Logs of printed products

Information

  • Patent Grant
  • 6675062
  • Patent Number
    6,675,062
  • Date Filed
    Thursday, January 31, 2002
    22 years ago
  • Date Issued
    Tuesday, January 6, 2004
    20 years ago
Abstract
A log of printed products having thereon an identification that is programmable and then readable to access information regarding the printed products that make up the log such as product identification, orientation and destination. The printed products include either bound or non-bound printed products. A method of utilizing a smart log includes creating a log of printed products, programming an identification associated with the log with information relating to the printed products, coupling the identification to the log, transporting the log to a destination for processing, reading the identification while the identification is coupled to the log, and handling the log in response to the information read from the identification.
Description




FIELD OF THE INVENTION




The invention relates to logs of printed products having thereon a programmable identification which is accessible to provide product information such as product identification and orientation, and relates to methods for producing such logs and methods for utilizing such logs.




BACKGROUND OF THE INVENTION




As used in the printing industry, a log is a stack of typically unbound printed products such as signatures that are contained on each end of the stack with an end board. The signatures and end boards are then strapped to create a unified structure that can be transported with a device such as a forklift or crane. Such a log makes transporting quantities of signatures more efficient. In use, the logs are transported to and loaded onto a log loader of a binding line where the log is unstrapped and end boards removed. The signatures are then feedable to the binding line.




When transporting and loading a log onto a log loader of a binding line, errors can occurs such as the log of signature being delivered to the wrong log loader or such as the log of signatures being loaded onto the log loader in an incorrect orientation. Different types and models of log loaders require different signature orientations, i.e., spine leading, lap leading, etc.




SUMMARY OF THE INVENTION




The invention provides a log of printed products which include thereon a programmable identification that is readable to provide information regarding the printed products that compose the log. The information readable from the log ensures that further processing of the log is conducted without errors or is conducted more efficiently.




In one embodiment of the invention, the log is composed of unbound printed products such as signatures. When the log of signatures is created, the programmable identification is programmed to include information such as signature identification and orientation. When needed, the log is transported to a binding line and loaded onto a log loader by a lifting device such as a crane and bundle clamp. One or both of the bundle clamp and log loader have a reader thereon to read the identification on the log. The accessed information eliminates errors by ensuring that the log is loaded onto the correct log loader and loaded in the correct orientation.




In another embodiment of the invention, the log is composed of bound printed products such as magazine, catalogs, books, direct mail pieces, or the like. The log has thereon a programmable identification which is readable to provide information regarding the contents of the log such as product type, orientation, postal destination, end of pallet, or the like. The identification is readable during subsequent transporting or processing of the log to reduce handling errors and increase processing efficiency.




The invention includes methods for producing logs of printed products having thereon a programmable identification containing readable information relating to the printed products that compose the log as well as methods for utilizing or further processing such logs. In particular, the invention also includes a method for forming a log of bound printed products.











Other features and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following detailed description, claims, and drawings.




BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of a log of signatures.





FIG. 2

is a perspective view of a log of signatures being created.





FIG. 3

is a schematic of a typical saddle stitcher binding line.





FIG. 4

is a perspective view of a bundle clamp loading a log loader.





FIG. 5

is a perspective view of the bundle clamp loading the log loader.





FIG. 6

is a perspective view of a log of bound printed products.





FIG. 7

is a schematic of a portion of a binding line.











Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.




DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT




Referring now to the drawings, there is shown in

FIG. 1

a printed product assembly or log


10


of printed products. The log


10


includes printed products such as the signatures


12


shown in

FIG. 1

stacked one adjacent the other. The logs


10


can be of varying sizes and other orientations such as U or L shaped in correspondingly configured enclosures. For example, log


10


can range from 36-50 inches in length. Optionally, on each end of the stack of signatures is an end board


14


. It should be noted however that the present invention can be implemented without the use of end boards. The end boards


14


are typically dimensioned to be approximately the same size as the signatures


12


but can be of other varying sizes. The end boards


14


can be fabricated of materials such as paper, wood or plastic. A fastener such as strap


16


is wrapped around the signatures


12


and end boards


14


to enable the log


10


to be moved as a unitary piece without falling apart.




The invention includes the use of a programmable identification


18


in conjunction with the log


10


. The identification


18


preferably is positioned within one or both of the end boards


14


and can take the form of an embedded microchip, a RF tag or similar programmable technology such as electronic, magnetic, optical or computer related technologies. For example, RF tag technology is available from Motorola. Preferably, the identification


18


is adhered to one of the end boards


14


such as with an adhesive. However, it should be noted that other attachment or securing methods can also be employed to associate the identification


18


to the end board


14


. If end boards are not used, the identification


18


can be placed on the stacked signature(s) such as with a RF tag or magnetic ink printed on one or more signatures such as on the lap of a signature.




