation. The solid ink stick loader includes an identification code detector located proximate an ink stick insertion area, the identification code detector being oriented to obtain an identification code positioned on the ink stick in a predetermined location, a first displaceable member located proximate the ink stick insertion area, the first displaceable member being movable between a first position and a second position, a second displaceable member located proximate the ink stick insertion area, the second displaceable member being movable between a third position and a fourth position, and a sensor coupled to at least one of the first displaceable member and the second displaceable member to generate a verification signal in response to the ink stick being in a position and orientation in the ink stick insertion area that enables the identification code detector to obtain the identification code from the ink stick, the sensor being coupled to the identification code detector to provide the verification signal to the identification code detector and enable the identification code detector to obtain the identification code from the ink stick.

Description:
TECHNICAL FIELD 
     The verification system and method described below relate to object identification systems, and more particularly, to ink jet printers that identify solid ink sticks. 
     BACKGROUND 
     Solid ink or phase change ink imaging devices, hereafter called solid ink printers, encompass various imaging devices, such as printers and multi-function devices. These printers offer many advantages over other types of image generating devices, such as laser and aqueous inkjet imaging devices. Solid ink or phase change ink printers conventionally receive ink in a solid form, either as pellets or as ink sticks. A color printer typically uses four colors of ink (yellow, cyan, magenta, and black). The solid ink pellets or ink sticks, hereafter referred to as ink, sticks, or ink sticks, are delivered to a melting device, which is typically coupled to an ink loader, for conversion of the solid ink to a liquid. A typical ink loader includes multiple feed channels, one for each color of ink used in the imaging device. Each feed channel directs the solid ink within the channel towards a melting device located at the end of the channel. Each melting device receives solid ink from the feed channel to which the melting device is connected and heats the solid ink impinging on it to convert the solid ink into liquid ink that is delivered to a print head for jetting onto a recording medium or intermediate transfer surface. 
     Each feed channel may have a corresponding insertion opening to receive solid ink sticks. Alternatively, a solid ink jet printer may have a common insertion port in which solid ink sticks are loaded and then delivered to the channel that corresponds to the loaded ink stick. In both types of loading systems, the ink stick may be identified by detecting encoded indicia on the stick and comparing the detected data to data stored in the printer. The stored data identifies the ink sticks that are configured for use in the printer and the color of the ink sticks. Only if the detected data corresponds to the stored data is an ink stick accepted by the printer or released from the insertion opening or port to a feed channel in the printer. 
     In printers having an insertion opening for each feed channel, keyed openings may be placed over the insertion ports to help ensure a printer user properly places and orients ink sticks of the correct color or series in a feed channel. To accomplish this goal, each keyed opening has a unique shape. The ink sticks of the color corresponding to a particular feed channel have a shape corresponding to the shape of the keyed opening. The keyed openings and corresponding ink stick shapes exclude from each ink feed channel ink sticks of all colors except the ink sticks of the proper color for the feed channel. Unique keying shapes for other factors are also employed in keyed openings to exclude from a feed channel ink sticks that are formulated or intended for other printer models. 
     As the number of pages printed per minute increases for solid ink printers so does the demand for ink in the printer. To supply larger amounts of ink to printers, the cross-sectional area of the feed channels may be increased. Consequently, the insertion openings for the channels and the keyed plates covering the openings are likewise enlarged. These larger openings enable smaller solid ink sticks to pass through without engaging the keyed plates over the openings. Thus, solid ink sticks that do not conform to the appropriate color for a feed channel can be loaded into the feed channel and delivered to the melting device at the end of the feed channel. Even if the smaller stick is the correct color for the feed channel, its size may impair the ability of the stick to cooperate with guiding structure within the feed channel. Likewise, as common insertion ports increase in size, ink stick not configured for use in the printer may be inserted in the port. As long as these sticks have an identification code that corresponds to a code stored in the memory of an identification code detector, these sticks may be used in the printer. Thus, ensuring insertion ports in a solid ink printer are loaded only with ink sticks configured for transport within the feed channel is a desirable goal. 
     SUMMARY 
     A solid ink stick loader verifies position and orientation of an ink stick prior to an ink stick identification operation. The solid ink stick loader includes an identification code detector located proximate an ink stick insertion area, the identification code detector being oriented to obtain an identification code positioned on the ink stick in a predetermined location, a first displaceable member located proximate the ink stick insertion area, the first displaceable member being movable between a first position and a second position, a second displaceable member located proximate the ink stick insertion area, the second displaceable member being movable between a third position and a fourth position, and a sensor coupled to at least one of the first displaceable member and the second displaceable member to generate a verification signal in response to the ink stick being in a position and orientation in the ink stick insertion area that enables the identification code detector to obtain the identification code from the ink stick, the sensor being coupled to the identification code detector to provide the verification signal to the identification code detector and enable the identification code detector to obtain the identification code from the ink stick. 
