U.S. patent application number 12/518059 was filed with the patent office on 2011-02-17 for paper-handling installation and method of automatically controlling the processing speed thereof.
Invention is credited to Michael Wiegmann.
Application Number | 20110037221 12/518059 |
Document ID | / |
Family ID | 39167828 |
Filed Date | 2011-02-17 |
United States Patent
Application |
20110037221 |
Kind Code |
A1 |
Wiegmann; Michael |
February 17, 2011 |
Paper-Handling Installation and Method of Automatically Controlling
the Processing Speed Thereof
Abstract
A paper-handling installation is initially set for executing a
job to process a predetermined number of articles during a
predetermined time period. During the processing, the number of
articles detected which are processed during the predetermined time
period is detected. If the detected number of articles is larger
than or equal to the predetermined number, the speed at which
articles are processed in a section of the paper-handling
installation will be increased. If the detected number of articles
is smaller than the predetermined number, it will be detected which
of the sections of the installation caused a reduction of the
throughput, and which installation parameters and/or article
parameters existed at that point in time. On the basis of the
parameters detected, an installation parameter of the section is
then set, and/or the speed is reduced in at least that section.
This procedure is repeated until the job has been executed.
Inventors: |
Wiegmann; Michael;
(Koenigsbrunn, DE) |
Correspondence
Address: |
GLENN PATENT GROUP
3475 EDISON WAY, SUITE L
MENLO PARK
CA
94025
US
|
Family ID: |
39167828 |
Appl. No.: |
12/518059 |
Filed: |
December 5, 2007 |
PCT Filed: |
December 5, 2007 |
PCT NO: |
PCT/EP2007/010566 |
371 Date: |
November 4, 2010 |
Current U.S.
Class: |
271/270 |
Current CPC
Class: |
B65H 2513/10 20130101;
B65H 2801/78 20130101; B65H 2511/31 20130101; B43M 3/04 20130101;
B65H 2511/52 20130101; B65H 2513/10 20130101; B65H 2511/52
20130101; B65H 2801/66 20130101; B65H 43/00 20130101; B65H 2220/01
20130101; B65H 2220/02 20130101; B65H 2511/31 20130101; B65H
2220/01 20130101 |
Class at
Publication: |
271/270 |
International
Class: |
B65H 43/00 20060101
B65H043/00; B65H 5/34 20060101 B65H005/34; B65H 7/20 20060101
B65H007/20 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 5, 2006 |
DE |
10 2006 058 219.5 |
Claims
1. A method of processing articles in a paper-handling
installation, the paper-handling installation being set, on the
basis of a job description, to process a predetermined number of
articles during a predetermined time period, the method comprising
the following being performed by the paper-handling installation:
(d) detecting the number of articles being processed by the
paper-handling installation during the predetermined time period;
(e) if the detected number of articles is larger than or equal to
the predetermined number of articles: (b.1) increasing the speed at
which the articles are processed in at least one section of the
paper-handling installation by a predetermined amount of increase,
and (b.2) setting the predetermined number of articles equal to the
detected number of articles; (f) if the detected number of articles
is smaller than the predetermined number of articles: (c.1)
detecting which of the sections of the paper-handling installation
has caused a reduction in throughput during the predetermined time
period, (c.2) determining at least one installation parameter
present here and/or at least one article parameter, and (c.3) on
the basis of the parameters determined in (c.2), setting at least
one section of the paper-handling installation and/or reducing the
speed at which the articles are processed in a section of the
paper-handling installation, by a predetermined amount of
reduction; and e) repeating (a) to (c) while the job is being
processed.
2. The method as claimed in claim 1, wherein (c.3) comprises:
determining a deviation of the parameters detected in (c.2) as
compared to parameters detected during a preceding time period;
comparing the deviation to a first predetermined threshold; if the
deviation is smaller than the first predetermined threshold,
maintaining the setting of the paper-handling installation; and if
the deviation is larger than the first predetermined threshold,
setting the at least one installation parameter and/or reducing the
speed on the basis of the parameters determined in (c.2).
3. The method as claimed in claim 1, wherein (c.1) comprises
determining the number of events occurring during the time period
which caused a reduction of the throughput, (c.3) comprising:
determining a deviation of the number of events detected in (c.1)
as compared to the number of events detected in a preceding time
period; comparing the deviation to a second predetermined
threshold; if the deviation is smaller than the second
predetermined threshold, maintaining the setting of the
paper-handling installation; and if the deviation is larger than
the second predetermined threshold, setting the at least one
installation parameter and/or reducing the speed on the basis of
the parameters determined in (c.2).
4. The method as claimed in claim 1, wherein (b.1) and (c.3)
comprise setting the speed such that the speed does not exceed or
fall below a predetermined maximum speed and a predetermined
minimum speed, respectively.
5. The method as claimed in claim 1, wherein (c.3) further
comprises taking into account at least one environmental parameter,
the at least one environmental parameter being detected during the
time period contemplated, or being detected once during a plurality
of time periods, and taking into account the at least one
environmental parameter in (c.3) comprising reading out optimum
installation parameters for the detected environmental parameter
from a look-up table.
6. The method as claimed in claim 1, wherein (c.3) further
comprises taking into account any wear and tear in the
paper-handling installation, the wear and tear being detected
during the time period contemplated, or being detected once during
a plurality of time periods, and taking into account the wear and
tear in (c.3) comprising reading out optimum installation
parameters for the detected wear and tear from a look-up table.
7. The method as claimed in claim 6, wherein a determination is
made, depending on the detected wear and tear of an element,
whether replacement of the element concerned or reduction of the
speed of the paper-handling installation will provide increased
throughput of same for the job, wherein (c.3) comprises reducing
the speed if this leads to a higher throughput, and wherein the
paper-handling installation is stopped and the operator is signaled
that the element is to be replaced if this leads to a higher
throughput.
8. The method as claimed in claim 1, wherein (c.2) further
comprises detecting the number of operators of the paper-handling
installation and their positions, the capacity utilization of the
paper-handling installation being set depending on the number of
operators.
9. The method as claimed in claim 1, wherein (b.1) and (c.3)
comprise storing the set speed and the set installation
parameters.
10. The method as claimed in claim 1, wherein the paper-handling
installation processes the articles in groups, the article
parameters further comprising the total number of articles within a
group.
11. The method as claimed in claim 10, wherein each of the groups
comprises a predetermined number of articles, wherein the
predetermined number of articles to be processed during the
predetermined time period is determined in dependence on the sizes
of the groups in the job, a value existing for each group which
indicates the average duration of generating a group within the
installation, and the predetermined number being dependent on the
values.
12. The method as claimed in claim 1, wherein the paper-handling
installation comprises at least two modules, wherein (b.1)
comprises increasing the speed in at least one of the modules, and
wherein (c.3) comprises setting the installation parameters and/or
the speed in at least one of the modules.
