Forms Stacker Jam Detector

1. Field of the Invention

This invention relates generally to high-speed line printers, and more particularly to improved methods and apparatus for detecting paper jams in the forms stacker assembly of such printers.

2. Description of the Prior Art

In the impact printing field, a wide variety of printing techniques have been utilized in the past, including the present type of printer, which uses an endless steel character band having letters of the alphabet as well as numerals embossed thereon. The band is conventionally rotated between a drive pulley and an idler pulley. As the band is driven at high speeds adjacent a platen, a selected hammer contained within a bank or banks arranged parallel with respect to the band and platen is actuated to impact with a particularly desired character upon the band, thereby printing the character on forms passing through the print gate. Once printed, the forms are then fed into a stacker assembly which is typically located at the rear of the printer.

Conventional forms stacker assemblies fan-fold the forms such that they are stacked neatly within the stacker bin. It can be readily appreciated, however, that such fan-folding of the forms may lead to various jam conditions which require intervention on the part of the printer operator as well as considerable printer downtime. Controls are provided in typical forms stacker assemblies not only to indicate when the stacker bin is filled but also to hold the forms compacted in place. Furthermore, various sensors are provided which are capable of detecting when jams occur.

For example, in U.S. Pat. No. 4,054,283, issued Oct. 18, 1977 to Rayfield, a count jam circuit is provided. The stacker receives line strobe signals from the printer indicative of the rate at which paper is fed by the printer to the stacker. In such a manner, the line strobe signals control the rate of oscillation of the chute through which paper received by the stacker from the printer passes between two extreme positions. The distance between the two positions defines the oscillation stroke, which is determined by means of a manually-operable selector to be a function of the form length of the paper to be stacked. Paper is then stacked on a pedestal or elevator which is incrementally movable between top and bottom positions. A stack sensor is also provided which senses the top of the stack and causes the pedestal to move toward the bottom position so as to maintain the distance between the chute and the top of the stack relatively constant.

It has also been known in the past to vary the speed of the elevator in accordance both with the speed of the printing and with the thickness of the paper so that the elevator continuously moves at a predetermined speed. Other techniques involve the use of photocells for detecting the position of materials within the stacker bins. However, in U.S. Pat. No. 4,213,601, issued July 22, 1980 to Cattorini et al., and assigned to the assignee of the present invention, simple mechanical sensors are used to generate electrical pulses which operate the elevator in accordance with signals generated by the printer's microprocessor. Exemplary of other mechanical approaches are those printers which utilize a reed or lever to sense misfolded forms.

Another prior art optical system for jam detection is also utilized in the Impact 5000 Series printers manufactured by Documation Incorporated, now StorageTek Printer Corporation, a subsidiary of Storage Technology Corporation. In such printers, a photoemitter and sensor receiver are placed on opposite sides of the stack, and are offset such that a signal transmitted through the photoemitter is interrupted by every other fold in the forms. When a predetermined number of "top of forms" are observed by the printer without the optical sensor's changing state, a stacker jam is flagged. Similar optical sensors are utilized to directly monitor the paper stack in the Model 4248 printers manufactured by the IBM Corporation.

Each of the above described prior art jam detectors suffer from similar disadvantages. For example, the mechanical approaches can easily become entangled with the paper thereby resulting in either damaged forms or printer parts. The optical sensors' performance, on the other hand, has proven in the past to be marginal due to their relative position within the forms path. That is, typical prior art jam detectors having optical sensors position those sensors within the stacker bin. Such positioning of the sensors leads to the discovery of a problem long after jam begins. It would, therefore, be desirable to provide an improved jam detector which does not suffer from the above described disadvantages.

Accordingly, it is a general object of the present invention to provide improved methods and apparatus for detecting paper jams in the forms stacker assembly of a high-speed line printer. More specifically, it is an object of the present invention to provide methods and apparatus for detecting paper jams in the forms stacker assembly of such printers, wherein such methods and apparatus disable the printer upon detection of the jam in order to cause the printer to stop printing and alert the printer operator of such jams.

