Patent Application
20110231008
The present subject matter relates to techniques and equipment to print documents, inspect the quality of the documents and correct for defective printed material in a document processing system.
Currently in continuous forms printing, there are three common means of recovering from a detected defect in the printed material. For the first method, the printer is stopped and the defective material is manually removed. This method is undesirable due to the high costs of the recovery since the high speed printer is stopped, the printed paper web 112 has to be cut crosswise and the defective material removed. As illustrated in
For the second method, print inspection system allows the defective material to proceed to the winder or fan-folder. Printer systems use marking devices to indicate the zone on the printed paper web or fan folded paper stack where the defect exists. During downstream processes, these zones are removed en masse from the printed material in a manner similar to the first method. The problem with this method is that a considerable amount of material has to be sacrificed to remove a single defect. The third method involves the printer throwing away all or most of the print run and re-printing the job.
Hence a need exists for a print inspection system that can detect a defective page in a document and uniquely identify that page and accompanying pages in the document. The defective document is then flagged for removal by a document processing system without stoppage of the printer, roller or document processing system by removing only the defective document from the production run.
The teachings herein alleviate one or more of the above noted problems by providing a system and method for detecting one or more defective pages in a document and uniquely identifying the document. Once the defective document is flagged, the present system and method can effectively remove the defective document on a document processing system while continuing the document processing run for subsequent documents in a mailing.
It is desirable to provide a method for using print inspection data to control a document processing system for removing a defective document from a mailing. The method includes receiving a data file at a document processing system controller. The received data file contains at least a unique identifier for each document and an indication whether any document is defective. For one of the documents, its associated unique identifier is read using an image processing device associated with the document processing system. A determination is made to determine if the read unique identifier is associated with a defective document. The defective document is removed from the mailing, while continuously processing subsequent documents in the mailing on the document processing system. A data record is created confirming the removal of the defective document.
It is further desirable to provide a print inspection and defect removal system. The system includes print inspection equipment for capturing an image of a plurality of documents for a mailing. A print inspection processor associates each document with a unique identification and determines if any of the documents is defective. A document processing system controller receives a data file containing at least the unique identifier for each document and an indication whether any document is defective. An image processing device associated with a document processing system reads the unique identifiers for each of the documents. The document processing system is configured to process the plurality of documents and remove any defective document from the mailing, while continuously processing subsequent documents in the mailing.
It is yet further desirable to provide a document finishing system. The system includes document finishing equipment for receiving a printed representation of documents for a mailing. A document finishing controller is in operable connection with the document finishing equipment and the document finishing controller is configured to receive a data file containing at least a unique identifier for each document and an indication whether any of the documents is defective. An image processing device is associated with the document finishing equipment and the image processing device reads the unique identifier for each document. The document finishing equipment is configured to process the documents and remove any defective document from the mailing, while continuously processing subsequent documents in the mailing.
Additional objects, advantages and novel features will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following and the accompanying drawings or may be learned by production or operation of the examples. The objects and advantages of the present teachings may be realized and attained by practice or use of the methodologies, instrumentalities and combinations particularly pointed out in the appended claims.
The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.
In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.
Print inspection systems process images of the printed material to evaluate the material at the printing system for a range of defects. Print inspection systems have the native ability to track and report the defective status of a specific print image and associate that status with the identity of the image which is correlated to a page of a document. This data and association is reported to the document factory monitoring system such as the Bowe Bell+Howell BÖWE One system and stored in the system as item data. Using this means of detecting and reporting print defects and storing the information in a central database, the printer can now allow the defective material to proceed to the winder or fan-folder. This maximizes the efficiency of the printing equipment. The printed paper web or fan folded paper is then sent downstream to intelligent document processing equipment as required. Inserters, wrappers and booklet makers are examples of intelligent document finishing systems which manufacture mailpieces. Sorters are another example of intelligent document processing equipment. Each of these document processing systems are equipped with a vision system which includes an image capture and analysis system. The vision system reads unique identifiers on the document pages or mailpieces, identifies each logical page or mailpiece and executes a lookup on the central database to determine if this item has been flagged as defective. If the page or mailpiece has been flagged as defective, the vision system sends the designated commands (in the form of control bits) to the intelligent inserting control system that commands the inserter to selectively divert the material or, alternately, stop or causes the sorter to reject the mailpiece.
