U.S. patent number 3,819,173 [Application Number 05/176,851] was granted by the patent office on 1974-06-25 for method and apparatus for producing magazines or the like.
This patent grant is currently assigned to Harris-Intertype Corporation. Invention is credited to Frederick Douglas Anderson, David Austin Reed.
United States Patent |
3,819,173 |
Anderson , et al. |
June 25, 1974 |
METHOD AND APPARATUS FOR PRODUCING MAGAZINES OR THE LIKE
Abstract
A method and apparatus for producing different magazines
composed of different predetermined combinations of signatures for
different subscribers in a continuous process and which includes
on-line printing and/or punching and insertion of individual
subscriber's subscription renewal or information cards, on-line
printing upon command of each subscriber's label and complete
custody of the subscriber's magazine throughout the process so that
if any particular subscriber's magazine is defective it is rejected
and a new magazine is reordered.
Inventors: |
Anderson; Frederick Douglas
(Shaker Heights, OH), Reed; David Austin (Easton, PA) |
Assignee: |
Harris-Intertype Corporation
(Cleveland, OH)
|
Family
ID: |
22646122 |
Appl.
No.: |
05/176,851 |
Filed: |
September 1, 1971 |
Current U.S.
Class: |
270/52.04;
493/379; 493/320 |
Current CPC
Class: |
B65H
39/055 (20130101); B65H 2301/4311 (20130101) |
Current International
Class: |
B65H
39/055 (20060101); B65H 39/00 (20060101); B65h
039/02 () |
Field of
Search: |
;270/54-58,7,14,15,20,21,37 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Michell; Robert W.
Assistant Examiner: Hum; Vance Y.
Claims
Having thus described the invention, what is claimed is:
1. A system for producing magazines containing different inserts
for different subscribers in accordance with known subscriber
information, the system comprising;
source means for feeding the magazines,
conveyor means for carrying the magazines from said source
means,
storage means for storing information identifying each subscriber
with the predetermined information to be included in the insert for
that subscriber's magazine,
a source of blank inserts,
inscribing means for inscribing information on said blank inserts
in accordance with the information stored in said storage
means,
inserting means for placing an insert in a magazine as it is being
carried by said conveyor means, and
control means connecting said storage means with said source of
inserts, said inscribing and inserting means for instructing the
feeding, inscribing and inserting of the inserts in accordance with
the information in said storage means as said magazines are being
fed by said source means and carried by said conveyor means.
2. The system of claim 1 and further including error detecting
means for detecting an error in the production of a magazine,
error identifying means for identifying the particular subscriber
affected by the error,
said control means including means operative when an error has been
identified to instruct said insert inscribing means and said
inserting means in accordance with the information in said storage
means for said particular subscriber.
3. The system of claim 1 wherein said storage means further
includes information as to each subscriber's mailing address,
means for preparing mailing labels,
means for applying mailing lables to the magazines as they are
carried by said conveyor means,
said control means being connected to said label preparing and
applying means for instructing the preparation and application of
each subscriber's mailing label in accordance with the information
in said storage means as the subscriber's magazine is carried by
said conveyor means.
4. The system of claim 3 and further including error detecting
means for detecting an error in the production of a magazine,
error identifying means for identifying the particular subscriber
affected by the error,
said control means including means operative when an error has been
identified to re-instruct said insert inscribing means, said
inserting means and said label preparing and applying means in
accordance with the information in said storage means for said
particular subscriber.
5. The system of claim 1 wherein the subscribers are grouped in
accordance with predetermined criteria with each group of
subscribers defining a run,
said control means using the information in said storage means in
the order in which the subscribers are grouped whereby the feeding
of magazines for each subscriber in one group is instructed before
the instructing of feeding of magazines for subscribers in the next
group,
divert means for diverting magazines from said conveyor means,
error detecting means for detecting an error in the system,
error identifying means operative upon the detection of an error
for identifying the particular subscriber affected by the
error,
said control means including means operative when an error has been
identified, to instruct said source means to feed another magazine
for said particular subscriber and instruct said inserting means in
accordance with the information in said storage means for said
particular subscriber,
said control system further including means operative upon
re-ordering a magazine for comparing the group in which said
particular subscriber is grouped with the group of subscribers for
which magazines are then being fed, and
means operative when said particular subscriber is from a group
different from the group then in process for actuating said divert
means to divert said particular subscriber's magazine from said
conveyor means.
6. A method for producing different magazines composed of different
predetermined combinations of signatures and different inserts for
different subscribers in accordance with predetermined cirteria
from known subscriber information, utilizing different signatures
located in different pockets of a gathering machine of the type in
which each cycle of operation of the gathering machine causes
feeding of signatures from at least some of the pockets to make up
each magazine and in which each pocket may be individually
instructed to feed or not feed during each gathering machine cycle,
the method comprising the steps of:
preparing a machine readable file identifying the different
subscribers with different predetermined combinations of at least
some of the gatherer pockets to be instructed to feed to provide
the predetermined combinations of signatures constituting the
appropriate magazines for the subscribers and identifying each
subscriber who is to receive an insert and the predetermined
information to be included in that insert,
progressively machine reading the file,
in accordance with the information read from the file, instructing
feeding of the gatherer pockets in the predetermined combination
required to provide the different magazines appropriate for the
corresponding different subscribers,
in accordance with the information read from the file automatically
inscribing the information for each subscriber on an insert card as
each subscriber's magazine is being prepared in the gathering
machine, and
inserting the different inscribed insert cards appropriate for each
subscriber in the different magazines appropriate for the
corresponding subscribers as the magazines are being fed from the
gathering machine.
