The embodiments disclosed herein generally relate to a system and method for producing documents. More particularly, the disclosure relates to a system and method for the production of dimensional documents.
Conventional systems for producing dimensional documents, such as megaphones, small boxes, photo-geo-domes, and the like, are generally complex and expensive. For example, they may include a printing system, a coating system and a die-cutting system all connected to automatically perform these operations in sequence. In one known method of producing dimensional documents having custom printing, the text and/or images are printed on stock, a two-dimensional document is then cut from the stock using a flat or rotary die system, and the two-dimensional document is folded and glued to form a three-dimensional document. In some cases, the printing is performed on a thin stock that is later glued to a heavier weight stock to provide greater stability and strength. In other cases, the printing is performed on heavyweight stock.
In another known method, the printing and/or images are printed on pre-cut stock to form a two-dimensional document, and the two-dimensional document is then folded and glued to form a three-dimensional document. In this method, the printing is generally performed on a heavier weight stock, requiring printing apparatus that can handle such stock. In addition, the pre-cut stock is generally more expensive, must be inventoried, and this method limits the flexibility of the printer in terms of the sizes and designs that can be produced.
Conventional systems that are less complex and/or less expensive than those described above only process one sheet of material at a time. Known systems suitable for small print shops require a dedicated operator to hand place a single printed sheet into the digital cutter, execute the cutting job from an attached computer, remove the job from the cutter when the cut is complete and then load the next printed sheet in place for subsequent cutting. To satisfy the needs of small print shops, a low-cost system with automatic feed-on and feed-off operations to minimize labor overhead is required.
One embodiment described herein is a media feeding and cutting system comprising a media cutter including a cutting surface and a digital cutting device, a first feeder, a positioner configured to position a sheet of media on the cutting surface, a second feeder and a processor. The first feeder is disposed adjacent to or is connected to the cutting surface, and is configured to automatically transport individual sheets of media from an in-feed receptacle toward the cutter using a first feed device. The positioner includes a first sensor that senses a first edge of a sheet of media. The second feeder is disposed adjacent to or is connected to the cutting surface, and automatically transports the cut sheet of media from the cutter to an out-feed receptacle. The processor operates the cutter, first feeder, positioner and second feeder.
Another embodiment described herein is a media feeding system comprising a media in-feed receptacle, a first feeder, a media out-feed receptacle, a second feeder, and a processor. The first feeder is configured to be retrofitted to a first side of a digital cutter, and includes a first feed device configured to automatically transport individual sheets of media in a forward feed direction from the media in-feed receptacle to the digital cutter. The second feeder is configured to automatically transport individual sheets of media from the cutter to the media out-feed receptacle. The processor is configured to operate the first feeder and the second feeder.
Yet another embodiment is a method of making an automatic digital cutter, comprising obtaining a media in-feed receptacle, a media out-feed receptacle, a first feeder, and a digital cutter. The first feeder includes a first feed device configured to automatically transport individual sheets of media in a forward feed direction. The digital cutter is configured for single sheet manual feed, and includes a cutter feed device configured to move a sheet of media in a forward and backward direction, and a controller. The method comprises retrofitting the digital cutter with the media in-feed receptacle, first feeder, and media out-feed receptacle, and programming the controller to utilize the cutter feed device to automatically position media fed to the cutter using the first feeder prior to cutting.
A further embodiment is a method of feeding media to and from a cutting surface of a digital cutter, comprising acquiring a sheet of media from an in-feed receptacle using an automatic first feeder that includes a first feed device, automatically moving the sheet of media in a forward feed direction between first and second baffles to the cutting surface using the first feeder, and automatically placing the sheet of media on the cutting surface. The sheet of media is then moved in a backward feed direction using a second feed device in order to position the sheet of media on the cutting surface at a desired location, cut, automatically fed out of the cutter using a second feeder, and released into an out-feed receptacle.
As used herein, “dimensional document” refers to a three-dimensional object formed by cutting and folding a flat sheet of media. In most cases, the dimensional document has printed matter, such as text and images disposed on the surface thereof (or in some cases has a uniform pigmented or dyed color). “Media” refer to any sheet-shaped stock, such as paper, cardboard, paper board, vinyl, etc. that may be formed into a dimensional document. “Cut” means to cut and/or score. A “digital cutter” is a device used to digitally cut and/or digitally score media. A “feeder” as used herein refers to an apparatus that feeds media. “Feed device” as used herein refers to a feed roll or rolls, or a vacuum feed device. “Retard feed technology” refers to various techniques for accurately separating and feeding sheets using a feed roll and a retard roll or pad, “Vacuum feed technology” refers to various techniques for moving a sheet through a feed path using a vacuum. “Cutting surface” refers to the platform or other horizontal, angled or vertical, flat or non-flat surface in the cutter where the media is positioned during cutting.