13. The method as claimed in claim 12, wherein (a) to (c) are
performed in a decentralized manner in each of the modules, a
central controller monitoring the interface between the
modules.
14. The method as claimed in claim 12, wherein (c.1) comprises
determining whether following an increase in the speed, one or more
events, which caused a reduction of the throughput, occurred (i) in
several modules in the paper-handling installation, or (ii) only in
one module of the paper-handling installation, wherein in case (i),
(c.3) comprises reducing the speed in some of the modules or in all
of the modules of the paper-handling installation, and wherein in
case (ii), (c.3) comprises reducing the speed only in the module
concerned.
15. A paper-handling installation for processing articles which is
set on the basis of a job description so as to process a
predetermined number of articles during a predetermined time
period, comprising: a first sensor for detecting the number of
articles which are processed by the paper-handling installation
during the predetermined time period; a second sensor for
determining at least one installation parameter and/or at least one
article parameter; and a control unit effectively connected to the
sensors and configured to, while processing the job, increase the
speed at which the articles are processed in at least one section
of the paper-handling installation, by a predetermined amount of
increase, and to set the predetermined number of articles equal to
the detected number of articles if the detected number of articles
is larger than or equal to the predetermined number of articles;
and detect which of the sections of the paper-handling installation
caused, during the predetermined time period, a reduction of the
throughput, and, on the basis of the parameters present here, to
set at least one installation parameter of at least one section of
the paper-handling installation and/or to reduce the speed at which
the articles are processed in one section of the paper-handling
installation by a predetermined amount of reduction if the detected
number of articles is smaller than the predetermined number of
articles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a U.S. national entry of PCT Patent
Application Serial No. PCT/EP2007/010566 filed 5 Dec. 2007, and
claims priority to German Patent Application No. 102006058219.5
filed on 5 Dec. 2006, which is incorporated herein by reference in
its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a method of controlling (or
open-loop controlling), or regulating (or closed-loop controlling),
the processing speed of a paper-handling installation, wherein
articles are moved while using at least one transport mechanism,
and to a paper-handling installation, the articles being moved
individually or in groups in the paper-handling installation. In
particular, the present invention relates to a method of
automatically controlling the processing speed of envelope
inserters or letter envelope processing systems and post-processing
systems, and to storing, for re-use, the parameters determined by
the control.
[0003] Conventional technology has known paper-handling
installations for which there is already the possibility of
strongly effecting or controlling speeds in individual modules--if
the system is designed to be modular--or in the entire system.
There is a need, for example, to process difficult articles to be
produced, e.g. articles having low paper grammage, smooth surface
finish, heavy inserts or heavy fillers and the like. To guarantee
safe processing within the overall arrangement, it is useful to
reduce or adapt the transport and further processing speeds and/or
the clock cycles at which the individual modules operate. In
addition, high efficiency performance of the system is achieved in
this manner. Conventionally, this is achieved in the following
manners. [0004] a first, well-known approach consists in simply
controlling the rotational speed of one or several motors in the
system or in the module. As a rule, the control is performed on the
component, i.e. the motor, by directly inputting the parameters.
Such changes may be achieved, for example, via digital input
values, e.g. with servomotors, or by utilizing controllers, for
example slide controllers, e.g. for changing the operating voltage
of the motor. In practice, these are mostly predefined, fixed
settings which may be changed, such a change being made on the part
of the operation personnel, however. [0005] a second possibility
consists in changing the timing of the light barriers used in the
system or in the module which serve to detect the presence of an
article to be processed. By adapting the timing, the requirement
behavior and the delay behavior of the handling stations, which
operate in a clocked manner, for transporting the articles is
controlled. This adaptation enables a reduction or extension of the
clock cycles, but does not result in any change in the actual
transport speed. Nevertheless, some kind of controlled speed of the
overall system results as a consequence of the changed clock cycle
values. In this context, too, the values are typically input via
digital values at operating units comprising displays, or at a
central, PC-assisted operating unit, and are typically input by the
operation personnel of the installation. [0006] A further
possibility that has been known in conventional technology consists
in combining the above-described approaches, i.e. in combining
speed control with adapting the timing. In this manner, a technical
advantage may be achieved over the above-described, isolated
approaches, since because of the reduced requirement times, the
associated speed may usually also be reduced by means of a
corresponding logical function. This combination is put into
practice, within an individual module or within the overall system,
by corresponding control logic, the control again being performed,
however, via inputting corresponding digital control values at the
operating units having displays or at the central, PC-assisted
operating unit, via sliding controllers and the like, which again
is performed on the part of the operation personnel.
[0007] The disadvantages of the above-described approaches are
obvious. All of the methods do not represent any actual closed-loop
control, but, as defined by control technology, a control with
predefined or fixed values without any reset values, target values
or the like as defined by a closed loop control system being taken
into account. All of the approaches actually are open loop control
systems wherein the operator is expected to determine or predefine
the optimum settings for processing.
[0008] In this context, a number of disadvantages result, mention
being made here only of several major disadvantages. There is the
question concerning the defaults according to which the settings at
the installations are actually to be performed, in addition, the
question arises where and in which areas of the module or of the
system such setting actually need to be made, who is responsible
for the correctness of the settings, who actually has access to the
setting possibilities, and how these access possibilities are
governed. In addition, the question arises as to how the benefit
may be quantified and specified with regard to the settings which
are ideal for the process.
SUMMARY
[0009] According to an embodiment, a method of processing articles
in a paper-handling installation, the paper-handling installation
being set, on the basis of a job description, to process a
predetermined number of articles during a predetermined time
period, may have the steps, performed by the paper-handling
installation, of: (a) detecting the number of articles being
processed by the paper-handling installation during the
predetermined time period; (b) if the detected number of articles
is larger than or equal to the predetermined number of articles:
(b.1) increasing the speed at which the articles are processed in
at least one section of the paper-handling installation by a
predetermined amount of increase, and (b.2) setting the
predetermined number of articles equal to the detected number of
articles; (c) if the detected number of articles is smaller than
the predetermined number of articles: (c.1) detecting which of the
sections of the paper-handling installation has caused a reduction
in throughput during the predetermined time period, (c.2)
determining at least one installation parameter present here and/or
at least one article parameter, and (c.3) on the basis of the
parameters determined in (c.2), setting at least one section of the
paper-handling installation and/or reducing the speed at which the
articles are processed in a section of the paper-handling
installation, by a predetermined amount of reduction; and (d)
repeating (a) to (c) while the job is being processed.