7. The method as defined in claim 6 wherein the step of preparing
the machine readable file includes the step of providing at least
the name and address of each subscriber in machine readable form
and the method further including the steps of:
responsive to reading the file, automatically printing labels
bearing the name and address of each subscriber, and
utilizing a labeling head to apply the label for each subscriber to
a magazine constituted of the predetermined signature combination
and inscribed insert card appropriate for that subscriber as the
magazine arrives at the labeling head.
8. The method of claim 6 and further including the steps of:
monitoring the process for the occurence of an error as the
magazines and insert cards are being produced,
detecting an error when it occurs and identifying the particular
subscriber whose magazine is affected by the error, and
in accordance with the information read from the file,
re-instructing feeding of the gatherer pockets and the inscribing
and inserting of the insert card appropriate for that
subscriber.
9. The method of claim 8 wherein the step of preparing the machine
readable file includes the step of grouping the subscribers in
accordance with predetermined criteria with each group of
subscribers defining a run and with the file means being read in
the order in which the subscribers are grouped,
said method further including the step of feeding the magazines to
a collection point for assembly by groups,
the step of re-instructing including the step of comparing the
group in which said particular subscriber is grouped with the group
then being fed, and
when the particular subscriber is in a group different from the
group then being fed, diverting the particular subscriber's
magazine from the stream of magazines prior to the collection
point.
10. A system for producing different magazines composed of
different predetermined combinations of signatures for different
subscribers in accordance with predetermined criteria from known
subscriber information, the system comprising:
source means for feeding magazines having different predetermined
combinations of signatures,
means for storing information identifying each subscriber with the
predetermined combination of signatures constituting the
appropriate magazine for that subscriber,
a source of inserts to be inserted in selected subscriber's
magazines,
means for inserting inserts in said magazines,
said storage means further including information identifying each
subscriber that is to receive an insert,
control means connected to said source means, said inserting means
and said storage means for instructing said source means to feed
magazines having the different predetermined combination of
signatures appropriate for the corresponding different subscribers
and instructing said inserting means to place an insert in the
appropriate subscriber's magazine in timed relation with the
feeding of magazines by said source means,
further including insert inscribing means for inscribing
information on the inserts in timed relation with the placing of
inserts in the magazines,
said storage means including information as to the content of each
subscriber's insert,
said control means being connected to said insert inscribing
means,
said insert inscribing means being responsive to the information in
said storage means for automatically inscribing an insert for a
subscriber as that subscriber's magazine is being fed.
11. A system for producing different magazines composed of
different predetermined combinations of signatures for different
subscribers in accordance with predetermined criteria from known
subscriber information, the system comprising;
source means for feeding magazines having different predetermined
combinations of signatures,
means for storing information identifying each subscriber with the
predetermined combination of signatures constituting the
appropriate magazine for that subscriber,
a source of inserts to be inserted in selected subscriber's
magazines,
means for inserting inserts in said magazines,
said storage means further including information identifying each
subscriber that is to receive an insert,
control means connected to said source means, said inserting means
and said storage means for instructing said source means to feed
magazines having the different predetermined combination of
signatures appropriate for the corresponding different subscribers
and instructing said inserting means to place an insert in the
appropriate subscriber's magazine,
further including error detecting means for detecting an error in
the production of a magazine,
error identifying means operative upon detection of an error for
identifying the particular subscriber affected by the error,
said control means including means operative when an error has been
identified to instruct said source means to feed another magazine
having the predetermined combination of signatures appropriate for
said particular subscriber and instruct said inserting means in
accordance with the information in said storage means for said
particular subscriber.
12. A system for producing different magazines composed of
different predetermined combinations of signatures for different
subscribers in accordance with predetermined criteria from known
subscriber information, the system comprising;
source means for feeding magazines having different predetermined
combinations of signatures,
means for storing information identifying each subscriber with the
predetermined combination of signatures constituting the
appropriate magazine for that subscriber,
a source of inserts to be inserted in selected subscriber's
magazines,
means for inserting inserts in said magazines,
said storage means further including information identifying each
subscriber that is to receive an insert,
control means connected to said source means, said inserting means
and said storage means for instructing said source means to feed
magazines having the different predetermined combination of
signatures appropriate for the corresponding different subscribers
and instructing said inserting means to place an insert in the
appropriate subscriber's magazine,
wherein the subscribers are grouped in accordance with
predetermined criteria with each group of subscribers defining a
run,
the information in said storage means being used by said control
means in the order in which the subscribers are grouped whereby the
feeding of magazines for each subscriber in one group is instructed
before the instructing of feeding of magazines for subscribers in
the next group,
conveyor means for conveying the magazines through the system to a
collection point,
divert means for diverting magazines from said conveyor means,
error detecting means for detecting an error in the production of a
magazine,
error identifying means operative upon the detection of an error
for identifying the particular subscriber affected by the
error,
said control means including means operative when an error has been
identified to instruct said source means to feed another magazine
having the predetermined combination of signatures appropriate for
said particular subscriber and instruct said inserting means in
accordance with the information in said storage means for said
particular subscriber,
said control system further including means operative upon
re-ordering a magazine for comparing the group in which said
particular subscriber is grouped with the group of subscribers for
which magazines are then being fed, and
means operative when said particular subscriber is from a group
different from the group then in process for actuating said divert
means to divert said particular subscriber's magazine from said
conveyor means.