The document factory monitoring system allows vision systems to detect, record, and report defects on commercial printers in a manner that allows the printer to continue to run. Since printers generally have no means of precisely removing defective pieces, this new technology allows the printer to access downstream document processing equipment that contains the ability to detect and remove defective pieces. The solution does not create “collateral damage” to non-defective pieces. In other words, the process does not result in removal of pieces that are known to be good.
Reference now is made in detail to the examples illustrated in the accompanying drawings and discussed below.
Referring to
Alternately, document fingerprinting may be utilized for document or page identification. Document fingerprinting is defined by the processes that are illustrated in U.S. Pat. App. Pub. No. 2008/0267510, entitled, Document Processing System Control Using Document Feature Analysis for Identification, and which is incorporated by reference in its entirety. The unique identifier examples provided are exemplary in nature and are not intended to limit the features that can be employed by those skilled in the art to uniquely identify a page or document. All of the required unique identifiers are derived from the print file by either the print controller 115 or by the data center processor 125 based on data provided by the print controller 115. In the document fingerprinting case, the unique identifier data is transferred to the print inspection computer 122 before the job run is started or as required during the job run.
Unique identifier data and page status (i.e. good or defective), from the print inspection computer 122 is stored in the central data storage 126 by the data center processor 125. The print inspection system runs in real time. In other words, every page is processed at production speeds without the need to reduce the normal printer throughput. The inspected paper web 113 is rolled on a winder 130 to form a printed paper roll 135, which is ready to be processed on an inserter 150 or wrapper (not shown). An inserter 150 inserts material in an envelope and a wrapper forms the envelope around the material to form the mailpiece. Either document processing system design is compatible with this system even though the figures focus on the operation of an inserter.
The production process continues with printed paper roll 135 being loaded on an unwinder 140 which is attached to the input channel 160 of the inserter 150. The printed paper roll 135 contains both good and defective pages as shown in
Based on the document assembly instructions for a given document, the inserter input channel 160 cuts the printed paper roll 135 at cut line 210 and then cuts the pair of pages along line 205. The page of document 1 is sent to an accumulator while page 1 of document 2 is held or sent to a different accumulator. The paper roll cut at 215 and 205 allows for the remaining two pages of document 2 to be accumulated and forwarded to the folder and collation track 161. Document 3 requires cuts at 220 and 225 plus 205 which enable pages 1, 2 and 3 to be accumulated, folded and sent to the collation track 161. Page 1 of document 4 is held or sent to a separate accumulator. Cuts 230, 235 and 205 are needed to accumulate the remaining pages of document 4. Even though document 4 is defective, it is folded and advanced to the collation track 161. Document 4 will be tracked along the collation track 161 through the envelope inserter 162 to the output section 170 where it will be diverted from the normal mail stream of quality documents. Alternatively the defective document could be diverted from the collation track 161 before being inserted in an envelope. Document 5 is processed in accordance with the steps above.
If the defective document can not be detected or tracked through the inserter, it can still be identified through features visible on the completed envelope by the imaging system 165 that is attached to the output section 170.
An additional alternative exists for diverting defective envelopes if the mail from the inserter is going to be processed on a sorter 180 before the mailing production is complete and sent to the postal authority for delivery. Before or during the sorting operation the results of the print inspection, for the mailing being processed, are sent to the sorter control computer 190 from the data center processor 125 or from the print inspection computer 122. This data includes the unique identifier(s) for the envelopes containing defective documents. During sorting operations, the mailpiece sorting imaging system 185 reads the barcodes and the data on the front to the envelope. If the sorter imaging system 185 detects a match between a unique identifier and a defective mailpiece indicator, the mailpiece will be diverted to the reject bin or bins 195.