The identification


18


is intended to make the log


10


a “smart log” and thus eliminate errors when transporting and using the logs in the binding process, errors such as in loading the wrong signature or a signature in the wrong orientation onto a loader of a binding line.




With reference to

FIG. 2

, a log


10


is conventionally created on press with the use of a stacker


20


(a portion of which is shown in FIG.


2


), also called a bundler or stacker/bundler, to make logs of a given length dimension. On a conventional stacker


20


such as model 3600 available from QTI of Sussex, Wis., an arm


22


having a suction cup


24


puts down the lower most end board


14


before the stack of signatures


12


is created then positions the uppermost end board


14


after the stack is created. At some point before, during or after creation of the stack, the identification


18


is appropriately programmed by programmer


26


, for example. The information programmed or embedded onto the identification


18


preferably includes signature identification (what form has been bundled), log orientation (where the backbone is and the direction of the high/low folio), and log position on a pallet. Any other information could be programmed or embedded as well. After a log


10


is created and the identification


18


programmed, the log


10


is typically piled via crane/hoist onto a pallet and stored until needed at a binding line or other processing destination.




Turning now to

FIG. 3

, a typical saddle stitcher binding line


28


is shown. It should be noted that the invention is capable of being used with other configurations and types of binding lines and capable of being used in other processing in other destination in addition to bindery lines. The binding line


28


includes generally the following conventional components: pallets


30


for the logs


10


, log loaders


32


, pockets


34


, a trimmer


36


, a mail table


38


, a stacker


40


and a controller


42


. It should also be noted that more or less than the nine log loaders


32


shown in

FIG. 3

can be utilized depending upon the specifics of a given binding job.




Before a binding job is begun, information regarding the job is downloaded into the controller


42


. Pocket assignments for each signature are inputted into the controller


42


; i.e., which pockets will be feeding which signatures, and inputs the log loader type to be used for each signature.




Different types and models of log loaders


32


, also called feeders, require different signature orientations; i.e. spine leading, lap leading, etc. Associated with each log loader


32


is a pallet


30


for the logs


10


that are to be loaded onto a particular log loader


32


. Logs


10


that correspond to a given pocket/log loader


32


are transported such as by a forklift from a storage location onto a pallet


30


and positioned adjacent a respective log loader


32


. A hoist such as a conventional crane system provided with a bundle clamp is preferably utilized to transfer logs


10


from the pallet


30


to the corresponding log loader


32


.




Turning now to

FIGS. 4 and 5

, it is imperative that the correct signatures


12


in the correct orientation are loaded onto a particular log loader


32


. To this end, the identification


18


on each log


10


is utilized to eliminate handling errors. Preferably, the bundle clamp


44


and the log loader


32


each include a reader


46


or scanner to read the data from the identification


18


on each log


10


. The position of the reader


46


on the bundle clamp


44


or log loader


32


can vary. Both the bundle clamp


44


and the log loader


32


are in communication with the controller


42


and can be in communication with each other. It should be noted that the reader


46


could be located only on the bundle clamp


44


or only on the log loader


32


instead of in both locations.




Typically, log loaders hold approximately two and one half logs of signatures. When a log


10


needs to be loaded onto a log loader


32


, the bundle clamp


44


picks up the log


10


. The reader


46


on the bundle clamp


44


reads the information from the identification


18


. The information is sent to the controller


42


for verification that the proper signatures


12


are being loaded onto a particular log loader


32


that corresponds to a particular pocket


34


. The information is also used to ensure that the bundle clamp


44


rotates and orients the signatures


12


properly with respect to the log loader


32


; i.e., lap leading and spine down. It should also be noted that the bundle clamp


44


could read the identification


18


from the log


10


before the bundle clamp


44


picks up the log


10


.




A crane (not shown) then moves the bundle clamp


44


with log


10


held therein to a particular log loader


32


and orients the log


10


in response to the information it obtained from the identification


18


on the log


10


. Before the bundle clamp


44


can release the log


10


onto the log loader


32


, the reader


46


on the log loader


32


reads the information from the identification


18


. The information is sent to and analyzed by the controller


42


. From a look-up table, the controller


42


knows the proper orientation and signature identification required for each log loader


32


. If the analyzed information does not match what the controller


42


is programmed to accept, the bundle clamp


44


is not permitted to open or release the log


10


. A technician is alerted as to the problem such as with an audible alarm or on a display.