13. A system for producing different magazines composed of
different predetermined combinations of signatures for different
subscribers in accordance with predetermined criteria from known
subscriber information, the system comprising;
source means for feeding magazines having different predetermined
combinations of signatures,
means for storing information identifying each subscriber with the
predetermined combination of signatures constituting the
appropriate magazine for that subscriber,
control means connected to said source means and said storage means
for instructing said source means to feed magazines having the
different predetermined combination of signatures appropriate for
the corresponding different subscribers,
wherein the subscribers are grouped in accordance with
predetermined criteria with each group of subscribers defining a
run,
the information in said storage means being used by said control
means in the order in which the subscribers are grouped whereby the
feeding of magazines for each subscriber in one group is instructed
before the instructing of feeding of magazines for subscribers in
the next group,
conveyor means for conveying the magazines through the system to a
collection point,
divert means for diverting magazines from said conveyor means,
error detecting means for detecting an error in the production of a
magazine,
error identifying means operative upon the detection of an error
for identifying the particular subscriber affected by the
error,
said control means including means operative when an error has been
identified to instruct said source means to feed another magazine
having the predetermined combination of signatures appropriate for
said particular subscriber and instruct said inserting means in
accordance with the information in said storage means for said
particular subscriber,
said control system further including means operative upon
reordering a magazine for comparing the group in which said
particular subscriber is grouped with the group of subscribers for
which magazines are then being fed, and
means operative when said particular subscriber is from a group
different from the group then in process for actuating said divert
means to divert said particular subscriber's magazine from said
conveyor means.
Description
This invention relates to a method and apparatus for producing
magazines or the like and, more particularly, to a highly automated
production system which includes the on-line punching and/or
printing of each individual subscriber's subscription renewal
card.
In the following specification and claims, it is to be understood
that the word "magazine" is used to denote any material assembled
from signatures, including but not limited to, journals,
periodicals, catalogs, directories, books and pamphlets.
In magazine publishing there is an increasing desire by advertisers
to direct their advertising at particular subscriber groups within
a magazines total national subscription. To be responsive to this
desire, the magazine publisher is faced with the problem of
providing different issues of the magazine containing different
combinations of advertising for different subscriber groups which,
in turn, requires that for different groups of subscribers, the
magazine be made up of different combinations of signatures.
There is disclosed in pending application, Ser. No. 141,331, filed
May 7, 1971, and assigned to the assignee herein, a method and
apparatus which enables the magazine publisher to achieve the ends
desired by the advertiser while minimizing magazine production time
and cost. As disclosed in that application, the system utilizes a
gathering machine having different sets of signatures located in
different pockets with each pocket being individually instructed to
feed or not feed during each gathering machine cycle, thereby, to
provide the predetermined combination of signatures constituting
the appropriate magazine for each individual subscriber. The
operation of the gathering machine pockets is controlled from
stored information based on known subscriber data which is also
used, in one disclosed embodiment, to prepare the subscriber's
mailing label as that same subscriber's magazine is being made up.
The aforementioned application further discloses a system for
maintaining complete custody of each individual subscriber's
magazine as it is being made up so that in the event a fault occurs
rendering that magazine defective, the magazine may be rejected and
a new magazine and label for that particular subscriber
automatically reordered.
This invention carries forward the basic concepts of the
above-mentioned application and provides a system which, in
addition to the capability of producing different magazines for
different subscribers, includes an on-line means for punching
and/or printing and inserting subscription renewal cards or the
like for selected individual subscribers as the subscriber's
magazine is being made up. Further, the system according to this
invention, contemplates maintaining complete custody of each
subscriber's magazine as it is being produced so that in the event
of a fault resulting in rejection of that magazine, the magazine is
reordered, a new card is punched and/or printed for insertion in
the magazine and means are provided for coordinating the downstream
delivery of the reordered magazine so that it is properly
coordinated with the sorting and mailing operation.
Other objects, features and aspects of the invention will be more
apparent upon a complete reading of the following description
which, together with the attached drawings, discloses but one form
which the invention may take.
Referring now to the drawings wherein like reference numerals
indicate like parts in the various views:
FIG. 1 is a simplified schematic flow diagram of a system for
producing magazines in accordance with the principles of this
invention.
FIG. 2 is a schematic side view of one portion of the system of
FIG. 1.