[0010] According to another embodiment, a paper-handling
installation for processing articles which is set on the basis of a
job description so as to process a predetermined number of articles
during a predetermined time period may have: a first sensor for
detecting the number of articles which are processed by the
paper-handling installation during the predetermined time period; a
second sensor for determining at least one installation parameter
and/or at least one article parameter; and a control unit
effectively connected to the sensors and configured to, while
processing the job, increase the speed at which the articles are
processed in at least one section of the paper-handling
installation, by a predetermined amount of increase, and to set the
predetermined number of articles equal to the detected number of
articles if the detected number of articles is larger than or equal
to the predetermined number of articles; and detect which of the
sections of the paper-handling installation caused, during the
predetermined time period, a reduction of the throughput, and, on
the basis of the parameters present here, to set at least one
installation parameter of at least one section of the
paper-handling installation and/or to reduce the speed at which the
articles are processed in one section of the paper-handling
installation by a predetermined amount of reduction if the detected
number of articles is smaller than the predetermined number of
articles.
[0011] The present invention provides a method of processing
articles in a paper-handling installation, the paper-handling
installation being set, on the basis of a job description, to
process a predetermined number of articles during a predetermined
time period or time interval, the method including: [0012] (a)
detecting the number of articles being processed by the
paper-handling installation during the predetermined time period or
time interval; [0013] (b) if the detected number of articles is
larger than or equal to the predetermined number of articles:
[0014] (b.1) increasing the speed at which the articles are
processed in at least one section of the paper-handling
installation by a predetermined amount of increase, and [0015]
(b.2) setting the predetermined number of articles equal to the
detected number of articles; [0016] (c) if the detected number of
articles is smaller than the predetermined number of articles:
[0017] (c.1) detecting which of the sections of the paper-handling
installation has reduced a reduction in throughput during the
predetermined time period, [0018] (c.2) determining at least one
installation parameter present here and/or at least one article
parameter, and [0019] (c.3) on the basis of the parameters
determined in step (c.2), setting at least one installation
parameter of a section of the paper-handling installation and/or
reducing the speed at which the articles are processed in a section
of the paper-handling installation, by a predetermined amount of
reduction; and [0020] d) repeating the steps (a) to (d) while the
job is being processed.
[0021] The present invention further provides a paper-handling
installation for processing articles which operates in accordance
with the inventive method.
[0022] The object set forth above is achieved by turning the
open-loop control into closed-loop control for controlling a
paper-handling system or a module of a paper-handling system.
Turning the open-loop control into closed-loop control ensures, on
the one hand, that by the module or the system independently
determining, setting and storing the optimum parameters, maximum
effective performance may be achieved, during deployment operation,
from job to job using different materials. On the other hand, the
possible influence exerted by the operator on the overall
performance of the module or of the system is reduced, while at the
same time the overall operability and the overall operation effort
is reduced without entailing a loss of control of the overall
processing, including the possibility of monitoring the
processes.
[0023] The inventive approach avoids the previous, conventional
procedure wherein adaptation in subareas of the individual
processes, e.g. within the module or within the system, was
possible, however without any automatic correction. In accordance
with the invention, tedious trials (trial-and-error operations)
and, consequently, the time and stress demanded of the operation
personnel by this, are thus avoided. The parameter changes in
processing which were performed on the part of the operation
personnel were indeed useful and helpful, but the inventive
approach represents a clearly more effective procedure as compared
to said approaches which were implemented as open loop control
systems. Due to the automatic, system-inherent identification of
the parameters on the part of the module/system in dependence on
the job to be processed, a controlled speed, or a controlled clock
is determined in a faster, more reliable and permanently repeatable
manner without this depending on the capabilities of the operation
personnel.
[0024] In accordance with the invention, a reduction of stops,
which represent a potential cause for damage to the articles or
even destruction of the articles, a reduction of wear and tear,
extension of the application spectrum is achieved for an optimum
speed of the processing within the module/system at a maximum
effectiveness, independently of any intervention on the part of an
operator.
[0025] In accordance with the invention, the entire system may
autonomously control itself, wherein advantageously all accesses to
the respective parameters, be it at the operating units or at a
central, PC-assisted operating unit, are accessible only to the
maintenance personnel, i.e. not the operation personnel, the
respective areas being protected, in accordance with an
advantageous embodiment, by corresponding encryption.
[0026] In particular, repeated performance of the same job is
improved by storing the results of the settings, since parameters
which have already been obtained during operation (and which were
essentially optimum parameters at the time of the latest
performance of the job) now exist as the starting point. Starting
from said existing parameters, the installation may now be set for
repeated performance of the job. The optimum speeds and optimum
clocks determined during a job are logged and made available again
as parameters for each individual component when the job stored is
called up again, corresponding autonomous control setting itself
during operation if the job is defined differently. The advantage
of this approach is that the system may be placed in an initial
state for processing the job, of which initial state one knows that
the installation for the planned articles operates, in principle,
at a high effectiveness with the parameters already determined.
[0027] Administration of these job parameters may evidently also be
transferred from one system to another system while using a
superordinated storage location, and/or may be taken into account
in central job preparation. A further implementation consists in
selecting the best-suited system for processing a specific job on
the basis of the parameters, which have been determined and
controlled, for adapting the speed and clock. Of course, this
adaptation may also be logged in the central operating system and
be used for further analyses, and it may therefore be
monitored.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Embodiments of the present invention will be detailed
subsequently referring to the appended drawings, in which:
[0029] FIG. 1A-1C show flowcharts of an advantageous embodiment for
setting the speed at which articles are processed in a
paper-handling installation;
[0030] FIG. 2 shows a flowchart of an advantageous embodiment of
the inventive method, wherein the degree of deviation of the
detected parameters is taken into account in successive time
intervals;
[0031] FIG. 3 shows a further advantageous embodiment of the
inventive method wherein the degree to which the numbers of defects
differ in successive intervals is taken into account to cause or
not to cause, as a function thereof, a change in the settings of
the installation.
[0032] FIG. 4 shows an isometric representation of an inventive
paper-handling system in accordance with an embodiment described by
means of an envelope inserter; and
[0033] FIG. 5 shows a block diagram depicting communication of
information between the central controller and the portions of the
envelope inserter of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In the description which follows, advantageous embodiments
of the present invention will be explained in more detail, the same
reference numerals being used for the same or similar elements. It
shall be noted that the description which follows merely represents
an advantageous embodiment of the present invention, but that the
invention is not limited to this specific implementation. In
addition, the term "plurality" will be used in the description
which follows, which term is to be understood as meaning two or
more in the context of the present invention.
[0035] The present invention may be employed wherever paper is
machined within a system and ends up being fed either to a storage
location and/or further processing system, or is inserted, along
with supplements, or inserts, or enclosures, into an envelope and
then is stored and/or subjected to after-treatment. For example,
the paper is fed from a stack or from a roller in an endless manner
or as individual sheets. Processing within the system comprises,
for example, separating, folding, collating, deflecting and similar
paper processing steps. Generally, the present invention may be
applied to any semi- and full-automatic paper processing systems
serving the purpose of sending or passing on information. The
present invention is not limited to enveloping systems, but may
also be employed in envelope sorting lines, e.g. sorters, or in
mail distribution systems. In addition, the inventive approach may
be applied both to individual modules within a system and to a
system as a compound structure.