If the analyzed information matches what the controller


42


is programmed to accept, the bundle clamp


44


is permitted to open and the log


10


is released onto the log loader


32


. A technician then removes the strap


16


and removes the end boards


14


and the signatures


12


proceed conventionally into the respective pocket


34


. The end boards


14


can then be reused in the formation of another log


10


and thus reprogrammed when a new log


10


is created. Optionally, the end boards


14


with identification


18


thereon could be discarded.




The above described embodiment of the invention involves a log


10


comprised of printed products that were individual conventional signatures


12


. A second embodiment of the invention is illustrated in

FIGS. 6 and 7

.




With reference to

FIG. 6

, a log


50


is shown that is comprised of already bound printed products


52


, also called books, such as magazines, catalogs, direct mail pieces, or the like stacked one adjacent the other. On each end of the stack of bound printed products is an end board


54


. The end boards


54


are preferably dimensioned to be approximately the same size as the bound printed products


52


and are fabricated of materials such as paper, wood or plastic. Straps


56


are wrapped around the printed products


52


and end boards


54


to enable the log


50


to be moved in one piece without falling apart.




To create a log


50


of bound printed products


52


, a stacker (not shown) also called a bundler or stacker/bundler, is employed such as model 3600 available from QTI of Sussex, Wis. After the log


50


is created, an identification


58


is appropriately programmed as explained above with respect to the first embodiment. The information programmed or embedded onto the identification


58


preferably includes product identification and distribution information such as subscriber information, postal destination end of pallet and sequence. Any other information could be programmed or embedded as well.




The information associated with each log


50


can then be utilized when moving the log


50


to a pallet to ensure that the log


50


is being transported to the proper location. The transportation device utilized to move the log


50


has thereon a suitable reader


46


to read the information from the identification


58


on the log


50


to ensure that no transportation errors occur.




The information associated with the log can also be utilized by a distribution or mailing center. For example, the U.S. Postal Service (USPS) could be provided with a reader


46


. Upon arrival or upon loading into sorting equipment by a crane, the reader


46


would read the identification


58


for a given log


50


and gain information about that log


50


such as the type of product, number of products in the log, products' ultimate destinations, postal fee information, etc. The read information could be used to increase the efficiency of the delivery system by enabling increased automation and less handling errors.




Turning now to

FIG. 7

in particular, a portion of a binding line


60


is shown and a second method for forming the logs


50


of bound printed product


52


is illustrated. The printed products


52


are bound in the usual bindery fashion in conjunction with a controller


62


. After the products


52


complete the assembly process, they are conveyed on a mail table


64


towards equipment used to prepare the products for shipment to the USPS or any other destination. In the usual fashion, the products


52


are bundled following USPS specifications. That is, bundled packages of products


52


(strapped, shrink wrapped or combinations thereof) are made for carrier route, 5-digit, 3-digit, etc. and piled on a pallet. The height and weight of these bundles are limited by USPS specifications and typical bindery equipment.




Lane A of

FIG. 7

utilizes equipment and a method of preparing traditional bundles of bound printed product


52


. The conventional equipment includes the following: a directional conveyor


66


, a reject conveyor


68


, a bundle stacker


70


, a bundle strapper


72


, bundle conveyors


74


, a bundle wrapper


76


, a heat tunnel


78


and a bundle pallet


80


. This equipment is typically used in the bindery to prepare bound printed products


52


for shipment. A hand strapper


82


is also shown that is used as a back-up method of securing bundles if any failures occur during the packaging process. Products


52


come off the mail table


64


into Lane A, bundles of products


52


are strapped and wrapped, transported through a heat tunnel


78


then conveyed via the bundle conveyor


74


to a pallet


80


. Bundles sizes vary depending upon the number of pieces for a particular postal sort.




Lane B of

FIG. 7

utilizes equipment and a method of preparing the bound printed products


52


in logs


50


, which is a more effective way of handling quantities of product


52


. The equipment utilized includes: a directional conveyor


84


, a reject conveyor


86


, a log stacker


88


, a log strapper


90


, a log conveyor


92


, a log crane


94


, and a log pallet


96


.




As shown in

FIG. 7

, workers for performing certain tasks are positioned at locations C, D and E. At location C, a worker piles product onto the pallet


80


if that product was produced in the traditional method of bundling. At location D, a worker operates the log crane


94


. At location E, a worker collects recalled printed products that are required to be loaded into a working pallet. Recalls are magazines that are re-manufactured for rejected products (missing pages, bad trim, missing staples, etc.). Because of the manufacturing process, these products cannot be produced before the log or bundle changes from one sort to the next unless generic books are used. The recalled magazines (if they do not get into the proper log or bundle) are removed from the binding line


60


onto the conveyors


68


and


86


. The worker collects these products


52


and places them into the required log or onto the required pallet.