FIG. 3 is a schematic side view of another portion of the system of
FIG. 1.
FIG. 4 is a schematic perspective view of the divert mechanism
which may be used in the system of FIG. 1.
FIG. 5 is a schematic illustration of a card inserter which may be
used in the system of FIG. 1.
FIG. 6 is a schematic block diagram of the functional operation of
the computer used to control the operation of the system of FIG.
1.
FIG. 7 is a schematic block diagram of the information storage and
retrieval function performed by the computer for controlling the
system of FIG. 1.
FIG. 8 is a schematic block diagram of the error identification
function of the control system.
FIG. 9 illustrates, in schematic block diagram form, a re-order
sub-routine for comparing zip codes.
Referring now more in detail to the drawings, and particularly FIG.
1, the system includes an inserter 10 having a plurality of pockets
adapted to contain different sets of signatures. An inserter chain
or conveyor 12 is adapted to receive the signatures from the
inserter 10 and convey the signatures past a master caliper 14, a
card insert station indicated generally at 16 and to a stitcher 18.
From the stitcher, the conveyor chain carries the magazines to a
trimmer 20 and a labeling station indicated generally by the
reference numeral 22 where a mailing label bearing the subscriber's
name and address is applied to the magazine. Thereafter, the
conveyor carries the magazine to a divert unit indicated generally
by the reference numeral 24 where it is either diverted to a divert
conveyor 26 or passed through to a town-sort stacker 28.
The inserter 10 may be a conventional 24 pocket saddle inserter
which is known perse and the details of which, for simplicity, have
been omitted. In addition, the master caliper 14, the saddle
stitcher 18, the trimmer 20 and the town-sort stacker 28 may also
be of conventional construction and a detailed description of the
specific structure, functioning and operation of these units is not
deemed necessary except in respect to certain modifications which
are described in more detail hereinafter.
THE SADDLE INSERTER
The sets of signatures to make up the various editions of the
magazine are placed in the various pockets, a, b, c, etc., of the
inserter 10. Each inserter pocket is provided with a suitable
feed-out mechanism such as a shaft driven rotary drum which may be
of the type disclosed in U.S. Pat. Nos. 2,251,943 and 2,855,195,
both assigned to the assignee herein and which is operative to
feed-out one signature from each pocket on to the conveyor 12 for
each cycle of the gathering machine 10.
In accordance with this invention, the feed mechanism for each
inserter pocket includes a pocket instruction mechanism 30 which
may be selectively engaged or disengaged in response to an
electrical signal to enable or prevent, respectively, the feeding
from the associated pocket feed mechanism of a signature at the
appropriate point in the inserter machine cycle when that pocket is
due to feed. Inhibiting the feed from selective pockets may be
controlled in various ways such as by inhibiting the vacuum and
calipering at the selected pockets or through the use of clutches
which, when actuated, would disengage the drive to the selected
pockets. The manner in which these pocket instruction mechanisms
are selectively operated will be described hereinafter.
THE CARD INSERTION STATION
The card insertion station 16 includes a card printer 15 and a card
punch 17 which enables the magazine publisher to insert, on a
selective basis, a subscription renewal or fulfillment information
card which is individually punched and/or printed with the
subscriber's data and inserted in that subscriber's particular
magazine as it passes along the conveyor chain 12. The card
insertion station may be used to insert punched cards, printed
cards, or cards which have been both punched and printed with the
desired information.
The cards to be inserted may be processed through a suitable high
speed computer printer which prints the desired information on the
card. One example of a high speed computer printer is available
from Di/An Controls, Boston, Massachusetts. A suitable card punch
mechanism which may, for example, be a model 70/236 card punch
available from the RCA Company is then used to punch each card.
That type of card punch is capable of feeding loose cards from a
hopper past a punch device where punching is effected in a
configuration in accordance with information instructions fed to
the device. The printed and punched cards C are then fed in the
order in which they are punched to a storage stack 32 where they
are subsequently removed and inserted in the appropriate
subscriber's magazine.
It is to be understood, and it will be more apparent hereinafter,
that the operation of the card printer 15 and the card punch unit
17 is controlled on command so that, for example, as the magazine
for a subscriber whose subscription is up for renewal is being
processed, the renewal card for that particular subscriber is being
prepared for insertion in his magazine.
Various devices may be used to insert the cards in the magazine as
it passes along the conveyor 12. FIG. 5 illustrates in schematic
form one such arrangement which may be used for the card insertion.
As shown, a rotary drum 34 is employed to extract the cards C one
at a time from the stack 32. A vacuum sucker 36 is used to extract
the lowermost card from the stack to a position where it can be
picked up by suitable grippers on the drum 34. The vacuum sucker 36
is pivoted toward and away from the stack by any suitable mechanism
such as a cam which is timed to reciprocate with the motion of the
drum 34. The vacuum applied to the vacuum sucker 36 is controlled
by a vacuum valve, schematically indicated at 38, which is also
controlled by the control system so that vacuum is selectively
communicated to the vacuum sucker 36 to render it operative to
remove a card from the stack only when the subscriber's magazine
corresponding to the lowermost card is approaching the card
insertion station.