One embodiment described herein is a device that automates the process of feeding sheets of media to a cutter used in forming dimensional documents. The system adds an automatic feed-on function, and optionally includes an automatic feed-off function, for a cutting system capable of performing digital cutting operations on sheet media. In embodiments, automation is accomplished by adding an in-feeder incorporating retard feed technology that employs one or more rolls and/or a retard pad, and/or incorporating vacuum feed technology, including hardware along with software and/or firmware, in order to automatically feed paper onto the cutting surface. Further automation occurs by incorporating hardware along with software and/or firmware to eject a cut sheet from the cutter, and integrating a stacking out-feed receptacle to receive the cut media after the cutter job is complete.
In one embodiment, an automated media in-feeder, a manual-feed cutter which is modified to receive automatically fed media from the in-feeder, and an output stacking receptacle are integrated in series to form a comprehensive, automated system. The system is economically produced and occupies a sufficiently small amount of space that it can be fit within a small print shop, rendering it a valuable alternative to complex and expensive automatic feeding and cutting systems. The embodiments described herein allow small print shops to get into the business of creating dimensional documents on heavy weight media, making the automatic production of packing and other dimensional documents a service that can be used by small business customers.
In embodiments, the in-feed media handling system employs retard feed technology. The details of certain embodiments of retard feed technology are described in U.S. Pat. No. 4,368,881, the contents of which are incorporated by reference herein in their entirety. The use of retard feed technology is particularly advantageous to allow heavy weight cover stock to be automatically fed as single sheets to the cutter without resulting in mis-feeding of media. In contrast, conventional low priced digital cutters require an operator to manually feed each sheet. In embodiments, the retard feed technology incorporates a retard roll. In embodiments, a retard pad can be used, often as part of a buckle feeder. Retard feed technology can be used with or without use of a fluffer.
In embodiments, vacuum feed technology can be used to feed media in and out of the cutter. A vacuum feed employing suction cups and/or a vacuum belt can be used, with or without use of a fluffier. In embodiments, buckle feeders can be used to feed media in and out of the cutter.
As is shown in
The retard roll 34 includes a cylindrical section 50 that is supported for rotation on a shaft 52. The retard roll 34 optionally has an integral slip clutch (not shown) to separate double fed sheets. The details of the slip clutch technology are described in U.S. Pat. No. 5,435,538, the contents of which are incorporated by reference herein in their entirety.
The pair of take-away rolls 40, 42 is disposed downstream of the retard feed assembly 30 and moves a sheet 24 of media along a media feed path 70, defined above and below the sheet by an upper baffle 74 and an intermediate baffle 76, and into the cutter 16′. The sheet 24 of media moves in a forward feed direction in the embodiment shown in
The cutter 16′ includes a housing 79, a cutting surface 80 and a pair of cutter rolls 82, 84, defining a nip 86 configured to move the sheet 24 through the cutter 16′. After the leading edge 88 of the sheet 24 passes into the cutter 16′, the sheet 24 is moved though the cutter 16′ by the take-away rolls 40, 42 (or the retard feed assembly, if no take-away rolls are used) until the leading edge portion of the sheet is picked up by the nip 86. After the leading portion of the sheet 24 is disposed between the cutter rolls 84, 86, the trailing edge 90 of the sheet passes out of the take-away rolls 40, 42 and beyond the lower baffle 76 of the media feed path 70. At this point, the trailing edge 90 of the sheet 24 falls downward onto the cutting surface 80. The sheet 24 continues to be moved along inside the cutter 16′ using the cutter rolls 82, 84.
A first edge sensor 92 is positioned to detect the leading edge 88 and/or the trailing edge 90 of the sheet 24. In embodiments, after the trailing edge 90 passes beyond the sensor 92, the sheet continues to move away from the feeder until a predetermined period of time has passed and the trailing edge 90 is on the cutting surface 80. Once the entire sheet 24 is on the cutting surface 80, the direction of movement of the sheet 24 optionally can be reversed, and the trailing edge 90 of the sheet 24 is guided backwards under the media path 70, below the lower baffle 78. In some cases the trailing edge 90 of the sheet 24 passes out from the feeder 16′ on an extension platform 102, which effectively extends the cutting surface upstream toward the in-feed receptacle 12′. The sheet 24 continues to travel in the reverse direction until the leading edge 88 of the sheet is detected by a second edge sensor 96. When the second edge sensor 96 determines that the sheet is correctly positioned to begin the registration process for cutting, movement of the sheet 24 stops by halting rotation of the cutter rolls 82, 84. The sheet is then registered for cutting and the sheet is digitally cut with a digital cutting knife or pen 100. A conventional digital cutting system, including a document registration system, can be used. Depending on the type of cutter that is employed, the sheet and/or the digital cutting blade move during the cutting process.
In a variation of the system shown in
After cutting is completed, the cut sheet is ejected to the output receptacle 20′ using the cutter rolls 82, 84. In order to effect ejection of a sheet 24, a conventional cutter can be adapted by programming the cutter rolls to perform this function. In this case, the automatic out-feeder 18′ includes the cutter rolls 82, 84. In another embodiment, an additional set of rolls (not shown) is added to eject the cut sheet of media.
