Multidirectionally stepped auto-collator system and method

A apparatus for automatically collating and transferring media sheets exiting an upstream source, comprising:

• a dynamically oriented baffle having a plurality of stepped bins, each stepped bin slidingly arranged adjacent another one of the plurality of stepped bins and having a longitudinal surface to receive a first set of the media sheets deposited thereon, the dynamically oriented baffle configured to first shift the plurality of stepped bins vertically and change height with respect to an adjacent stepped bin, the first shift of the stepped bins resulting in the plurality of stepped bins having a first stair configuration descending in a first direction;
• a compiler positioned along the processing path between the upstream source and the dynamically oriented baffle, the compiler being operatively connected to the dynamically oriented baffle, the compiler configured to receive the media sheets exiting the upstream source and to temporarily hold the media sheets, and following one of the first operation and the second operation, the compiler further configured to release the held media sheets to the dynamically oriented baffle;
• an automated reciprocating pusher configured for automatic bidirectional movement in a cross process direction to the deposited media sheets, wherein, in response to detecting that the first set of the media sheets have settled into the bins for collation thereof, the automated reciprocating pusher is configured during a first operation to move the first set of the media sheets in the first direction from the stepped bins in the first stair configuration into a first compiled collated stack at a first position;
• the dynamically oriented baffle further configured to dynamically second shift the stepped bins vertically and change vertical orientation with respect to the adjacent stepped bin, the second shift of the stepped bins resulting in the plurality of stepped bins having a second stair configuration descending in a second direction opposite the first direction, the longitudinal surfaces of the stepped bins further configured to receive a second set of the media sheets deposited thereon;
• and
• in response to detecting that a second set of media sheets have settled into the bins for collation thereof, the automated reciprocating pusher is further configured during a second operation to move the second set of the media sheets in the second direction from the stepped bins in the second stair configuration into a second compiled collated stack at a second position distanced from the first position, and the automated reciprocating pusher is further configured to move bidirectionally horizontally in the first direction and second direction without vertical movement therebetween.

A method for automatically collating and transferring media sheets exiting an upstream source, comprising:

• providing a dynamically oriented baffle having a plurality of stepped bins, each stepped bin slidingly arranged adjacent another one of the plurality of stepped bins and having a longitudinal surface to receive media sheets deposited thereon, the dynamically oriented baffle configured to first shift the plurality of stepped bins vertically and change height with respect to an adjacent stepped bin, the first shift of the stepped bins resulting in the plurality of stepped bins having a first stair configuration descending in a first direction;
• receiving a first set of the media sheets from the upstream source onto the longitudinal surfaces of the plurality of stepped bins;
• providing an automated reciprocating pusher configured for movement in a cross process direction to the deposited media sheets;
• during a first operation, moving the automated reciprocating pusher in a first direction to move the first set of the media sheets from the stepped bins in the first stair configuration into a first compiled collated stack at a first position;
• and
• dynamically shifting the stepped bins vertically and into a different vertical orientation with respect to the adjacent stepped bin resulting in the plurality of stepped bins having a second stair configuration descending in a second direction opposite the first direction, the plurality of stepped bins further configured to receive a second set of media sheets deposited thereon.