The rotary drum 34 cooperates with insertion feed belts 40, 41, 42.
Appropriate guides 44 adjacent the saddle conveyor chain 12 open
the signatures of the magazine as it approaches the card insertion
station so that a card may be fed by the belts 41, 42 between the
open signatures in the manner illustrated in FIG. 5. The card may
be loosely held between the signatures or, if desired, the cards
may be bound in, in which event a suitable paster 46 may be used to
apply glue to the card as it is being inserted between the
signatures.
THE LABEL STATION
The label station 22 contemplates the on-line printing of each
subscriber's label as that subscriber's magazine is being made up,
and applying the label to that magazine as it passes beneath the
label head. To this end, a label printer 49 which may be a
conventional high speed computer printer such as is commercially
avalable from Di/An Controls, Inc., Boston, Massachusetts, is
employed. This label printer is operative to print, on command,
labels on a continuous roll of labels which then enter a
conventional labeling head 49 where the labels are applied to the
magazines as they pass therebeneath. It will be appreciated that
each subscriber's label is printed in the same sequence as that
subscriber's magazine is produced, so that, assuming no feed,
trimming or binding errors, each subscriber's uniquely tailored
magazine should arrive at the label head at the same time that
subscriber's label arrives at the label head.
In the event there is an error in the system and the uniquely
tailored magazine for a particular subscriber is rejected after his
label has been printed, it is necessary to reject that label so it
is not applied to the wrong magazine. To this end, a suitable label
reject mechanism 51 is provided. This label reject mechanism may be
simply a dummy book which is inserted beneath the label head 49 to
receive the label in the manner described in the aforementioned
co-pending patent application. Any other suitable device
selectively operable for rejecting the unwanted label may be
used.
THE DEVERT UNIT
One form of a suitable divert unit 24 is schematically illustrated
in FIG. 4. This divert unit comprises a set of deflector fingers 50
which are movable between an inoperative position where they are
positioned beneath the conveyor raceway and an operative position
where they project above the raceway. The movement of the deflector
fingers is controlled by a suitable actuator 52. In the operative
position, the deflector fingers cooperate with signatures traveling
along the raceway to deflect the signatures upward between a pair
of upper and lower belt conveyors 54, 56 which convey the diverted
signatures to the divert conveyor 26.
The belt conveyors 54, 56 may be continuously driven by means not
shown so that if at any time the deflector fingers 50 are actuated,
the belt conveyors are immediately operative to convey the diverted
signatures to the conveyor 26. Those signatures which are not
diverted continue along the raceway beneath the belt conveyors 54,
56 and the conveyor 26 to the town-sort stacker 28.
ERROR DETECTION
It is contemplated that the system will be monitored for the
occurrence of errors throughout the entire production process. To
this end, each of the inserter pockets is provided with an
appropriate error detection sensor which is operative to detect a
missed feed of a signature at each pocket. One suitable form of an
inserter pocket detector is disclosed in the aforementioned pending
application. The master caliper 14 also functions in a conventional
manner as a gross maximum-minimum detector of the magazines as they
pass from the inserter, and both the stitcher and trimmer are
provided with conventional error detection systems, not shown. In
addition, a plurality of chain sensors are placed at strategic
locations along the conveyor chain as shown in FIGS. 2 and 3. These
sensors may be photoelectric cells which are controlled by the
control system and are operative to sense the presence or absence
of a magazine on the conveyor chain 12.
It is contemplated that if, at any point in the production process,
an erronously prepared magazine is detected or there is no magazine
present when one should be present, this information will be used
to signal reordering of that particular subscriber's magazine and
inhibit, where possible, all subsequent operations on that erronous
magazine at the downstream devices. Suitable reject mechanisms, one
being shown at stitcher 18, may be employed at various locations to
remove the defective magazine from the conveyor.
THE CONTROL SYSTEM
It is contemplated that the above-described system will be
controlled in all phases of its operation by a suitable process
computer, indicated generally at 62. This process computer may be
any commercially available process computer such as a PDP8. It is
further contemplated that the information for each production run
will be fed to the process computer 62 by suitable means such as a
magnetically coded control tape 64.
The tape 64 is prepared by suitable data processing techniques in
which information provided by the subscriber's including their
names and mailing addresses and such items of demographic
information as age, income, occupation, etc., are used to classify
each subscriber in accordance with predetermined arbitrary criteria
which allocates each subscriber to one of the different types of
magazines to be produced. Thereafter, the name-address, subscriber
identification number, and make up code for each subscriber is
coded on the tape 64. For example, a subscriber may be in a group
which is to receive magazines made up of signatures from inserter
pockets a-n, r and s and this information is then coded on the tape
for subsequent use by the process computer 62 during the production
of that subscriber's magazine. In addition, if the subscriber is to
receive a subscription renewal or information card, that
information is also associated with the subscriber in an
appropriate manner on the tape 64.
To facilitate sorting and mailing, it is preferred that the
subscribers be grouped on the tape 64 by zip code so that all
subscribers in a particular zip code can be run as a group. In
addition, magazines which are to receive special handling, such as
inspector's copies, are identified by a suitable code.
