This application claims the priority, under 35 U.S.C. §119, of German Patent Application DE 20 2010 003 084.6, filed Mar. 2, 2010, and European Patent Application EP 11 001 028.7, filed Feb. 9, 2011; the prior applications are herewith incorporated by reference in their entirety.
The invention relates to a production system for flat printed products having a printing press and, as viewed in a transport direction, a following intermediate processing and transfer station and at least one following folding station, in particular a pocket folding station, in which the printed products can be transported in an uninterrupted material flow through the production system. The invention also relates to a sheet guiding apparatus for a production system according to the invention or for a sheet folding machine, including a sheet diverter for dividing a stream of sheets to a plurality of transport tracks, and at least a first and a second transport track. The invention further relates to a method for producing printed products of n different types in a production system having a digital printing press, a sheet folding machine and a sheet guiding apparatus with a switchable sheet diverter having n switching positions for transferring to one of n following transport tracks, in which the sheet guiding apparatus is configured, in particular, according to the invention.
Pocket folding machines and knife folding machines are known from the prior art for producing printed products such as brochures, pamphlets, booklets, signatures or the like. The combination of pocket folding machines with knife folding machines is customary as a combined folding machine. In that case, parallel folds are folded in pocket folding units and cross folds are folded in the following knife folding units. In that case, the sheet runs through at least the following stations in a running through direction of the combined folding machine: feeder, transfer table, pocket folding unit, knife folding unit, delivery.
In that case, sheets are fed in portrait format in a feeder, and parallel folds are folded in a first folding station in pocket folding units and cross folds are folded in a following folding station in knife folding units. German Published Patent Application DE 10 2006 055 301 A1 discloses combined folding machines with a plurality of pocket folding units and knife folding units which are disposed in a subordinate manner.
The construction of a pocket folding machine with a multiplicity of pocket folding units is apparent from German Published Patent Application DE 10 2004 041 471 A1. In that case, sheets are fed in portrait format in a feeder, and parallel folds are folded in a first folding station in pocket folding units and further parallel folds are folded in a following second folding station in pocket folding units. In that case, the second folding station is rotated by 90° with respect to the first folding station. In that case, a respective pocket folding unit is formed of a folding pocket and three folding rolls which are disposed in two folding roll pairs.
Transverse feeding of the folding sheets requires an adaptation of the folding patterns and affords additional options to save paper and time. According to the prior art, the speed problem has previously been moved to the second folding station in the case of transverse feeding. Although the reduced inlet length had an effect in the feeder and in the first parallel folding unit, the full inlet length had to be transported again to the second station which is rotated by 90 degrees. A very high speed of the second station was therefore necessary, which could lead to folding problems and reductions in quality.
Combinations of printing presses with folding machines are also known from the prior art. For instance, German Published Patent Application DE 195 23 881 A1, corresponding to U.S. Pat. No. 5,730,056, discloses a rotary printing press with a further processing unit which is connected behind it and has different folding stations, namely folding cylinders and knife folding units. A digital printing press with a folding machine which is connected behind it is apparent from German Published Patent Application DE 196 29 072 A1, in which the folding machine has pocket folding units.
Speed problems also occur in production systems of that type. In printing presses, either webs or sheets at a small spacing are printed at high speed. Due to speed limits in the following folding machine, the printing press can be operated only at a reduced speed if the printing press and folding machine are coupled directly.
It is accordingly an object of the invention to provide a sheet guiding apparatus, a production system for printed products having a sheet guiding apparatus and a method for producing printed products, which overcome the hereinafore-mentioned disadvantages of the heretofore-known apparatuses, systems and methods of this general type and which increase the productivity of a production process in the production of printed products, in particular of signatures, brochures, newspapers and books, without an increase in the speed of a folding machine used in the production.