In the embodiment shown in
In some cases, the cutter 16′, or a component disposed downstream from the cutter 16′, imparts folds or creases in the media to facilitate folding of the document into a dimensional shape. Some cutters include a ceasing stage after cutting. A non-limiting example of a known creasing system is described in U.S. Patent Publication No. 2011/0152048, the contents of which are incorporated by reference herein in their entirety.
The automatic in-feeder 114 includes a retard feed assembly 130, and a nudger roll 136 upstream from the retard feed assembly 130. The retard feed assembly 130 includes a drive roll 132 and a retard roll 134 that together form a nip 138 for forwarding the sheets into the cutter 116. During operation the nudger roll 136 contacts the uppermost sheet 124 of stack 122 from in-feed receptacle 112, and rotates to advance the uppermost sheet 124 from stack 122 into the retard feed assembly 130.
The retard roll 134 includes a cylindrical section 150 that is supported for rotation on a shaft 152. The retard roll facilitates separation of double fed sheets. As indicated above, the details of the slip clutch technology are described in U.S. Pat. No. 5,435,538.
The drive roll 132 and retard roll 134 rotate to move a sheet 124 of media forward through the cutter 116. The cutter 116 includes a cutting surface 180 and a pair of cutter rolls 182, 184, defining a nip 186 configured to move the sheet 124 through the cutter 116. The sheet 124 is moved though the cutter 116 by the drive roll 132 and retard roll 134 until the leading edge portion of the sheet is picked up by the cutter nip 186. After the leading edge portion of the sheet 124 is disposed between the cutter rolls 182, 184, the trailing edge 190 of the sheet passes out of the retard feed assembly 130. At this point, the trailing edge 190 of the sheet 124 falls downward onto the extension platform 202 that extends upsteam from the cutting surface 180. The sheet 124 continues to be moved along inside the cutter 116 using the cutter rolls 182, 184. Once disposed horizontally on the cutting plate 180, the sheet 124 is registered, cut with a digital cutting knife 200 and ejected in a manner that may be the same as is described above in connection with
As mentioned above, in the embodiment shown in
Similar to the embodiment of
The flowcharts shown in
More particularly, as is shown in
If the travel direction of the sheet has been reversed at 322, the sheet travels in the reverse direction until it is properly aligned, according to sheet edge detection via the second sensor. At this point, the cutter nip stops at 326. If an identification code was found to be present, shown at 328, the (previously read) identification code information from the media is used by the controller to determine the proper cutting program to use. (If no identification code was found, the uncut sheet is ejected at 338 into the output receptacle by rotation of the cutter nip in a forward direction.) The controller sends a signal to the cutter as to which cutting program is to be used to cut the media, and the appropriate sheet registration algorithm is activated at 330. After the registration marks are found at 332, the media is digitally cut at 334. (If there is a problem finding the registration marks, a misalignment problem probably occurred and the sheet is ejected at 338.)
Once cutting is finished, the cutter nips are activated at 338 to eject the cut sheet. This action by the cutter nips can be effected, for example, by programming the cutter controller to utilize the cutter nip to feed the cut media to the out-feed receptacle. After ejection, the cutter nip can be turned off at 340. A determination is made at 342 as to whether there are more sheets in the job. If so, the process returns to 316. If not, the job ends at 344.
In one variation of the process shown in
For partially manual operation of the system, as is shown in
After the travel direction of the sheet is reversed at 422, the sheet travels in the reverse direction until it is properly aligned, according to sheet edge detection via the second sensor. At this point, the cutter nip stops at 426. The appropriate sheet registration algorithm is activated at 430 based on the cutting program that was selected at 411. After the registration marks are found at 432, the media is digitally cut at 434. (If there is a problem finding the registration marks, a misalignment problem probably occurred and the sheet is ejected at 438.)
Once cutting is finished, the cutter nips are activated at 438 to eject the cut sheet. After ejection, the cutter nip can be turned off at 440. A determination is made at 442 as to whether there are more sheets in the job. If so, the process returns to 416. If not, the job ends at 444.
In one variation of the process shown in
Non-limiting examples of digital cutters that can be combined or integrated with the media loading system include the Graphtec Craft Robo Pro, Roland Desktop, Cricut, Maki and Ioline. A non-limiting example of feed technology that can be adapted for use with this system is Xerox® retard feed technology, which can be incorporated into an adapted version of a by-pass feeder used in a multifunction printing device.
The embodiments shown in
Typical systems occupy a floor footprint in the range of 8-25 square feet, or 10-18 square feet, or 10-15 square feet, enabling the system to be used in small print shops. The volume occupied by the system typically is in the range of 20-100 cubic feet, or 20-60 cubic feet, or 20-40 cubic feet.
As indicated above, the system enables a print shop to produce low cost dimensional documents for low volume print jobs in an economically competitive manner. The system and method are particularly well suited for use in low volume and short run packaging applications ranging from 2 to 500 pieces. Print jobs in the range of 1-500, or 1-250 or 1-100 are well suited for cutting using the system and method described.
It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims. Unless specifically defined in a specific claim itself, steps or components of the invention should not be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.
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