In summary, the tape 64, when it is ready to be used by the process
computer 62, contains coded information in machine readable form
for each subscriber who is to receive a magazine in the particular
production run to be made. The subscribers are grouped by zip code
and for each subscriber the tape contains information as to his
name and address, his identification number, the particular
inserter pockets which are to be operated in producing his
magazine, information for punching and/or printing a card for
insertion in his magazine and special processing instructions, if
any.
The control system may operate on the coded information on tape 64
in different ways depending on the particular computer utilized and
the particular programming of that computer. However, in general,
the control system:
a. With each cycle of the inserter, instructs each pocket to feed
or not to feed depending on the particular subscriber's magazine
beneath each pocket.
b. Determines whether a renewal or information card is to be
produced for a particular subscriber and, if so, instructs the
printing and/or punching of that card and instructs insertion of
the card at the appropriate point in the cycle when the particular
subscribers magazine is at the card insertion station 16.
c. Orders printing of each subscriber's label and instructs
application of that label at the appropriate point in the cycle
when the magazine corresponding to the appropriate label is beneath
the label head 49.
d. If there are four or less subscribers in a particular zip code
group, instructs the divert unit 24 to divert those magazines from
the town-sort stacker.
e. Recognizes changes in zip code, instructs the stacker 28 to
start a new stack with the first magazine in the zip code
group.
f. Recognizes special magazines such as bulk mailings, inspector
copies, or other high priority copies, and instructs the divert
unit 24 to divert those magazines for special handling.
g. Continuously monitors the entire system for any errors that may
occur.
In the event of an error at any point in the cycle, the control
system is operative to:
h. Ascertain the subscriber whose magazine was affected by the
error, reject the magazine and reorder that particular subscriber's
magazine.
i. If the error occurred in the inserter, discontinue all further
feeding of signatures for that particular subscriber's
magazine.
j. If the error occurred after a label has been printed, reject the
label at the appropriate point in the cycle.
k. If the reordered magazine is made up after a new zip code run
has commenced, advise the divert unit to divert the reordered
magazine so that it may be manually assembled with the proper zip
code group.
The foregoing functions may be coordinated by the process computer
in various ways, but illustrated in FIGS. 6-9 is a schematic
presentation of the operative functions of the computer to
accomplish the desired results. It will be appreciated by those
skilled in the computer art that other internal computer
arrangements to achieve the functional results described may be
employed.
As schematically illustrated, the control tape 64 is interrogated
by a read unit 66 and information is transferred to a buffer
storage 68 and thereafter to the core memory of the computer where
it is stored for use in controlling the production process. More
particularly, the information from the buffer store is fed to a
store instruct unit 70 which assigns the information to different
addresses in the core for use at the proper time. As shown, the
pocket instructions for each subscriber are stored in a pocket
instruct store 72, the name and address information for the
subscriber is stored in a label instruct store 74, the card
instruction information for the subscriber is stored in a card
instruct store 76 and special process instructions for the
subscriber are stored in a process instruct store 78. It will be
appreciated that each of the store units 72, 74, 76 and 78
represents a block of addresses in the core memory and are
illustrated as separate blocks merely to facilitate an
understanding of the invention.
The information stored in units 72, 74, 76, 78 is read by a read
and instruct unit 80 which, in accordance with the information
taken from the store units, issues instructions to the appropriate
system devices. Since, at each cycle in a continuous production
run, a number of different subscriber's magazines are in process at
one time, it is necessary for the computer, for each cycle, to
issue appropriate instructions to all of the devices in the system.
The coordination of the instructions for each cycle may be
accomplished in various ways, the following description being but
an illustrative example of one suitable technique. Thus, referring
to FIG. 7, the information stored in the core memory may, for
conceptual purposes, be considered to be entered in a table in
which each row contains the information for a particular
subscriber, together with an identification number which is
assigned to the subscriber by unit 70 as the subscriber is entered
in the table. The number assigned to the subscriber corresponds to
the cycle in which that subscriber's magazine will be started, with
the subscribers being numbered consecutively. In addition, the row
assigned to each subscriber is provided with a defect record and a
divert record for a purpose to be described hereinafter.
The process computer 62 uses the information in the table in the
following manner. Each location in the system at which a device is
positioned and which requires instructions from the process
computer may be expressed in terms of chain spacings from the
entrance to the inserter. For example, the 7th inserter pocket is
seven chain spacings downstream from the entrance to the inserter.
Similarly, the card insertion station 16 may, for example, be
located thirty-two chain spacings downstream from the entrance to
the inserter. In addition, lead time requirements for such actions
as printing and punching of the insertion cards or the printing of
labels may also be expressed in terms of chain spacings from the
entrance to the inserter. To control the system, the process
computer 62 must, in advance of each cycle, determine the
appropriate instructions to be issued to control the devices at the
various locations in the system. In effect, this requires a
determination by the computer of which subscriber's magazine is at
which point in the process and, thereafter, employ a look-up
routine to determine from the table the instructions to issue for
that particular subscriber's magazine.