Another object of the present invention is to provide methods and apparatus for detecting jams in the forms stacker assembly of high-speed line printers which are adaptable to lightweight paper.

Still another object of the present invention is to provide methods and apparatus for detecting jams in the forms stacker assembly of high-speed line printers which reduce printer downtime.

Briefly, the above objects are accomplished in a high-speed line printer having a forms stacker assembly with powered rollers feeding the forms exiting the printer to a stacker bin by a stacker jam detector which includes a novel photosensor system. The system according to the present invention includes an emitter which sends a beam of light towards a reflective surface, the reflected beam being sensed under normal conditions by a receiver. Means for interposing the beams, thereby indicating an abnormal condition such as misaligned paper or a stacker jam, is positioned within the forms stacker assembly such that the misaligned paper activates the interposing means to thereby disable the printer. In such a manner, printing is quickly stopped, the printer operator is alerted, and damage to the forms or printer parts is minimized.

The above and other objects, advantages, and novel features according to the present invention will become more apparent from the following detailed description of a preferred embodiment when considered in conjunction with the accompanying drawings wherein:

FIG. 1 is a generalized block diagram of a typical high-speed line printer;

FIG. 2 diagrammatically illustrates the paper forms path in the printer shown in FIG. 1;

FIG. 3 shows in greater detail the forms stacker assembly illustrated in FIG. 2, including a forms jam detector according to the present invention; and

FIG. 4 illustrates a preferred method of detecting jams in the forms stacker assembly shown in FIG. 4.

Referring now to the drawings, wherein like characters designate like or corresponding parts throughout the several views, there is shown in FIG. 1 a typical high-speed line printer 10, such as the Impact 5000 Series printer, manufactured by Documation Incorporated, now StorageTek Printer Corporation, a subsidiary of Storage Technology Corporation. The printer 10, as is conventional, receives commands and data to be printed from a host system 12 through an input/output (I/0) interface 14. Such commands and data are then processed by control electronics 16 which includes an interface co-processor 18, a machine coprocessor 20, and a hammer control processor 22 for each of the banks 24 of hammers 26 which are arranged parallel to a rotatable (in the direction shown by the arrows) print band 28. The control electronics 16 also includes a forms control buffer (FCB) 30, a universal character set buffer (UCSB) 32, and a print line buffer (PLB) 34.

Power required for the printer 10 is provided by a three-phase power supply 36, while necessary cooling and vacuum is provided by a cooling and vacuum subsystem 38. A printer operator (not shown) may selectively control the printer 10 through front and rear control panels 40a and 40b. After printing is performed upon the forms 42, the forms 42 are conventionally fed to a processor controlled powered stacker or forms stacker assembly 44. Further details relating to the operation and control of the Impact 5000 Series printers may be found in the following Documation Incorporated manuals, each of which are incorporated herein by reference: "Theory of Operation" --3800014155; "Product Description Manual" --EP-026-0; "Operator's Manual" --3800014171; "Maintenance Manual" --3800014131; "Interface Feature Manual" --3800014159; "Installation Manual" --3800014151; "Illustrated Parts Catalog" --3800014141; and "Schematics" --3800014161.

An explanation of a typical path through which the paper forms 42 traverse will now be made with reference to FIG. 2. The forms path through the printer 10 starts at a forms loading area 46 below the printgate assembly 48. Thereafter, forms tractors 50 draw the paper forms 42 over a top paper bail 52, down a rear paper bail 54, through a forms guide 56 and into the forms stacker area 58. The forms stacker assembly 44 includes such forms guide 56 and the forms stacker are 58.

As shown in greater detail in FIGS. 3 and 4, the forms stacker assembly 44 consists generally of a fixed stack, automatically ascending powered roll unit. Compacting paddlewheels or paddlewheel assemblies 60 assist in maintaining an orderly paper stack 62 as is well known. Operator assistance is required for initial loading, adjusting fold length, setting platform bracket up or down and unloading the forms stacker assembly 44, but other functions may be controlled automatically with the front and rear control panels 40a and 40b through the control electronics 16 (FIG. 1).