With the foregoing and other objects in view there is provided, in accordance with the invention, a production system for flat printed products, comprising a printing press and an intermediate processing and transfer station which is disposed so as to follow the printing press, as viewed in the transport direction, that is to say downstream. At least one folding station, in particular a pocket folding station, is disposed further in the following direction, that is to say further downstream. The printed products can be transported in an uninterrupted, continuous material flow through the production system, that is to say there is no intermediate storage with a required intervention of the machine operator for renewed feeding. Uninterrupted therefore does not mean in this case that the printed products have to be transported without a spacing. According to the invention, a sheet guiding apparatus having a switchable sheet diverter is disposed between the intermediate processing and transfer station and the at least one folding station. The sheet diverter serves to transfer the printed products onto a first or a second transport track. The use of the sheet guiding apparatus advantageously achieves a situation where the at least one folding station no longer represents a chokepoint (or so-called bottleneck) in terms of production technology of the production system. Since the sheet guiding apparatus makes it possible to guide the flat printed products either onto a first or a second transport track and to feed them to a further processing device, the processing speed of the at least one following folding machine no longer has to be increased in order to increase the production output of the production system.
In accordance with another particularly advantageous and therefore preferred embodiment, the printing press is a digital printing press. This ensures that printed products with different contents or printed products which are formed of a plurality of differently printed individual sheets can be produced following one another by the production system and without a great amount of time for machine changeovers.
In accordance with a further preferred structural variant, the printing press is configured as a web-fed printing press, and the intermediate processing and transfer station has a cross cutter for dividing a printing material web into individual sheets. As a result, the folding accuracy of sheet folding stations and the cost advantages of the material costs of a printing material web in contrast to a printing material individual sheet stack can advantageously be combined with one another.
In accordance with an added advantageous embodiment, the intermediate processing and transfer station can have a gathering device for forming stacks of individual sheets. This can, for example, be a so-called a drum gatherer which is optionally equipped with a glue application device for joining the individual sheets. The individual sheets can also be individual sheets with different printed contents which are together to form a printed product, for example a signature. The stack which is formed by the gathering device can then be transferred to a folding station which is disposed so as to follow it and can be folded there to form a brochure.
In accordance with a first structural variant (see
The productivity of pocket folding machines can therefore be increased considerably by the use of a sheet guiding apparatus according to the invention. Two aspects contribute substantially to this: A transverse feed of the sheets to be folded in the feeder or a provision of sheets in landscape format by the cross cutter of the intermediate processing and transfer station together with a sheet guiding apparatus in front of the second folding station. As a result of the lower inlet length of the sheet at an identical machine speed, the performance increase lies at approximately 30 percent depending on the sheet format.
The sheet guiding apparatus makes it possible to guide the folded sheets alternately to two (or more) transport tracks, to align them in parallel on two (or more) guides and to transport them to the second folding station. Since twice as many folded sheets can be transported in this way, the speed of the second station can therefore be reduced by half. As a result of the transverse entry of the sheet in the first parallel folding unit at a constant machine speed, firstly the productivity is increased considerably and secondly, as a result of the low speed of the second station, the folding quality is improved and the folding process is made more stable.
In accordance with a second structural variant (see
In accordance with yet another advantageous development of one of the above-described production systems, the sheet guiding apparatus has a guiding device for transferring a printed product onto the second transport track. In other words, the guiding device serves to bridge the first transport track. Possible refinements of the guiding device will be described further below.