To this end, the computer is programmed to perform a sequence of
table look-up routines for each cycle. The sequencing of these
table look-up functions may vary but, in general, a block
representing a sequence unit 82 controls the squence of operation
of the computer. In accordance with instructions from the sequence
unit 82, a locater unit 84, together with a subtracter 86 and an
address register 88, locate the information in the table
appropriate for the next machine cycle. The locater unit 84
contains a "list" of each location in the system at which some
action is or may be taken during each cycle and the sequence unit
82 is used to actuate the locater unit to run through its list in a
predetermined sequence. For example, to determine the pocket
instructions for the next cycle of the inserter, the locater unit
84 would, in sequence, instruct the subtracter unit 86 to read the
cycle count unit 87 and subtract from that count each number,
starting with 0, corresponding to pockets a-s. For example,
assuming the cycle count reads 80 thus indicating that the magazine
for the subscriber assigned number 80 is to be commenced in that
cycle, the subtractor 86 would first subtract 0 from 80 with the
result being used by the address register 88 and coordinate lead 89
to locate in the table the appropriate row for the subscriber
assigned to number 80. The proper column is determined by the lead
90 which, under control of sequence unit 82, steps in sequence from
the first pocket column to the last during this pocket information
look-up routine.
In the example given, the pocket instruction information for pocket
a as determined by the coordinates 89 and 90 would be read by the
read instruct unit 80 and fed to the input/output interface
equipment 92 for use in instructing the feeding of pocket a. A
similar routine would be performed for each other pocket. Thus, the
sequencer 82 in the next sequence of operation would actuate
locater 84 to cause the subtractor 86 to subtract from the cycle
count the number corresponding to the location of the next
operative device in the system. In this example, this would be
pocket b so that subtracter 86 would subtract the number 1 from the
cycle count which, in the example given is 80, thereby establishing
the number 79. The address register 88 would then, through its
contact 89, move to the row corresponding to subscriber 79, the
contact 90 would index to the next column and the pocket
instructions for subscriber 79 would be read and transmitted to the
input/output equipment for controlling pocket b. The same sequence
would be followed for establishing the instructions for controlling
each of the pockets during the 80th cycle.
The same look-up routine is followed for all other actions to be
taken during the 80th cycle. For example, lead time requirements
may require inscribing of an insert card to be initiated ten
cycles, or chain spacings, in advance of the card insertion station
16. Accordingly, a part of the routine for ascertaining the
instructions for the 80th cycle would include determining, in the
manner described, the subscriber whose magazine will be, during the
80th cycle, ten spaces upstream from the insertion station, and
reading from the table the information to be inscribed on the
card.
The same look-up routine will be followed by the computer for the
next machine cycle. Thus, for machine cycle 81, the computer will
go into and out of the core, under the control of the sequence unit
82, to establish the appropriate pocket information for each
subscriber whose magazine is in the inserter as well as to
establish the insert card to be printed and/or punched and inserted
and the label to be printed during that machine cycle.
In this manner, the insertion cards and the labels are prepared in
the proper sequence so that as each uniquely tailored magazine
arrives at the card insertion station and at the label head, and
assuming no feed stitching or trimming errors, the proper card is
inserted and the proper label is applied.
In the event there is an error in the system and the uniquely
tailored magazine for a particular subscriber is rejected, a
potential mismatch situation is presented. To avoid such an
occurrence, an arrangement is provided which not only avoids
mismatches but which also is capable of reordering the rejected
magazine while the run is being made. The accomplishment of this
function involves not only the detection of the error but also the
determination of the particular subscriber whose magazine is
defective, the reordering of that magazine, insertion card and
label, and making certain that the reordering magazine is grouped
with the proper zip code grouping for mailing.
FIG. 8 presents, in block diagram form, one technique by which this
error identification may be accomplished. As illustrated, three
chain sensors 60 and two inserter pocket sensors are shown, it
being understood that each chain sensor and pocket sensor would
have a similar arrangement. Each of the sensors is connected to a
subtract unit 94 with each subtract unit being preset to subtract,
upon receipt of an error signal, a preset value which corresponds
to the location of the particular sensor expressed in terms of
chain spacings from the entrance to the inserter. When one of the
sensors signals an error, this signal activates the associated
subtract unit to subtract from the current cycle count its preset
value thereby establishing the number of the subscriber affected by
the error. For example, assume the magazine for the subscriber
assigned number 60 is found to be missing at the sensor immediately
before station 16. Assuming that sensor is 30 spaces downstream,
the inspection should have taken place in the 90th machine cycle.
The subtract unit, upon receiving the error signal, subtracts 30
from the cycle count which, in this example, is 90 thereby
identifying the subscriber as number 60.
The subtract unit then sends this information to the input/output
unit 92 which issues a retrieve-reorder instruction to the read
unit 80, instructing it to retrieve the information for the
subscriber assigned number 60 and reorder that magazine. Upon
receipt of the retrieve-reorder signal, the computer reads the
information stored in memory for the subscriber assigned to number
60 and re-enters that information in the table as a new subscriber.
Upon re-entering the information, a new number is assigned to that
subscriber which is the next number in sequence. In addition, a
"bit" of information is entered in the defect record for the
appropriate subscriber which, in the example given, is subscriber
number 60.