[0036] The inventive approach utilizes a plurality of parameters
including, e.g., installation parameters, environmental parameters
and article parameters. These parameters are used for enabling
closed-loop control of the installation, which will be described in
detail below.
[0037] The installation parameters comprise parameters which relate
to the setting of individual components within the installation or
of one of several components within the installation as well as
their wear and tear. For example, the installation parameters
relate to the following components of a paper-handling
installation: [0038] for the transport elements employed in the
installation, e.g. for the rollers, the belt or vacuum conveyors:
the roller or belt pitch and the intake pressure; for lateral
guides: the position/the pitch of the guide elements; for a lock
chamber: the roller pitch; or for nozzles: the amount and time of
supply of blow air; [0039] for the driving elements used in the
installation, e.g. for the motors: the rotational speed of the
transport motors, and the acceleration of the articles by the
driving elements; [0040] for the functional components employed in
the installation: e.g. the take-up speed and the acceleration of
the articles, and in addition, for example for a collating station:
a meter reading indicating the collation quantity, and the weight
of the group collated; for sheet feeders: the filling level; for an
envelope inserter: the filling speed; for an output path: the
filling quantity.
[0041] The parameter values are detected via sensors provided in
the installation accordingly, and/or are obtained from the position
of servomotors provided for adjusting various elements (e.g.
servomotors for the rollers, guide elements, etc.)
[0042] Additionally, information on the state of the installation,
e.g. on the wear-and-tear state of individual elements (e.g.
wearout of the transport rollers or belts used) within the
installation is detected.
[0043] The environmental parameters relate to, for example,
environmental factors, e.g. temperature, humidity, static charge,
etc. The values of the environmental parameters are also detected
centrally and/or at important locations within the installation by
suitable sensors.
[0044] The article parameters comprise the physical nature of the
articles to be processed, such as of the paper to be processed, of
inserts to be processed, and of envelopes to be processed, for
example the weight of the article, the size of the article, the
dimensions of the article, the nature of the material of the
article, the basis weight of the article, the flexural strength of
the article, the coefficient of friction of the article, the air
permeability of the article, the roughness of the article, and the
thickness of the article. These parameters, too, are monitored by
suitable sensors within the installation.
[0045] It shall be noted that the above listing of the potential
parameters is only exemplary, but not exhaustive.
[0046] In addition, a job description is provided which in addition
to the indications on the settings of the various parameters of the
installation also contains supplementary information on the
articles to be processed. For example, a job description contains
the number of the articles to be produced in the entire job, the
number of the articles which may be contained in each group, the
indication of the feeders from which the articles are to be fed and
combined into a group, etc. In addition, the job description
contains information on the height and the width of the article to
be processed, on the initial transport speed in the various
sections of the installation, for example at the inlet, at the
outlet, for example for a potential transverse transport, etc.
[0047] Depending on the conditions, a job description contains
further indications known to experts, in principle. Said job
description is electronically provided, to the paper-handling
installation, for example in the form of a file, either by
transmission via a network or by reading in the file from a data
carrier.
[0048] Advantageous embodiments of the inventive method will be
explained below in more detail with reference to FIGS. 1 to 3.
[0049] FIG. 1 shows a flowchart depicting an advantageous
embodiment of the inventive method. The method starts at step S100,
which comprises processing articles in a paper-handling
installation starting from an initial state. In this context, the
paper-handling installation has been set on the basis of a job
description, the job description also indicating a predetermined
number of articles to be processed during a predetermined time
interval or time period. Once the paper-handling installation has
been set and the articles to be merged have been provided at the
various inlet points of the installation, the installation starts
to process the job.
[0050] The inventive method is provided to control the processing
of the articles such that a maximally possible number of articles
processed during a predetermined time period is yielded (maximum
throughput).
[0051] Step S102 comprises detecting, during the predetermined time
period, for example during a specified time unit of several minutes
of several hours, the number of articles processed during this time
period. Step S104 comprises determining whether the number of
articles actually processed is larger than or equal to the
predetermined number of articles. If it is established that the
number of articles exceeds the predetermined number, the method
proceeds to step S106 (see FIG. 1B). Said step comprises increasing
the speed at which articles are processed in at least one section
of the paper-handling installation by a predetermined amount of
increase, and step S108 comprises setting the previously detected
new number equal to the predetermined number, and step S110
comprises storing the parameters and speed which have now been set
for future use. In other words, it is recognized that the
installation operates reliably with the current settings, so that
in accordance with the invention, the processing speed is
increased, wherein monitoring is performed, as will be described in
detail below, as to whether the increase in the processing speed
results in an increase in the throughput. In accordance with the
invention, the installation is thus controlled so as to achieve as
high a throughput (number of articles processed per predefined time
period) as possible.
[0052] Subsequently, the method proceeds to step S112 (see FIG.
1C), which comprises determining whether the job has been
completed. If this is so, the method will end at step S114. If the
job has not yet been completed, the method will return to step
S102.
[0053] If it is established, in step S104, that the number of
articles to be processed within the time period is lower than the
expected or predetermined number (with or without previous
increase), the method will proceed to step S116.
[0054] The drop in the number of articles as compared to the
predetermined number is due to the fact that during processing of
the articles in the paper-handling installation a defect has
occurred at one or several locations, said defect usually leading
to a preliminary stop (interruption of the processing) of the
installation until the defect has been remedied, for example by the
intervention of an operator. Likewise, the number of articles to be
processed will be reduced if any groups of articles which have been
collated within the installation are defective, for example if the
wrong inserts or a wrong number of inserts have been added to a
letter. In this case, said defective articles will be removed from
the installation, which entails a corresponding reduction of the
throughput.
[0055] As defined by the present invention, a defect is understood
to be anything which results in a reduction of the throughput of
articles processed, i.e., for example, an interruption of the
processing or manufacturing of defective articles.
[0056] In this case, step S116 comprises examining at which point
in the paper-handling installation a defect has occurred during the
time period contemplated. Subsequently, step S118 comprises
determining, for this area of the installation, at least one state
or value of an installation parameter and/or an article parameter
which existed while the defect occurred and which, as a rule,
caused the occurrence of the defect. For example, a mechanical
component within the installation may have misadjusted, so that
re-adjustment may be performed, or the properties of the article to
be processed have changed. All of these factors by themselves,
respectively, or in combination may have led to the occurrence of
the defect.
[0057] Depending on which installation parameters and/or article
parameters existed at the time of the occurrence of the defect,
step S120 comprises setting at least one installation parameter
within a section of the paper-handling installation. In addition or
alternatively, the speed at which the articles are processed in the
respective section of the paper-handling installation may also be
reduced by a predetermined amount of reduction, as is also depicted
in step S120. For example, if it is established that the
installation parameters and/or article parameters had not changed,
when the defect occurred, as compared to previous
parameters/article parameters, it may be assumed that the transport
speed resulted in the occurrence of the defect, and in this case,
said transport speed will be lowered. As was mentioned above, this
may either be performed by itself or along with setting other
parameters of the installation.