In operation, as the assembled printed products


52


are conveyed on the mail table


64


, a controller


62


decides which Lane, A or B, the printed products


52


will be directed to. Typically, carrier route sort products


52


would be directed to Lane A because the products


52


for carrier routes justify a traditional bundle.




Because any mailed pieces (other than a carrier route package) need to be sorted by the USPS or like entity, an effective way to present product to the sorting system is in the form of a log


50


. A log


50


of product


52


presents more pieces to the sorting system in the same amount of time than numerous bundles of product, which are currently lifted one, or a few at a time, by USPS personnel. Further, a log


50


of product


52


typically has less waste material than a series of bundles. A log


50


utilizes fewer straps


56


, whereas the amount of bundles equaling the products


52


held in one log


50


would produce many more straps as well as wrapping material. Consequently, because more pieces are delivered to a sorter in the same amount of time, and less waste material required for the same amount of product, a log


50


of product


52


is more efficient than a traditional bundle.




An example of the usage of Lane B is as follows. If 700 pounds of magazines are to be manufactured for a 5-digit postal destination and each magazine weighs ⅕ of a pound, then 3500 magazines will be produced for this 5-digit pallet. If each magazine is ⅕ of an inch thick, then 700 inches of magazines need to be fitted onto a pallet. To optimally fit a typical pallet, which is approximately 47 inches by 40 inches, logs


50


would be created in approximately 46 inch lengths. As the magazines proceed on the directional conveyor


84


into the log stacker


88


, the controller


62


preferably, although not necessarily, monitors the process. When 46 inches of magazines have been stacked, the log


50


is delivered to the log strapper


90


where it is strapped. Without interruption, and while one log


50


is being strapped, another log


50


can be formed in the log stacker


88


. The strapped log


50


is conveyed towards a crane


94


where it is picked up and then placed on the pallet


96


. After fourteen logs


50


have been created at 644 inches, approximately 56 inches of product remain to be produced. The controller


62


or stacker can either create another log of 46 inches and then a 10 inch log, or split the remaining 56 inches of product into equal lengths (28 inch logs) or any combination thereof. Monitoring the process of sorting the bound printed products


52


is well known in the industry, and therefore, knowing where one bundle, log or pallet ends and the next begins, is commonly executed in many binderies. The end of bundle/log/pallet information could be data included in the programmable identification


18


. Such information could be used to help ensure bundle/log/pallet integrity. Sounding a horn or illuminating a light when a pallet is complete could be an aid for any technician working this area. Sorting the printed products


52


either in logs


50


or bundles poses no difficulties for the controller


62


. It should be noted that bundles of any size or length could be made at any time.




When the above described 5-digit pallet of magazines is completed, the next pallet is begun. If the next pallet is anything except a carrier route pallet, it is directed into Lane B. If the next sequence of production is a carrier route pallet, it would be directed into Lane A where bundles of magazines would be produced.




When creating the logs


50


in Lane B, the end boards


54


are placed on each end of the stack that is to form the log


50


at the log stacker


88


. Optionally, an identification


58


as described above for that log


50


can be programmed. Further, when creating logs


50


of bound printed product


52


, it may be necessary to compensate the products during the stacking process. Because bound printed products are sometimes thicker near the backbone, compensating them will offset this bulkier dimension and create a straighter more manageable log


50


. For example,

FIG. 6

shows a log of compensated magazines wherein after every ten magazines, the next ten are turned 180°.