With the objects of the invention in view, there is furthermore provided a method for producing printed products of n different types, with n being equal to 1, 2, 3 . . . and a natural number. The method is carried out in a production system, having a digital printing press, a sheet folding machine and a sheet guiding apparatus, which can be configured, in particular, as described in the above text. The sheet guiding apparatus is configured as a switchable sheet diverter with n switching positions for transferring the printed products onto one of n following transport tracks. In this case, the method comprises the following steps: first of all, a printing material is printed with an n-th printing content. If the printing material is a printing material web, it is subsequently divided into individual printing material sheets. Thereupon, the printing material sheets are folded to form signatures. They are then guided further by the sheet guiding apparatus onto one of the n transport tracks. Thus, for example, a first signature which has been folded from printing material sheets which have a first printing content is guided onto the first transport track. If a printed product of the n-th type is formed of a plurality of signatures, the above-described steps are repeated and the signatures are gathered, for example in a delivery. All of these steps are also carried out to produce the further types of printed products. It is not necessary in this case that first of all a complete product of the n-th type be finished before a printed product of another type is produced. A parallel production of this type having different types of printed products is made possible by the sheet guiding apparatus which has a sorting function.
A method of this type therefore allows different products to be produced on the same production line and to be delivered physically separately from one another. As a result, the productivity of the production system which is used can be increased advantageously. It is no longer required to provide a plurality of production systems for different products. Instead, one production system is sufficient, with it also being necessary to preset only this one production system for job preparation. The outlay for presetting work can therefore be reduced.
In accordance with another advantageous development of the method according to the invention, the printing content which is printed onto the printing material by the digital printing press has an identification feature for identifying the type of printed product (such as a barcode, for example a linear code or a data matrix code). This identification feature is read by a detection system which is situated upstream of the sheet guiding apparatus and brings about an actuation of the sheet guiding apparatus. If, for example, the detection system determines that the printed product is a printed product of the first type, the sheet guiding apparatus is adjusted into its first switching position, with the result that the printed product is guided onto the first transport track. Furthermore, it is advantageous to provide additional monitoring and control systems (for example, barcode reading units and/or cameras) in the further processing course, for monitoring the product quality.
In accordance with a further advantageous development of the method according to the invention, printed products of two types are produced, the printed product of the first type being a main print and the printed product of the second type being a reprint. If there is a disruption in the main production which leads to individual products not passing or passing only with waste into the delivery station of the printed products, a reprint can be brought about immediately either by the machine operator or by a superordinate machine controller. In this case, the reprint is produced by the same production system. However, the sheet guiding apparatus is actuated in such a way that the reprint is separated physically from the main production and is guided onto the second transport track, with the result that the reprint is delivered separately from the main print. The reprint can be manually fed to the printed product later at the correct location. In contrast to the previously stated sequential processing of main print and reprint, this method variant according to the invention considerably increases the productivity of the production system which is used.
In accordance with one alternative development of the method according to the invention, printed products are produced in different versions. In this case, they can be, in particular, different language versions (for example, German, English, French) or different country versions (for example, Great Britain, USA, Australia) or different variant versions (for example, operating instructions for a pneumatic variant, or a hydraulic variant) or different container size versions (for example, a drug with 20 tablets or 100 tablets). These different versions are printed in any desired order on the digital printing press and are subsequently guided by the sheet guiding apparatus onto a transport track which is assigned to the respective version, and are therefore sorted. After folding has been carried out, the different versions of the signatures are delivered separately according to the versions and can therefore be forwarded separately to the end user. This method has the advantage that a larger number of variants can be produced inexpensively without losses in productivity. This is particularly significant for the production of printed products in small to medium runs.
The sheet guiding apparatus of the production system with the function of a sheet diverter can advantageously be configured as the sheet guiding apparatus which is described in the following text.
The sheet guiding apparatus can advantageously be actuated mechanically or pneumatically.
The sheet guiding apparatus can be integrated into a sheet folding machine in different ways. It can be fastened to the first folding station, it can be fastened to a transfer table which is disposed behind the first folding station, or it can be configured as an independent machine module with a supporting structure and rollers for displacing the module which can thus be positioned between the first folding station and the transfer table.