[0058] If it is found that a property of the parameter of the
article to be processed, for example the roughness of the paper, is
changing, it will be sufficient, for example, to change the contact
pressure of the transport drums within the affected section of the
paper installation without a change in the speed being necessary.
However, if it is additionally found that the thickness of the
paper has also changed, so that said paper can no longer be moved
at the original speed, the transport speed may also be changed. For
example, if only the thickness of the paper has changed, it might
be sufficient to change the speed only. Setting the speed within
the installation is performed, for example, by changing a
rotational speed of a motor, by changing an acceleration of
articles within the paper-handling installation, and/or by changing
the clock performance. Advantageously, the change is performed step
by step, or in stages (incrementally).
[0059] Once the installation has been reset in step S120, the
method proceeds to step 112 in FIG. 1C, which comprises checking
whether the job has been completed. If this is not so, the method
returns to step S102, as was mentioned above. As was mentioned
above, the parameters set are stored, which additionally opens up
the possibility of creating a log with regard to the settings
during processing of the job. The settings stored in step S110 may
further be associated with the job file, so that said settings may
be utilized, during repeated performance of the job, for initially
setting the installation, so that the installation may be
automatically set to the corresponding values at a later point in
time when processing a corresponding job, which may be
accomplished, for example, by controlling corresponding servomotors
which cause the change in the transport elements. During repeated
performance of the job at a later point in time, the stored data
set is initially loaded, and initial setting of the paper-handling
installation is effected, while re-adjustment is then performed in
accordance with the invention, depending on the current state of
the installation, on current environmental parameters and while
taking into account any potential variations in the properties of
the article to be processed. In this manner, in accordance with the
invention, fast initial setting of the paper-handling installation
to jobs which have already been performed once or several times is
enabled, and at the same time, automatic control/adjustment of the
installation is enabled so to offset any differences in the
articles to be processed and/or changes in the installation and
environmental parameters as compared to the initial parameters.
[0060] In accordance with the invention, the processing speed
within the paper-handling installation is thus controlled, an
increase in the processing speed being generally conducted, as long
as no defects occur, so as to achieve optimum throughput within the
installation. Advantageously, the speed is set such that the speed
does not exceed or fall below predetermined maximum and
predetermined minimum speeds, respectively. In other words, a
"window" is predefined for the installation and/or for components
or modules of the installation, respectively, said window
indicating the upper and/or lower limits of the potential speeds.
For example, a merger shall be contemplated which receives two
sheets in parallel and conveys them along a travel path such that
the sheets will be arranged one above the other at the end of the
travel path. For some merger types, the sheets are moved along this
travel path without being driven, so that a predetermined speed of
the sheets may not be fallen below while they are being fed to the
travel path, so as to ensure that the sheets will reach the end of
the travel path. Likewise, an upper limit is specified above which
the sheets will be damaged. Both the upper and lower limits depend,
among other things, on the paper and/or on its properties
(parameters, see above).
[0061] With reference to FIGS. 2 and 3, two further advantageous
embodiments of the present invention will be explained below which
introduce threshold values with regard to the deviations of the
parameters and/or with regard to the number of defects occurring
during a time interval, decisions being made, depending on said
threshold values, as to whether the changes are severe enough for
settings of the installation to have to be changed, or whether said
changes are within acceptable tolerance ranges.
[0062] In accordance with the embodiment of the present invention
which is shown in FIG. 2, step S130 comprises determining a
deviation of the detected parameters as compared to those
parameters which were detected during a preceding interval or
during a preceding time period. In step S132, said deviation is
compared to a predetermined threshold. If the threshold is
exceeded, step S134 comprises setting the installation parameter
and/or reducing the speed. If the threshold is not exceeded, the
setting of the paper-handling installation in maintained unchanged
(see step S136).
[0063] In a further embodiment, shown in FIG. 3, of the present
invention, step S140 comprises detecting a number of the defects
which occurred during the time period or time interval, and step
S142 comprises detecting a deviation of the number of defects
detected as compared to a preceding time period or interval. Step
S144 comprises comparing the deviation with a predetermined
threshold, and if the threshold is exceeded, step S146 comprises
changing the setting of an installation parameter and/or reducing
the speed. If the threshold is not exceeded, the setting of the
installation is maintained (see step S136).
[0064] Within the context of the above description of an
advantageous embodiment of the inventive method, a description was
given to the effect that in connection with the setting of the
installation parameters and/or the reduction of the speed, the
installation parameters or article parameters which exist during
the time instant of a defect are taken into account. In accordance
with a further advantageous embodiment of the present invention, it
is also possible to additionally take into account one or several
of the above-described environmental parameters. Likewise, the wear
and tear of individual elements within the paper-handling
installation may also be taken into account. The environmental
parameters and/or wear-and-tear parameters which have just been
mentioned are either continuously monitored or are monitored at a
time instant during the time interval contemplated, or are
monitored once during a plurality of time intervals. If the
environmental parameters and/or the wear and tear are taken into
account, the installation is advantageously set while accessing a
look-up table wherein corresponding optimum installation parameters
are stored for various environmental parameters or for various
signs of wear and tear, so that the installation may be reset, e.g.
as a function of an environmental temperature, from an initial
temperature range comprising a first setting to a second
temperature range comprising a second setting of the installation
parameters.
[0065] In accordance with a further embodiment of the present
invention it is provided that it is determined, depending on the
detected wear and tear of an element, whether or not interruption
of the job execution in order to replace the component exhibiting
the wear and tear is useful. This is determined as a function of a
possible throughput of the paper-handling installation for the job.
For example, a situation may arise when there is the possibility of
continuing to operate the installation despite detected wear and
tear of a component, but of operating it at reduced speed. In this
case a decision is made as to whether execution of the job at the
reduced speed is occurs faster than is the case when the
installation is stopped, the worn element is replaced, and the
installation is operated again at full speed. By way of example,
wearout of a cutter shall be contemplated here, wherein in this
context, replacement of a knife would take two hours. If it is
determined that within this time period, the job may be executed at
reduced speed while yielding an equally good result, a decision
will be made that replacement of the worn element will be put off
until an idle phase after the job has been terminated, so as first
to finish processing the job being executed. Advantageously, a
look-up table is accessed for this purpose, from which look-up
table the amount of time taken to replace an element may be
derived, so that the inventive method determines, on the basis of
the job description from which the number of articles which are to
be processed in the overall job is known, determines whether the
job is to be interrupted or is to be completed at reduced
speed.