Claims
  • 1. A printed product assembly comprising:a plurality of printed products aligned in a stack having two ends; an end board adjacent each end of said stack; and a programmable identification secured to one end board, said identification being readable while secured to said one end board and including information regarding said printed products.
  • 2. The printed product assembly as set forth in claim 1 wherein said printed products include unbound signatures.
  • 3. The printed product assembly as set forth in claim 1 wherein said printed products include bound books.
  • 4. The printed product assembly as set forth in claim 1 wherein said programmable identification includes a microchip.
  • 5. The printed product assembly as set forth in claim 1 wherein said programmable identification includes RF technology.
  • 6. A printed product assembly comprising:a plurality of printed products each having the same orientation and being arranged in a log; a fastener surrounding said log; and an identification coupled to said log and being readable while coupled to said log, said identification being programmable to hold information regarding said orientation of said printed products in said log.
  • 7. The printed product assembly as set forth in claim 6 wherein said fastener includes at least one end board.
  • 8. The printed product assembly as set forth in claim 6 wherein said fastener includes at least one strap.
  • 9. The printed product assembly as set forth in claim 6 and further including an end board and wherein said identification is secured to said end board.
  • 10. The printed product assembly as set forth in claim 6 wherein said printed products include unbound signatures.
  • 11. The printed product assembly as set forth in claim 6 wherein said printed products include bound books.
  • 12. The printed product assembly as set forth in claim 6 wherein said programmable identification includes microchip technology.
  • 13. The printed product assembly as set forth in claim 6 wherein said programmable identification includes RF technology.
  • 14. A method for creating a smart log stack of printed products, said method comprising:stacking a plurality of printed products in the same orientation; coupling a programmable identification to said stack to be readable in situ; and programming said identification with information relating to said orientation of said printed products.
  • 15. The method of claim 14 further comprising binding said stack of printed products, and wherein in said binding step, said stack is bound with a strap.
  • 16. The method of claim 14 further comprising binding said stack of printed products, and wherein in said binding step, said stack is bound with at least one end board.
  • 17. The method of claim 14 wherein said programmable identification includes microchip technology.
  • 18. The method of claim 14 wherein said programmable identification includes RF technology.
  • 19. The method of claim 14 wherein in said stacking step, a stacker is utilized.
  • 20. The method of claim 14 wherein said stack has two ends, said binding stack is bound with end boards at each of the two ends, and wherein coupling a programmable identification to said stack to be readable while being coupled to said stack includes coupling said identification to at least one of said end boards.
  • 21. A method of utilizing a smart log comprising:creating a log of printed products; programming an identification associated with said log with information relating to said printed products; coupling said identification to said log; transporting said log to a destination for processing; reading said identification in situ; and handling said log in response to said information read from said identification.
  • 22. The method of claim 21 wherein said printed products include bound books.
  • 23. The method of claim 21 wherein said printed products include signatures.
  • 24. The method of claim 21 wherein in said handling step, said log is oriented properly with respect to said processing.
  • 25. The method of claim 21 wherein creating a log of printed products includes arranging said printed products between two end boards, and wherein coupling said identification to said log includes coupling said identification to one of said two end boards.
  • 26. A method of utilizing a smart log comprising:creating a log of printed products; programming an identification associated with said log with information relating to said printed products; transporting said log to a destination for processing; reading said identification; and handling said log in response to said information read from said identification; wherein in said transporting step, said destination is a binding line.
  • 27. A method of utilizing a smart log of printed products comprising:creating a log of printed products; programming an identification associated with said log with information relating to said printed products; transporting said log to a log loader of a binding line; reading said identification; and orienting said log properly with respect to said log loader in response to said read information from said identification.
  • 28. A method of utilizing a smart log of printed products comprising:creating a log of printed products; programming an identification associated with said log with information relating to said printed products; moving said log adjacent a log loader; reading said identification on said log; orienting said log properly with respect to said log loader in response to said read information from said identification; and releasing said log onto said log loader if said log is in said proper orientation.
  • 29. The method of claim 28 wherein said identification is read by a reader located on said log loader.
  • 30. The method of claim 28 wherein said log is moved using a hoist and wherein said identification is read by a reader located on said hoist.
  • 31. The method of claim 28 wherein said hoist includes a bundle clamp.
  • 32. A method of utilizing a smart log of printed products comprising: creating a log of printed products;programming an identification associated with said log with information relating to said printed products; moving said log to a binding line; reading said identification on said log; and orienting said log properly with respect to said binding line in response to said read information from said identification.
  • 33. The method of claim 32 wherein in said orienting step, said orienting includes associating said log with a predetermined log loader.
  • 34. The method of claim 32 wherein in said orienting step, said orienting includes positioning said log with respect to said log loader.
  • 35. A method of utilizing a stack of printed products comprising:creating a stack of printed products; programming an identification associated with said stack with information relating to said printed products; transporting said stack to a destination for processing; reading said identification; handling said stack in response to said information read from said identification; and coupling said identification to said stack, said identification being readable while said identification is coupled to said stack.
  • 36. The method of claim 35 wherein said stack has two ends, and wherein creating a stack of printed products includes coupling an end board to each end of said stack.
  • 37. A method of utilizing a smart log, the method comprising:reading a programmable identification on said log; and transporting said log to a log loader.
  • 38. The method of claim 37 further comprising verifying said log is at the appropriate log loader based on the programmable identification.
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