     A method verifies the position and orientation of an object located in a loading area within a printer prior to reading identification data from the object. The method includes detecting an object to be identified in an area, detecting a feature of the detected object at a predetermined position, and generating a signal indicating position and orientation of the object in the area. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Features for verifying position and orientation of a solid ink stick in particular, and of an object to be identified in general are discussed with reference to the drawings. 
         FIG. 1  is a side view of a solid ink stick interacting with a pair of displaceable members to enable movement of the solid ink stick from an insertion port in a solid ink printer. 
         FIG. 2  is a side view of a solid ink stick interacting with a pair of displaceable members to disable movement of the solid ink stick from an insertion port in a solid ink printer. 
         FIG. 3  is a side view of another solid ink stick interacting with a pair of displaceable members to disable movement of the solid ink stick from an insertion port in a solid ink printer. 
         FIG. 4  is a side view of an embodiment of a displaceable member that interacts with an object to be identified. 
         FIG. 5A  is a simplified side view of an embodiment of a displaceable member that interacts with an object to block movement of a slide. 
         FIG. 5B  is a simplified side view of the displaceable member in  FIG. 5A  in a position to allow movement of the slide. 
         FIG. 6  is a side view of a pair of displaceable members joined by a mechanical linkage in a position that enables a single sensor to generate a signal to enable movement of an object to be identified. 
         FIG. 7  is a side view of a pair of displaceable members joined by a mechanical linkage in a position that enables a single sensor to generate a signal to disable movement of an object to be identified. 
         FIG. 8  is a side view of a pair of displaceable members joined by a mechanical linkage that enables a single sensor to generate a signal to disable movement of an object to be identified. 
         FIG. 9  shows a number of embodiments of ink sticks with verification interlock features that interact with the displaceable members of a verification interlock. 
     
    
    
     DETAILED DESCRIPTION 
     The term “printer” refers, for example, to reproduction devices in general, such as printers, facsimile machines, copiers, and related multi-function products. An exemplary solid ink printer having an insertion port  10  for the loading of solid ink sticks is shown in  FIG. 1 . The solid ink printer may have an insertion port for each feed channel or it may have only one common insertion port from which a solid ink stick, once identified, is moved to the corresponding feed channel. An identification code detector (not shown) obtains an identification code from the solid ink stick in the insertion port. This code is compared to data stored in the printer to determine whether the solid ink stick is configured for used in the printer and the feed channel in which the solid ink stick should be used. The identification code detector may be a single device or an array of code activators, such as optical sources, and an array of code detectors, such as optical receivers, that operate to read an identification code on a solid ink stick. 
     In the port  10 , the solid ink stick  14  is inserted from the left, although other port configurations may be used that permit loading of the solid ink stick from any direction other than the wall  24  in which the displaceable members  18  and  20  are located. The solid ink stick  14  includes a side  28  and a feature  30 . “Feature” refers to a recess or protuberance in a surface of an object having a predetermined position that enables the orientation of the object to be verified by the displaceable members. In  FIG. 1 , the feature  30  is a recess into which displaceable member  20  can extend, although features may be used to provide an indication of an object&#39;s orientation in the insertion port. 
     In order to enable the solid ink stick to be moved from the insertion port  10 , the displaceable members  18  and  20  must be in a predetermined configuration that corresponds to a predetermined position of one side of the solid ink stick and its feature. As shown in  FIG. 1 , the displaceable member  20  must extend into the feature  30  and the displaceable member  18  must be depressed by the side  28  in order for movement of the solid ink stick to be enabled. Thus, insertion of the solid ink stick  14  within the port  10  enables the displaceable member  20  to be fully extended and the displaceable member  18  to be retracted within the wall  24 . The interaction of the solid ink stick with two displaceable members enables the position and orientation of a solid ink stick to be verified as being correct for identification and movement of the solid ink stick. As described below, the two displaceable members may be independent of one other with each one having a sensor for detecting movement of the member. Alternatively, the two members may be coupled to one another, either through a mechanical link or through common structure in an integrated part. 
     Identification of an ink stick as being appropriate or inappropriate for use within a printer enables movement of the identified ink stick from the insertion area. This enablement does not necessarily include movement. Identification may be performed using electronic sensors, positioning and displacement of mechanical arms, links, or other actuators, or decoding of data placed on the ink stick. The results of the identification process may be conveyed to a user with an accept/reject signal that may be displayed or used to generate a visible or audible signal at the printer, such as at a control panel, or remotely, at, for example, a pager or remote terminal. Once the identification results are communicated to a user or operator, the printer may wait for a confirmation signal from the user or operator before opening a gate or operating a conveyor to move the ink stick. Thus, communication of the identification results is required for movement of the ink stick, but does not necessarily cause the ink stick to move immediately. Consequently, the term “enabling movement” or the like is intended to encompass such motionless activities or the like. 