[0066] In accordance with a further embodiment, the operation
personnel is also taken into account. The operators of the
installation are equipped with transponders to detect the number of
operators and their positions. This allows adjusting a capacity
utilization of the paper-handling installation as a function of the
number of operators. If the number of operators is not sufficient,
for example, for regularly placing inserts at the supplement
feeders, or for regularly removing the finished articles from the
output belt, this will lead to an interruption (a stoppage) of the
installation (defect), which in turn will result in a decrease in
the throughput. By monitoring the number of operators it is
established whether or not there are a sufficient number of persons
present for allowing continuous operation at full capacity. If the
number of operators is not sufficient, the processing speed will be
reduced accordingly, which, however, will lead to increased
throughput overall due to the lack of interruptions occurring on
account of insert feeders running empty or of the storage belt
filling up.
[0067] Irrespective of the number of operators, one may further
monitor in this embodiment, in accordance with the invention,
whether any defects have occurred during the operation without the
set parameters having changed during successive time intervals. It
is possible to detect, along with the information on the number of
operators and the positions of the operators, that at installation
sections, defects occur which call for intervention of an operating
person, so that it may be established that the installation speed
may be reduced for proper handling on the part of the operator.
When it is detected that the number of operating persons has
increased, the speed may be increased again.
[0068] In addition, the inventive approach also allows sensing an
activity of the operating person on the basis of their movements,
so as to communicate, for example, that a frequently occurring
interruption is not an installation defect, but is due to the fact
that the operating person has not added further inserts, or
enclosures, fast enough or has removed completed articles from the
output belt.
[0069] As was already briefly mentioned above, the articles are
processed either individually or in groups in the paper-handling
installation, and in the latter case, the article parameters
further comprise the total number of articles within a group.
However, it shall be noted, in this context, that it is not
mandatory for each group to comprise the same number of articles,
but depending on the job description, different groups will contain
different amounts of articles. In this case, a variation in the
number of articles (groups) output does not necessarily represent a
reduction in the throughput which is to be traced back to a defect.
Depending on the size of the group, the duration of compiling the
group up to the group being output varies. If, for example, only
groups of five elements (letter, enclosures, etc.) are being
processed during the time interval, the throughput will be higher
than if groups of ten elements are processed during the same time
interval.
[0070] This situation is taken into account in that values are
provided for the groups which indicate the average time period
useful for generating the groups, so that the "predetermined
number" of articles (here groups) processed during a time interval,
said "predetermined number" being used for inventive control, is
determined on the basis of said values.
[0071] So far, the inventive method has been described by means of
an installation which is already in operation. Before the inventive
control sets in, the paper-handling installation is initially set
for processing the job to be performed. To this end, the job
description (see above) is advantageously obtained which describes
the initial setting of the installation parameters for the job to
be processed. In accordance with the installation parameters
obtained, the installation is then set (configured). At this stage,
an environmental parameter (see above) may also be detected, so
that the set paper-handling installation may be reset on the basis
of this environmental parameter detected. In addition, a sign of
wear of the paper-handling installation may be recognized, which is
useful when the installation has executed one or several other jobs
since the latest job execution, which possibly led to wear and tear
of individual parts. In this case, too, resetting of the
paper-handling installation is performed on the basis of the
detected sign of wear.
[0072] During the operation of the installation, monitoring of the
environmental parameters and/or of the signs of wear may be
continuously performed in addition to the control as was previously
described, so as to allow, irrespective of the throughput, a
reaction to said changed parameters in that the paper-handling
installation is reset on the basis of the detected parameter
values. In addition, the installation parameters and the article
parameters may also be continuously monitored during operation so
as to automatically reset the installation in case of any
deviations, in this case the parameters being detected, as was
already mentioned, either continuously or at specific fixed points
in time during one or several intervals.
[0073] So far, a paper-handling installation has been described
which comprises several sections, for example a feeder, a collating
station, an envelope inserter, etc., as will be described in detail
below with reference to FIG. 4. However, in accordance with the
invention, the present method may also be applied to paper-handling
installations of modular designs, in which case, depending on the
circumstances detected, the speed is set in one or more of the
modules. Likewise, the parameters may be set in one or more of the
modules, in case of a modular design the modules advantageously
effecting control in a decentralized manner, and only the interface
between the modules being monitored by a central controller. In
addition, it may be determined, in an advantageous embodiment,
whether following an increase in the speed, a defect has occurred
in several of the modules or in only one of the modules, so that
depending on this, the speed is decreased either in all or in some
of the modules or only in the module in question.
[0074] FIG. 4 shows a paper-handling installation, which is
controlled in accordance with the invention, by way of example of
an enveloping installation. Such a paper-handling installation
comprises a supply channel comprising, for example, cutters and
sheet feeders. The supply channel is followed by an input
channel/processing channel, wherein articles are collated, folded
and gathered. A gathering path provided in the input
channel/processing channel comprises one or more insert feeders,
for example. The input channel/processing channel is followed by
the envelope filling, in this context an envelope inserter
comprising an envelope feeder, for example, which provides the
envelopes. The envelope inserter is followed by post-processing,
for example output of the enveloped articles to a post-processing
system, for example a sorter and the like.
[0075] The enveloping installation 100 comprises a first input 102,
a second input 104, and a third input 106, continuous webs 108,
110, 112, which are printed for dual-use, being provided at all of
the inputs 102 to 106, respectively. All of the inputs 102, 104,
106 for continuous processing comprise a cutting device not shown
in FIG. 4 for cutting the supplied paper web transversely, on the
one hand, and longitudinally, on the other hand, so as to generate
the individual articles to be processed.
[0076] The first input 102 is followed by a merger or merger path
114, which is followed by a collating station 116 wherein a
predetermined number of articles are collated and are moved further
along as a group. The collating station 116 is followed by a
folding unit 118 and a transport module 120.
[0077] The second input 104 provides the paper web 110, which is
printed for dual-use, and also comprises, just like the input 102,
a device for transversally and longitudinally cutting the paper web
110. In contrast to the first input 102, the second input 104
comprises initially further processing the cut documents in
parallel, in a folding unit 122, which is followed by a deflection
station 124 wherein the folded articles which are now placed one
behind the other are together transferred to a collating station
126, and from there to a transport module 128.
[0078] The articles provided by the transport modules 120 and 128
are collated in a collating station 129 and are supplied to a
further collating station 132 via the transport module 130.
[0079] The third input 106 represents the continuous paper web 112,
which is printed for dual-use, so that just like the inputs 102 and
104, the input 106, too, comprises a means for transversely and
longitudinally cutting the paper web 112. Similarly to the input
104, the cut articles are provided in parallel to a folding unit
134 and from there to a deflection means 136, from which the
articles, which are now placed one behind the other, are provided
to a collating station 138. Starting from the collating station
138, the articles collated there are supplied, via the transport
module 140, to the collating station 132, where they are merged
with the articles provided from the inputs 102. Starting from the
collating station 132, the articles collated are provided to the
feeders 142a and 142b, where optionally further inserts may be
added to the stacks of articles formed in the collating station
132. Finally, the articles, or groups of articles, thus formed are
provided to the envelope inserter 144, which inserts them into
corresponding envelopes and deposits the envelopes on a shingled
belt 146.