It is preferred that upon the occurrence of an error, all
downstream functions relating to the defective magazine be
disabled. This can be accomplished by the computer inspecting the
defect record for each subscriber in advance of issuing any
instructions pertinent to that subscriber. Using the tabular
example illustrated in FIG. 7, this would simply require lead 90
moving to the defect column each time in advance of indexing to the
next column from which information is to be read. For example,
before reading instructions for the inscribing of an insert card,
the computer may be programmed to first inspect the defect record
column so that if the subscriber whose insert card is to be
inscribed during a particular machine cycle has been found to be
defective, the "bit" of information stored in that subscriber's
defect record will be used to prevent inscribing of the card.
However, if an error occurs after a card has been inscribed for the
magazine affected by the error, the error is ignored and the card
is either inserted in the defective magazine, if it remains on the
conveyor 12, or if the magazine has been removed from the conveyor
the card inserter is triggered and the card will simply fall into a
suitable tray.
Similarly, if a magazine is rejected prior to printing of the
subscriber's label, instructions to the label printer are withheld
in accordance with the defect record for that magazine until the
reordered magazine is at the appropriate stage in the process.
However, if the error occurs after the subscriber's label has been
printed, the defect record will be used to trigger the label reject
mechanism 52 as the empty chain space corresponding to the rejected
magazine passes beneath the label head.
The defect record may also be used by the computer to disable
caliper 14 in the event of an error upstream so that there is no
calipering operation as the defective magazine or empty chain space
passes the caliper.
A separate pocket disable mechanism such as that disclosed in U.S.
Pat. Nos. 3,519,264 and 3,525,516, schematically indicated at 95,
may be used to sequentially disable further feeding of the inserter
pockets upon detection of an error until the defective magazine has
cleared the inserter.
With the described system, it is desirable to re-order a defective
magazine as soon as possible thereby to assure that the reordered
magazine is produced during the zip code run in which it is
grouped. However, if the error occurs at the end of the zip code
run and the magazine cannot be reordered before a new zip code
group has been started, it is contemplated that the divert unit 24
will be utilized to divert the reordered magazine on to conveyor 26
where it may be manually assembled with its proper zip code group.
This can be accomplished by programming the computer such that each
time a magazine is reordered, the computer performs an additional
sub-routine which compares the zip code run in which the re-ordered
magazine is properly grouped with the current zip code run being
produced. If the comparison indicates that the re-ordered magazine
is in a zip code run different from the zip code run currently
being produced, the computer, in addition to reordering the
magazine, inserts a "bit" of information in the divert record for
that magazine so that when the reordered magazine reaches the
divert unit, the stored "bit" of information is used to actuate the
divert fingers 50 to divert the magazine to the divert conveyors
26. At the same time, a suitable visual or audible signal may be
actuated to signal the personnel downstream that a divert magazine
is on its way so that they can manually place the magazine in its
appropriate zip code group. To facilitate an understanding of this
reorder sub-routine, FIG. 9 illustrates in block diagram form the
manner in which the zip-code comparison may be made. Thus, the
information for the subscriber is read from memory and, prior to
re-storing it, it is temporarily held in register 96. The zip code
for that subscriber is then entered in a register 99 while the zip
code of the subscriber whose magazine was started in the
immediately preceeding cycle is retrieved from memory and entered
in register 98. The two zip codes are compared by comparator 100
and, if a difference is found, a divert "bit" is entered in the
divert record for the subscriber whose date is standing in register
96. Thereafter, the data in register 96 is re-stored in memory by
the store instruct unit and used for re-ordering the magazine.
The processing of special magazines such as inspector's copies or
the like may be handled in a similar manner. Thus, the tape 64 may
be coded with special process instructions to divert a certain
number of magazines. When those magazines are ordered, the read
instruct unit 80 utilizes the process instructions to insert a
"bit" of information in the divert record for those magazines which
will then actuate the divert mechanism at the appropriate point in
the production cycle.
The divert unit may also be used for the special handling of zip
code groups having four or less in the group. In this connection,
it is conventional to use indicia to indicate the beginning or end
of zip code runs and by scanning the zip codes stored in memory,
together with counting the magazines between consecutive indicia,
groups of less than five can be quickly identified and a divert
instruction stored in the divert record for each subscriber in the
group.
While various schematic block diagrams have been illustrated and
described, it is to be understood that these have been utilized
merely as a convenient means to describe the functional operation
of the system. Obviously, various types of computers using
different types of information storage and information retrieval
techniques can be used to control the system. In using a process
computer such as a PDP8, the functional components corresponding to
the various block diagrams disclosed would be embodied in the
computer program. However, a special purpose computer using
standard components which perform the functions described in the
block diagrams may be used as well.
Moreover, while the control information has been disclosed as being
coded on a tape from which it is transferred into a memory for
subsequent use, it is contemplated that any suitable form of
information storage may be used for the control system. In general,
this invention contemplates the use of a file or store of
information, whether on tape, a disk, a drum or in memory cores or
any combination thereof, form which information can be taken to
control the disclosed system.
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