     In  FIG. 2  and  FIG. 3 , two situations are shown that result in the solid ink stick remaining in the insertion port. In  FIG. 2 , the solid ink stick  14 , which can be used in the printer, has been loaded into the port; however, it has not been fully inserted into the port. Consequently, displaceable member  18  has not been sufficiently depressed by the side  28  to enable movement of the solid ink stick. Thus, even if an identification code detector determines the identification code on the solid ink stick corresponds to a code indicating the stick can be used in the printer, the stick will be not moved. This type of operation helps prevent the solid ink stick from becoming jammed if the stick is moved before it is in proper position for movement. For example, if an otherwise proper ink stick is not in the correct position to engage a solid ink transport system coupled to the insertion port, then the displaceable arms prevent attempts to engage the solid ink transport system with the ink stick. In  FIG. 3 , a solid ink stick  40  is one that is not configured for use in the feed channel or printer coupled to the port  10 . This anomaly is detected because the ink stick  40  does not have the feature  30 . Consequently, the displaceable member  20  is depressed rather than extended and movement of the stick is not enabled. 
       FIG. 4  illustrates one embodiment of a displaceable member. The displaceable member  50  includes a series of teeth  54  that engages a gear  58  that is biased by a spring  60  or the like to a position that extends the displaceable member from an insertion port wall. A surface that urges the displaceable member  50  against the biasing force causes the displaceable member  50  to move to the right and the teeth  54  rotate the gear  58  in a counterclockwise direction. A sensor  64  generates a signal in response to the movement of the gear. The number of gear teeth moving past the sensor  64  may be counted to evaluate whether the displaceable member  50  has been sufficiently moved to enable movement of the object acting on the displaceable member. After the ink stick or other object is removed, the biasing on the gear  58  returns the displaceable member to its original position. 
       FIGS. 5A and 5B  illustrates another embodiment of a displaceable member. This configuration includes a displaceable member  70 , a pivoting link  74 , a blocking member  76 , and a lockable slide  78 . The displaceable member  70  is coupled to the pivoting link  74  at one end of the link by pin  82 . A pivot pin  80  is mounted to a rigid structure at the other end of the link  74  so the pivoting link  74  pivots about its pivot pin  80 . In response to the displaceable member  70  being moved to the right, the pivoting link  74  pivots about pivot pin  80  to urge the end of the blocking member  76  into engagement with slide  78  to prevent its movement. Upon removal of the ink stick that moved member  70  towards the slide  78 , the member  70  moves under the influence of a biasing member (not shown) or gravity, if arranged vertically, to the left. This movement pivots link  74  in the clockwise direction link and disengages blocking member  76  from slide  78 . When slide  78  is free to move, its movement may be used to release a movable gate, actuate an ink stick transport, or activate a sensor, for example. Slots  88  and  90  in link  74  enable the movement of the member  74  and blocking member  76  to be coordinated. 
     In the embodiments shown in  FIG. 4  and  FIG. 5 , each displaceable member may be configured with a sensor that generates a position signal. For example, the sensor  64  may be an optical sensor having an optical source and optical detector that are positioned to enable the gear teeth to pass between them. The gaps between the gear teeth enable the light to pass from the source to the detector, while the gear teeth block the light from the source. The changes in the signal generated by the sensor may be counted to determine the amount of movement of the displaceable member to evaluate whether the ink stick is in the correct position and orientation for identification. In a similar manner, a sensor may be positioned with respect to each sensor associated with a displaceable member of the embodiment shown in  FIG. 5  to enable the sensor to generate a signal indicative of the blocking member&#39;s movement. The signal from each sensor for each displaceable member may be provided to a signal position generator, which generates a position indicative of the ink stick&#39;s position and orientation from the two signals generated by the sensors associated with the two displaceable members. For example, flip-flops, or other logic gates may be used to generate a position signal indicating the ink stick is in position for identification in response to the signals from the sensors indicating the displaceable member interacting with the object feature is in the correct position and the displaceable member interacting with the object side is also in the correct position. 
     Another embodiment may enable one displaceable member to interact with a sensor to generate a position signal for use within the printer and the other displaceable member may be coupled to a movable gate to enable movement of a solid ink stick from an insertion port selectively. In all of the embodiments discussed herein, the displaceable members may directly block or enable an identification code detector, a movable gate, or transport device. Alternatively or additionally, the displaceable members may generate signals that are used by a controller to operate a gate, an identification code detector, or transport device in a selective manner. 