[0080] In addition, FIG. 4 shows the central controller 148 of the
installation 100, the connection of said controller 148 to the
modules being schematically depicted at 148a. Also, a sensor 150 is
shown which is also connected to the central controller 148, as is
schematically shown at 148b. In the embodiment shown, the
controller 148 is realized, for example, by a computer,
possibilities of setting the operation of the installation, and the
data processing means for logging the documents to be processed
being included, at the same time, via a user interface. The
controller 148 further monitors the functioning of the individual
modules and of the overall system, for example for detecting fault
conditions.
[0081] The system described in FIG. 4 is an enveloping system, for
example, as is mainly used for banks and insurance companies, for
example for using insurance policy documents which are printed for
single use or for dual use. As has already been mentioned, the
system comprises three inputs 102, 104, 106 for continuous
processing, each with collating and folding possibilities, as well
as a folding insert feeder 142a comprising bar code readout for
intelligent individual-sheet processing. The system enables merging
documents or articles from all of the inputs 102 to 106. The
vertical stack belt 146 allows a large storage volume and,
consequently, reduced expenditure in terms of operation
personnel.
[0082] In addition, at important measuring points such as at the
inputs 102, 104, 106, for example at all of the or at selected
processing elements, namely at the collating stations 116, 126,
128, 132, 138, at the feeders 142a and 142b, at the envelope
inserter 144, and at the storage location 146, the enveloping
installation 100 shown in FIG. 4 comprises sensors S.sub.1 and
S.sub.2, which, in accordance with the embodiment described by FIG.
4, detect the nature of the material of the article to be processed
which is present at the corresponding station, as well as further
properties, such as the number of sheets within a group at the
corresponding collating stations. On the one hand, this information
is serially transferred, in a so-called "handshake" operation,
between the individual elements of the modular arrangement shown in
FIG. 4, and is further transmitted, for actively controlling the
overall system, to the central controller 148. In addition, one or
more of the modules shown in FIG. 4 may comprise sensors S.sub.1,
which detect wear and tear of the components used, and may also
communicate via the overall system and to the central controller
148 for evaluation. In addition, FIG. 4 may also show the sensor
150, which has already been mentioned and which may serve to detect
environmental parameters, such as the temperature and/or humidity,
the information obtained by the sensor 150 also being provided to
the controller 148.
[0083] Alternatively or additionally, sensors for detecting the
environmental parameters may also be provided within the individual
modules, which is useful particularly for large installations,
since due to the large spatial expansion of such installations,
central detection of the environmental parameters would not be
accurate enough. In the embodiment shown, the sensor S.sub.2
associated with the storage location 146 is provided so as to
supply a signal, on the basis of which the control unit 148 will
determine the actual output performance.
[0084] FIG. 4 further shows operators 160A, 160B, each of which is
equipped with a transponder T. The control unit 148 communicates
with the transponders T to detect the number of operators 160A,
160B and their positions. Depending on the number of operators
160A, 160B, the control unit 148 may set the capacity utilization
of the paper-handling installation 100, as was described above.
[0085] During operation, the installation shown in FIG. 4 operates
in the above-described manner, such that the corresponding sensor
signals are output to the central controller 148 via the
above-described sensors S.sub.1, S.sub.2. In an advantageous
embodiment, the central controller 148 obtains a job description
for the job to be processed, as was described above. On the basis
of the information stored in said job, in conjunction with the
properties detected, the central controller 148 causes the
corresponding modules to be controlled so that they be set. In
accordance with another advantageous embodiment of the present
invention, the central controller 148 falls back on stored
parameters with regard to the speeds set which were already
detected in preceding runs, and on account of the sensor signals
detected it causes suitable post-control for the process to be
performed at that particular point in time.
[0086] Examples of the inventive approach will be explained below
with reference to FIG. 4.
[0087] One example of detecting properties of the article to be
processed comprises detecting a code provided on the paper web,
said code being detected by a reader in the input channels 102, 104
and 106. Such readers are designed, for example, to read the code
from the paper web while said paper web is passed along the read
head at, e.g., 5 m/s. With a correctly printed code, the read head
is able, at said speed, to correctly detect the code. However,
there may be situations when the code on the paper web is only
poorly legible, be it that it is partly covered by other features
or imprints due to a malfunction in the previous processing
operation, that too little toner was applied, or that only little
contrast exists. In this case, read errors are detected, since a
read operation now is no longer possible at the speed mentioned. An
increase in the number of read errors indicates a poorly printed
code, so that the installation is operative to reduce the "reading
rate", i.e. the speed of the paper web at which the code is passed
along the read head, once a specific threshold of the number of
read errors is reached. The speed may be reduced to 3 m/s, for
example, either in one step or gradually, until the read error rate
is below the threshold mentioned. In addition, if the threshold is
fallen below, signaling may be generated in order to generate a
message which indicates that the code is only poorly legible.
[0088] If the installation is a so-called online installation, i.e.
if the papers to be processed are directly generated by an upstream
high-speed printer, a return channel may optionally be produced
between the installation shown in FIG. 4 and the associated online
printers, so as to control said online printers--in the event that
a poorly printed code is detected--to improve the print of the
code.
[0089] Even though the above example concerning code detection was
described in the context of the input channels 102, 104 and 106,
this embodiment may also be employed at any other location within
the installation at which a code is detected.
[0090] Optionally, provision may be made for an alert message to be
output to the operator once the speed has been reduced because the
threshold concerning the read errors has been fallen below, so that
said operator may possibly take steps to counteract said tendency
with regard to the poorly printed code. If the quality of the code
continuous to deteriorate, or if the code still cannot be read even
though the speed has been reduced, an error message will be output
once a further threshold has been reached, and processing will be
stopped.
[0091] In a further example, the installation comprises several
sheet feeders, and it is found that the defects can be traced back
to the fact that a feeder has been depleted. For example, the
arrangement shown in FIG. 4 comprises three feeders 142a, 142b, a
first job withdrawing sheets from all of the sheet feeders, for
example. As a result, the individual sheet feeders are depleted in
a relatively uniform manner, so that as a rule, refilling is
possible without any problems. However, if a job is performed
wherein only one of the sheet feeders is used, said sheet feeder
will be depleted relatively fast, so that an operator may possibly
not be able to keep up with refilling it, which will make itself
felt by an increased number of interruptions. The installation may
be automatically configured to reduce the processing speed and/or
to suggest an alternative operating mode, for example toggle mode,
to the operator, said toggle mode comprising the use two of the
sheet feeders, from which sheets are alternatively withdrawn, so
that an operator will have sufficient time for refilling the
installations.
[0092] The above description of the advantageous embodiments was
based on the overall system shown in FIG. 4, but those skilled in
the art will also know further systems comprising other modules
than those shown in FIG. 4, and the principles of the present
invention may naturally also be readily transferred to other such
modules as will be mentioned below with reference to FIG. 5.