For all of the methods used to detect and divert defective material, positive feedback is sent to the data center processor 125 to ensure that correct mailing documentation is created for the postal authority. In addition, corrective action maybe initiated at any point in the process such as but not limited to ordering re-prints of the defective document(s).
Referring to
Even though the disclosed process prevents stoppage of the printer, correcting for defects is expensive. Therefore, thresholds are set for the rate and severity of the defects that have to occur before a page or document is flagged as defective. If the defect does not exceed the threshold S530 processing continues with step S520. If the threshold is exceeded S530, the inspection failure is recorded with the setting of a defect flag in the data record for the page and document S535. The defect flag is associated with a unique identifier(s) for the document containing the defective page. If the printer system is configured for reprints, the print controller 115 is notified. The data center processor 125 also is notified of the defective document and corresponding unique identifier(s). Alternately, the print inspection computer can transfer the notification of a defective document and corresponding unique identifier(s) to the inserter system controller 175 or the sorter controller 190 based on the production processing configuration. The data center processor also can schedule a reprint on a different printer if that is the current production configuration. Continuous processing of the print job continues without stoppage of the printed paper web 112, inspection system processing 121, and transfer of the inspected printed paper web 113 to the winder 130 to form printed paper roll 135, step S540. Normal production processing continues with step S510 until the printing of the electronic print file is complete.
Turning now to
If there are no imaging systems 155 or 165 to read the unique identifier(s) (S615 and S625—NO decision S626) or there are no diverters on the inserter (S640—NO decision S641) a sorting option S655 must exist if the mail production run is to proceed without stoppage(s). If sorter is not to be used, the inserter control system 175 must issue a stop command so that the defective document can be removed manually step S660. If the mailpiece being run is going to be sorted on a sorter 180, step S655, no action is required to identify if the mailpiece contains a defective document. The defective mailpiece will be detected and rejected by the sorter 180. Step S665 sends mailpiece item data to the data center processor 125 and processing continues until all documents are processed S670. When the job is completed S670, it is determined whether sortation is required S675. If no sortation is to be done, the production job is completed and data reports for the postal authority and client are prepared as required by the data center processor 125. When sortation is required, the mailpieces from the production run are collected and transferred to the sorter for sortation. The data files containing at least the unique identifier(s) for the defective mailpieces are transferred to the sorter control computer 190 from either the print inspection computer 122 or from the data center processor 125 if they have not already been sent S680. The next step S685 performs the mailpiece sortation, identifies any mailpieces that contain defective documents and sorts these mailpieces to the reject bin (195
As shown by the above discussion, functions relating to the printing, print inspection, mailpiece production and removal of defective material may be implemented on one or more computers operating as the control processors 115, 125 connected for data communication with the processing resource controllers 122, 175, 190 as shown in
As known in the data processing and communications arts, a general-purpose computer typically comprises a central processor or other processing device, an internal communication bus, various types of memory or storage media (RAM, ROM, EEPROM, cache memory, disk drives etc.) for code and data storage, and one or more network interface cards or ports for communication purposes. The software functionalities involve programming; including executable code as well as associated stored data, e.g. files used for the workflow templates for a number of production jobs as well as the various files for tracking data accumulated during one or more productions runs. The software code is executable by the general-purpose computer that functions as the control processor and/or the associated terminal device. In operation, the code is stored within the general-purpose computer platform. At other times, however, the software may be stored at other locations and/or transported for loading into the appropriate general-purpose computer system. Execution of such code by a processor of the computer platform enables the platform to implement the methodology for generating an integrated mailpiece, in essentially the manner performed in the implementations discussed and illustrated herein.
For example, control processor 125 may be a PC based implementation of a central control processing system like that of
In operation, the main memory stores at least portions of instructions for execution by the CPU and data for processing in accord with the executed instructions, for example, as uploaded from mass storage. The mass storage may include one or more magnetic disk or tape drives or optical disk drives, for storing data and instructions for use by CPU. For example, at least one mass storage system in the form of a disk drive or tape drive, stores the operating system and various application software as well as data. The mass storage within the computer system may also include one or more drives for various portable media, such as a floppy disk, a compact disc read only memory (CD-ROM), or an integrated circuit non-volatile memory adapter (i.e. PC-MCIA adapter) to input and output data and code to and from the computer system.