The sheet guiding apparatus can additionally be used for real double stream or multiple stream, in which the sheet is cut (dividing cut/center cut) in the first folding unit: the sheet diverter can be divided centrally for processing a double stream and is given two positions which can be rotated with respect to one another. By switching over to this permanent position, the first partial stream of the double stream is aligned on the first guide and the second partial stream of the double stream is aligned on the second guide and transported further to the second folding station. The sheet diverter is segmented for processing a multiple stream which is produced by more than one dividing cut into the folded signature. In other words: the sheet diverter is formed of a plurality of diverter parts which can be actuated individually. In this case, the diverter parts are actuated in groups in such a way that the extent of one group of diverter parts corresponds approximately to the extent of a signature transversely with respect to the sheet transport direction.
Customary folding machines are suitable in an optimum manner for use of the sheet guiding apparatus. In order to allow the sheets to enter in landscape, a pocket folding machine can be required which is one format class larger than the format class of the sheet. The necessary sheet guiding apparatus can be simply retrofitted in the customary folding machines.
Other features which are considered as characteristic for the invention are set forth in the appended claims.
Although the invention is illustrated and described herein as embodied in a sheet guiding apparatus, a production system for printed products having a sheet guiding apparatus and a method for producing printed products, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims, noting that the invention and advantageous developments thereof as described also represent advantageous developments of the invention in any desired combination with one another.
The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
c is a plan view of a further embodiment of a production system according to the invention;
Referring now to the figures of the drawings in detail and first, particularly, to
In one embodiment which is not shown, the guide plate 14 can be provided with venturi nozzles.
A transfer movement of a sheet 1000 onto the first transport track 2 or the second transport track 3 as a result of the sheet guiding apparatus 1, is shown in greater detail in
The situation after the switching movement 19 has been carried out is shown in
In a third non-illustrated embodiment, the guiding device 17 can be configured as a belt section.
The connection of the sheet guiding apparatus 1 to the transfer table 103 can be seen in
If a double stream of sheets 1000 is to be processed in the sheet folding machine 100, a rotary knife is situated in the first pocket folding station 102 for carrying out a separating cut or center cut. A sheet 1000 which comes from the feeder 101 is halved by way of the rotary knife, and two parallel sheet streams leave the first pocket folding station 102 and pass into the region of the diverter 10 of the sheet guiding apparatus 1. In order to transfer the first sheet stream to the first transport track 2 and the second sheet stream to the second transport track 3, the drive 12 for carrying out a switching movement 19 of the sheet diverter 10 is taken out of operation. The right-hand diverter part 10.1 and the left-hand diverter part 10.2 are then rotated manually with respect to one another in such a way that one of the two diverter parts 10.1 and 10.2 is situated in a first position and forwards a sheet stream to the first transport track, and the other of the two diverter parts 10.1 and 10.2 is situated in the second position and forwards a sheet stream to the second transport track 3. The two diverter parts 10.1 and 10.2, which together form the sheet diverter 10, are shown in
The figures only show the sheet diverter 10 in its first and second position. However, a further position can also be provided, in which waste sheets 1000 can be removed.
In a first operating form, the sheet guiding apparatus 1 is actuated in a synchronized manner in such a way that sheets or stacks which come from the intermediate processing and transfer station 201 are forwarded alternately to the first pocket folding station 102 or to the second pocket folding station 104. Since the first pocket folding station 102 and the second pocket folding station 104 are fed the sheets or stacks with a different orientation, only different products can be produced. In a second operating form of the production system 999, only one of the two pocket folding stations 102, 104 is used for processing printed products, while the other of the two pocket folding stations 104, 102 can already be prepared for a subsequent job.
The products can be different versions. In one alternative embodiment, which is not shown in
A sheet diverter 10 which is segmented in this way for separating a multiple stream can also advantageously be used in one of the above-described structural variants. If a plurality of sheet guiding apparatuses 1 are connected in series (as shown in
In non-illustrated variants, the web-shaped printing material can be printed in a separate printing press. The printing press 200 which is shown in
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20 2010 003 084 U | Mar 2010 | DE | national |
11001028 | Feb 2011 | EP | regional |
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