[0093] FIG. 5 shows a block diagram which illustrates communication
of information between the central controller 148 and the
individual stations of a paper-processing system as is shown, for
example, with reference to FIG. 4. In this case, the individual
blocks in FIG. 5 have the corresponding reference numerals of the
modules shown in FIG. 4 associated with them, and the filled-in
horizontal arrows indicate the communication along the installation
in the "handshake operation", and the non-filled-in vertical arrows
indicate the status and situation messages for active control which
are exchanged between the central controller 148 and the individual
modules.
[0094] As may be seen, the system controller or system regulator
148 contains default actuating variables for the individual
modules, which initially set, for example, the motor speed and the
clock cycle of individual modules so as to provide a defined
starting point for processing a job. As an alternative to such
actuating variables, which are set, for example, by an operator,
optimum operating points which were determined in preceding runs
may be read out from a memory so as to set the overall installation
in accordance with the known parameters. As was described above,
the useful setting may also be derived on the basis of information
from job programming and/or from corresponding specifications of a
job.
[0095] The four processing channels shown in FIG. 5 comprise, on
the one hand, the so-called supply channel 160, the processing
channel 162, the finishing channel 164, and the post-processing
channel 166. As was mentioned above, the respective channels have
the corresponding modules of the exemplary enveloping system 100 of
FIG. 4 associated with them, and the supply channel also has
so-called autoloaders, dispensers and printers associated with it
in addition to the cutters 102, 104, 106 and sheet feeders 142a and
142b, which are shown in FIG. 4. In addition to the collating
stations 116, 126, 128, 132, 136 shown in FIG. 4, to the folding
units 118, 122, 134 shown in FIG. 4, and the deflection means 124
and 136 shown in FIG. 4, the processing channel 162 also has rotary
means, stapling means and the like associated with it. In addition
to the envelope inserter 144 shown in FIG. 4, the finishing channel
164 also has stackers and sorters and similar elements associated
with it. In addition to the storage location 146 shown in FIG. 4,
the post-processing channel also has franking means, printers,
readers, sorters, packaging means and the like associated with
it.
[0096] In all of the channels, environmental parameters, article
parameters and installation parameters are detected. Even though
with reference to FIG. 4, a paper-handling installation in
accordance with the present invention was described by means of an
enveloping system of a modular design, it shall be noted at this
point that the inventive apparatus is not limited to modular
systems. Likewise, the inventive approach may be applied to a
non-modular paper-handling installation comprising one or more
paper-handling stations. For example, the inventive approach may
also be applied only in conjunction with the envelope inserter 144
shown in FIG. 4, or with a subset of the modules shown, in which
case the envelope inserter 144 will receive only the articles to be
enveloped, and will envelope and output same. In addition, it shall
be noted that the inventive paper-handling installation is not
limited to the enveloping installation shown in FIG. 4. The
inventive approach may also be employed for other installations
having other configurations, it being possible for such
installations to comprise additional autoloaders, dispensers,
printers, rotary means, staplers, sorters, franking units,
packaging means, etc.
[0097] In addition it shall be noted that the embodiment described
with reference to FIG. 4 comprises sensors, respectively, at the
above-indicated elements of the respective channels, it also being
possible, however, for the sensors to be provided either at all of
the individual modules or only at selected individual modules,
possibly at less than the above-described modules, depending on the
conditions of the installation.
[0098] As was described above, the inventive method may be applied
to an overall installation, to parts of an installation, or to
individual modules of a modularly designed installation, the
individual sections or modules of the overall installation being
controlled via a central controller in each case. In accordance
with the present invention, individual selected sections or
modules, which are particularly critical to the processing of the
articles, are monitored, and their speeds are controlled, but
provision may also be made for monitoring and controlling each
individual section or module.
[0099] The present invention is not limited to the above-described
embodiments, but may be applied wherever paper is machined within a
system and is eventually fed to a storage location and/or
further-processing means, for example, and it therefore generally
relates to any semi- or full-automatic paper processing
systems.
[0100] In the description of the embodiments of the invention, any
reduction of the throughput of articles processed which is due to
an interruption of the processing or to the generation of defective
articles has been regarded as a defect, as have the events
underlying the interruption of the processing and/or the generation
of defective articles.
[0101] In addition to events caused by a malfunction of the
installation or of one or more modules of the installation, one may
also consider other events, for example the case that all of the
modules of an installation per se are properly set, but that one or
more of the modules are modified, for example with regard to their
processing speeds, such that modules which directly follow them or
are further downstream from them will refuse to take on the
articles for processing, since the articles are supplied too fast,
for example (for example, a folding unit may accept articles, e.g.
paper, only at a maximum speed to ensure proper folding). In this
case (event), the articles are no longer withdrawn from the
precursor component, so that the throughput is reduced without a
"classical defect" occurring.
[0102] In addition, the throughput may decrease--without the
occurrence of any "classic defects"--if the articles are run, e.g.
at too large a distance from one another. If the problem of jams or
the like occurs at too small a distance, which results in a
stoppage of the installation and therefore reduces the throughput,
a reduction will be given even if the distance between the articles
is too large.
[0103] In the above-mentioned cases, too, the inventive approach
will be effective and result in the installation and/or the
installation parts (or modules) to be controlled so as to adapt the
speeds during processing, to increase or reduce the distance,
etc.
[0104] In addition, in the description of the embodiments of the
invention, the setting of the speed of the processing was explained
primarily by means of settings of the motors transporting the
articles. However, the present invention is not limited thereto.
Instead of changing the conveying speeds of the motors, other
parameters which influence the processing speed may be modified.
For example, the points in time when an article from a predecessor
component is requested by a successor component may be changed
(increased/decreased), for example, within the installation and/or
between the modules so as to influence the processing speed.
Likewise, the distance of the articles may be changed
(increased/decreased) so as to influence the processing speed.
[0105] In addition, the description of the embodiments of the
invention has further been based on the assumption that the
installation already runs at normal operation. If a job processing
is newly started, the job is performed either repeatedly or for the
first time. If the job is performed repeatedly, the initial value
of the desired throughput may be stored along with the job and
provided to the installation.
[0106] During the restart of the installation for processing a new
job, an initial value of the desired throughput may be missing (in
particular if the job is performed for the first time). In this
case, provision is made for the initial value of the desired
throughput to be either predefined by the job, to be set by an
operator, or to be set to a default value (e.g. zero).
[0107] In addition, provision may be made that setting the
installation parameters initially comprises performing relatively
large steps until normal operation is achieved, so as to achieve
fast control of the installation, after the start, to reach the
desired condition. The step size may be changed in a linear manner,
for example.
[0108] While this invention has been described in terms of several
embodiments, there are alterations, permutations, and equivalents
which fall within the scope of this invention. It should also be
noted that there are many alternative ways of implementing the
methods and compositions of the present invention. It is therefore
intended that the following appended claims be interpreted as
including all such alterations, permutations and equivalents as
fall within the true spirit and scope of the present invention.
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