     Another embodiment of the displaceable members that enables a single sensor to be used with two displaceable members is shown in  FIG. 6 ,  FIG. 7 , and  FIG. 8 . In  FIG. 6 , the displaceable members  100  and  104  are coupled to one another by a mechanical linkage  110 . The linkage pivots about a pivot pin  114 . The linkage  110  includes a position flag  118 . The position flag moves into and out of a position in which the flag  118  blocks the path between an optical source and an optical detector in an optical sensor  120 . In  FIG. 6 , no object is in an insertion port and the displaceable members  100  and  104  extend to the same length and the flag  118  blocks the light from being received by the optical detector in the sensor  120 . In  FIG. 7 , an ink stick that is configured for use in the insertion port is inserted into the port. When the ink stick has been fully inserted into the port, the displaceable member  100  is moved to the right by the side of the ink stick and the linkage  110  pivots in the counterclockwise direction. This movement extends the displaceable member  104 . If the ink stick has the corresponding recess in the corresponding position, the displaceable member  104  extends into the feature and the flag  118  moves into a position in which the flag no longer blocks the light between the optical source and detector in the sensor  120 . The sensor then generates a position signal that indicates the ink stick is in position for identification. In  FIG. 8 , the recess is not in the correct position to receive the displaceable member  104 . Consequently, the displaceable members  100  and  104  block further ingress of the ink stick into the insertion port and the sensor  120  generates a position signal that indicates the ink stick is not in position for identification. Although the displaceable members are shown in these figures as being coupled to one another through a mechanical link, the displaceable members may be integrally formed in a single component, such as a plastic injection molded part. 
     The position signal generated by any of the embodiments may be used in a number of ways to help prevent ink sticks that are either improperly placed in the port or are not configured for use in the port. For example, the position signal may be used to enable the identification code detector. The position signal may be coupled to the identification code detector and, if the signal indicates the ink stick is in the proper position and orientation for identification, the detector is enabled to obtain the identification code from the ink stick. In another embodiment, the insertion port may include a movable gate that blocks egress of the ink stick from the insertion port to the ink stick transport system. This movable gate is operated by a gate actuator, such as an electrical motor coupled to the gate. The position signal may be coupled to the gate actuator to prevent the actuator from operating the gate to enable movement of the ink stick from the insertion port in response to the signal indicating the ink stick is either not configured for use in the port or not in the correct position or orientation for identification. This embodiment enables the printer to respond to the identification code detector only when the ink stick is in the correct position and orientation for identification. 
     For the two displaceable members to verify position and orientation of an ink stick correctly, the ink stick includes at least two surface features that interact with the displaceable members. While the ink stick may be formed with features specifically incorporated in the ink stick for verification of the position and orientation of the ink stick, the displaceable members may be configured to interact with surface features that exist in current ink stick designs. For example, ink sticks are configured with protrusions and indentations for interactions with feed channel structures. The displaceable members may be arranged in an insertion area to take advantage of accessing the feed channel features for position and orientation verification. Such an arrangement may be most advantageously used in an insertion area for a single channel as an arrangement of displaceable members in a common insertion area for multiple feed channels that accurately interacts with a multitude of different ink configurations may be difficult. In an insertion area that supplies ink stick to multiple feed channels, the ink sticks may be formed with specific verification interlock features. 
     A number of ink stick embodiments depicting various verification interlock features are shown in  FIG. 9 . These ink sticks take advantage of the push-pull operation of the verification interlock to provide the interlock features on the ink stick surface. Specifically, only one protuberance or one indentation is required in the formation of the ink stick to provide a verification interlock feature. For example, ink sticks  900 A,  900 B,  900 C, and  900 D provide a verification interlock feature  904 A,  904 B,  904 C,  904 D, respectively, with a single indentation  908 A,  908 B,  908 C, or  908 D. These indentations interact with the displaceable member being pulled or extended to verify position and orientation. The planar faces  912 A,  912 B,  912 C, and  912 D provide the interaction with the displaceable member being pushed. The indentations  904 B and  904 C indent two planar surfaces of the ink stick, while the insets  904 A and  904 D indent only one planar ink stick surface. In a similar manner, ink sticks  900 E and  900 F provide a verification interlock feature  904 E and  904 F, respectively, with a single protuberance  908 E or  908 F. These protuberances interact with the displaceable member being pushed to verify position and orientation. Planar surfaces  912 E and  912 F interact with the displaceable member being extended. Provided that an ink stick verification interlock features do not adversely impact the integrity of other ink stick features, such as feed channel features, then the verification interlocks may be incorporated in a plurality of ink stick configurations to enable a single insertion port to have the displaceable members installed for interaction with the interlock. 
     Those skilled in the art will recognize that numerous modifications can be made to the specific implementations described above. Therefore, the following claims are not to be limited to the specific embodiments illustrated and described above. The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.