As is conventional, the forms stacker assembly 44 is housed within the rear of the main enclosure of the printer 10 as an integral art of its cabinet. Often times, the forms stacker assembly 44 is enclosed by a clear door (not shown) which minimizes sound transmission from the cabinet. The compacting paddlewheels 60, as well as a conventionally-powered feed roller 64 and idler roller 66 which receive the paper forms 42 exiting from the forms guide 56 (FIG. 2) and forward it to the forms stacker area 58, are enclosed within the forms guide 56 which ascends or descends by automatic control to track with the changing height of the paper stack 62. As is readily apparent from FIG. 3, the paper stack 62 is folded by the paddlewheels 60 in an orderly manner. It should be noted at this juncture that use of the terms "feed roller" and "idler roller" apply equally as well to high-speed line printers which employ a feed roller means and idler roller means comprised of a plurality of such rollers.

If the paper stack 62 is randomly built up due to a misalignment of the paper forms 42 as shown in FIG. 4, the printer 10 may become jammed. Accordingly, a forms jam detector is used to disable the printer 10, alert the printer operator, and prevent damage either to the paper forms 42 or the various components of the printer -0. As shown in FIG. 3, when the paper forms 42 are stacking properly, a light beam E emitted by a conventional photoemitter 68 is reflected by means 70 causing a reflected beam R to be received by a conventional photoreceiver 72. Furthermore, in accordance with one important aspect of the present invention, the forms jam detector includes a means 74 for interposing the emitted light beam E, thereby precluding the reflection of the reflected beam R by the reflective means 70. For whatever reason, when the paper stack 62 randomly builds up as shown in FIG. 4, a portion 42a of the paper forms 42 proximate to the forms guide 56 will be forced upward to displace the interposing means 74 upward across the path of the emitted light beam E.

The reflective means 70 preferably comprises a simple planar mirror as shown in FIGS. 3 and 4, but any suitable reflective surface may be utilized in accordance with the present invention so long as it efficiently reflects the emitted light beam E. Alternatively, the use of a reflective means 70 may be eliminated if the photoreceiver 72 is positioned opposite the photoemitter 64, although the preferred arrangement as shown in FIGS. 3 and 4 simplifies the electronics arrangement through the co-location of the photoreceiver 68 and photoemitter 72 on a single logic board 76. The logic board 76, particularly the photoreceiver 72, may thus be conveniently coupled to the control electronics 16 (FIG. 1) such that an output from the forms jam detector according to the present invention will readily disable the printer 10, alert the printer operator through an indication on the front and rear control panels 40a and 40b, and prevent damage either to the paper forms 42 or the various components of the printer 10.

In the preferred embodiment of the present invention, the interposing means 74 comprises a piece of lightweight, opaque plastic tubing suspended upon a tab portion 56a of the forms guide 56. The interposing means 74 is, thus, displaceable upwards to block the path of the emitted light beam E through a minimum amount of force exerted by the portion 42a of the paper forms 42. A typical amount of such force is approximately from one to two grams with a conventionally thin paper form 42, although greater or lesser amounts of force may be compensated for through selection of heavier or lighter interposing mean 74.

As is apparent from the foregoing description of the forms jam detector, a method for detecting such jams in the forms stacker assemblies of conventional high-speed line printers may be accomplished in accordance with the present invention by first projecting a beam of electromagnetic radiation, preferably in the form of light, from suitable means. Means for receiving the projected beam are then provided, as well as means for interposing such beam. During normal operations of the forms stacker assembly, the receiving means will receive the projected beam. However, when the forms stacker assembly becomes jammed to cause a misalignment of the paper forms and subsequent upward displacement of the paper forms from their stack, an unstacked portion of the paper forms is utilize to displace the interposing means, block the beam, and diable the printer. Reflective means may also be provided to reflect the projected beam in order to simplify coordination and placement of the projection and receiving means.

Obviously, many modifications and variations of a forms jam detector are possible in light of the above teachings. It is therefore, to be understood that within the scope of the appended claims the present invention may be practiced otherwise than as specifically described herein.