The system also includes one or more input/output interfaces for communications, shown by way of example as an interface for data communications with one or more other processing systems. Although not shown, one or more such interfaces may enable communications via a network, e.g., to enable sending and receiving instructions electronically. The physical communication links may be optical, wired, or wireless.
The computer system may further include appropriate input/output ports for interconnection with a display and a keyboard serving as the respective user interface for the processor/controller. For example, a printer control computer may include a graphics subsystem to drive the output display. The output display, for example, may include a cathode ray tube (CRT) display, or a liquid crystal display (LCD) or other type of display device. The input control devices for such an implementation of the system would include the keyboard for inputting alphanumeric and other key information. The input control devices for the system may further include a cursor control device (not shown), such as a mouse, a touchpad, a trackball, stylus, or cursor direction keys. The links of the peripherals to the system may be wired connections or use wireless communications.
The computer system runs a variety of applications programs and stores data, enabling one or more interactions via the user interface provided, and/or over a network to implement the desired processing, in this case, including those for generating an integrated mailpiece, as discussed above.
The components contained in the computer system are those typically found in general purpose computer systems. Although summarized in the discussion above mainly as a PC type implementation, those skilled in the art will recognize that the class of applicable computer systems also encompasses systems used as host computers, servers, workstations, network terminals, and the like. In fact, these components are intended to represent a broad category of such computer components that are well known in the art. The present examples are not limited to any one network or computing infrastructure model—i.e., peer-to-peer, client server, distributed, etc.
Hence aspects of the techniques discussed herein encompass hardware and programmed equipment for controlling the relevant document processing as well as software programming, for controlling the relevant functions. A software or program product, which may be referred to as a “program article of manufacture” may take the form of code or executable instructions for causing a computer or other programmable equipment to perform the relevant data processing steps regarding the manufacturing of an integrated mailpiece, where the code or instructions are carried by or otherwise embodied in a medium readable by a computer or other machine. Instructions or code for implementing such operations may be in the form of computer instruction in any form (e.g., source code, object code, interpreted code, etc.) stored in or carried by any readable medium.
Such a program article or product therefore takes the form of executable code and/or associated data that is carried on or embodied in a type of machine readable medium. “Storage” type media include any or all of the memory of the computers, processors or the like, or associated modules thereof, such as various semiconductor memories, tape drives, disk drives and the like, which may provide storage at any time for the software programming. All or portions of the software may at times be communicated through the Internet or various other telecommunication networks. Such communications, for example, may enable loading of the relevant software from one computer or processor into another, for example, from a management server or host computer into the image processor and comparator. Thus, another type of media that may bear the software elements includes optical, electrical and electromagnetic waves, such as used across physical interfaces between local devices, through wired and optical landline networks and over various air-links. The physical elements that carry such waves, such as wired or wireless links, optical links or the like, also may be considered as media bearing the software. As used herein, unless restricted to tangible “storage” media, terms such as computer or machine “readable medium” refer to any medium that participates in providing instructions to a processor for execution.
Hence, a machine readable medium may take many forms, including but not limited to, a tangible storage medium, a carrier wave medium or physical transmission medium. Non-volatile storage media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) or the like. Volatile storage media include dynamic memory, such as main memory of such a computer platform. Tangible transmission media include coaxial cables; copper wire and fiber optics, including the wires that comprise a bus within a computer system. Carrier-wave transmission media can take the form of electric or electromagnetic signals, or acoustic or light waves such as those generated during radio frequency (RF) and infrared (IR) data communications. Common forms of computer-readable media therefore include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards paper tape, any other physical storage medium with patterns of holes, a RAM, a PROM and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting data or instructions, cables or links transporting such a carrier wave, or any other medium from which a computer can read programming code and/or data. Many of these forms of computer readable media may be involved in carrying one or more sequences of one or more instructions to a processor for execution.
While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings.
