U.S. patent number 3,917,252 [Application Number 05/141,331] was granted by the patent office on 1975-11-04 for method and apparatus for producing magazines or the like.
This patent grant is currently assigned to Harris-Intertype Corporation. Invention is credited to Donald C. Harder, Victoriano F. Rana.
United States Patent |
3,917,252 |
Harder , et al. |
November 4, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
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 groups of subscribers classified in accordance with
predetermined criteria from known subscriber information. A
gathering machine having different sets of signatures located in
different pockets operates in accordance with instructions from a
machine readable file. Machine reading of the file which contains
information relating subscribers with their appropriate groups,
instructs different combinations of some of the gatherer pockets to
feed to provide differently constituted magazines for different
subscribers. Labeling equipment, correlated with the operation of
the gathering machine, insures that a name and address label for
each subscriber is applied to a magazine composed of the
appropriate combination of signatures for that subscriber. An
arrangement using pre-printed labels and an arrangement for on-line
printing of the labels are disclosed.
Inventors: |
Harder; Donald C. (Cleveland,
OH), Rana; Victoriano F. (Easton, PA) |
Assignee: |
Harris-Intertype Corporation
(Cleveland, OH)
|
Family
ID: |
22495242 |
Appl.
No.: |
05/141,331 |
Filed: |
May 7, 1971 |
Current U.S.
Class: |
270/52.05 |
Current CPC
Class: |
B65H
39/00 (20130101); B65H 43/00 (20130101); B42C
1/12 (20130101); B65C 9/40 (20130101); B65H
39/04 (20130101); B65H 2301/4311 (20130101) |
Current International
Class: |
B42C
1/12 (20060101); B65C 9/00 (20060101); B65C
9/40 (20060101); B65H 43/00 (20060101); B65H
39/04 (20060101); B65H 39/00 (20060101); B65h
039/02 () |
Field of
Search: |
;270/58,54,55,1,20,12,5,21 |
References Cited
[Referenced By]
U.S. Patent Documents
|
|
|
3519264 |
July 1970 |
Beacham et al. |
3525516 |
August 1970 |
Bushnell et al. |
3608888 |
September 1971 |
McCain et al. |
3608893 |
September 1971 |
McCain et al. |
|
Other References
Peterson, Rehn C., "Look What's Happening in Signature Handling",
Printing Production Magazine, Oct. 1969, pp. 50, 51, 84, 85. .
Harder, Donald C., "Why Not a Computerized Bindery", Printing
Production Magazine, Nov. 1969, pp. 40, 41, 71, 72. .
Cosden, Thomas B., "For the Bindery, A New Technology for
Assembling Custom-Built Products", Book Production Industry, Mar.
1970..
|
Primary Examiner: Michell; Robert W.
Assistant Examiner: Hum; Vance Y.
Claims
What is claimed is:
1. A method for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
different sub-groups within each group by demographic
characteristics in accordance with predetermined criteria from
known subscriber information which includes for each subscriber his
name and address and at least one item of demographic information,
utilizing different sets of signatures located in different pockets
of a gathering machine of the type in which each cycle of the
gathering machine causes successive 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 cycle, the method comprising the steps
of:
preparing a machine readable file identifying each subgroup in each
different group with; (1) the corresponding number of subscribers
within the subgroup, and (2) a predetermined combination of at
least some of the gatherer pockets to be instructed to feed during
a gathering machine cycle to provide the predetermined combination
of signatures constituting the appropriate magazine for that
subgroup,
preparing a preprinted stock of subscriber names and address labels
arranged by group and subgroup in the same order as the groups and
subgroups are arranged in the file,
progressively machine reading the file in timed relation to the
cycles of operation of the gathering machine, in accordance with
the reading of the file, instructing feeding of the gatherer
pockets in the predetermined combinations to produce, for each
subgroup, a number of magazines of the appropriate predetermined
signature combination equal to the number of subscribers in that
subgroup,
feeding the preprinted stock of labels to a labeling head operating
in timed relation to the gathering machine with the labels for each
subgroup being timed to coincide with the arrival at the labeling
head of the particular magazines produced for that subgroup,
monitoring the feeding of signatures at each gathering pocket to
detect a misfeed or nonfeed at each pocket instructed to feed
during each machine cycle,
whenever an error is detected, tracking the defective magazine
affected by the error in its subsequent passage through the
gathering machine,
rejecting the defective magazine after iti leaves the gathering
machine,
maintaining a cumulative count of each actuation of each pocket of
the gathering machine,
comparing the cumulative error count with the cumulative actuation
count and deriving an error rate,
for each subgroup, applying the error rate to the number of
magazines to be produced for the subgroup to estimate a predicted
number of defective magazines for that subgroup, and
for the same subgroup, operating the gathering machine for an
additional number of cycles in excess of the number of subscribers
in that subgroup to produce an additional number of magazines equal
to the predicted number of defective magazines.
2. The method as defined in claim 1 but whenever the predicted
number of defective magazines exceeds the number of actual
defective magazines produced during completion of the magazines for
a particular sub-group, thereby leading to at least one excess
magazine for that sub-group passing to the labeling head, including
the step of:
rejecting the excess magazine to maintain a match between the
number of preprinted labels for the particular sub-group and the
number of magazines for that sub-group arriving at the labeling
head.
3. The method as defined in claim 1 but whenever the predicted
number of defective magazines for a particular sub-group is less
than the actual number of defective magazines upon completion of
the magazines for the particular sub-group thereby leaving at least
one gap caused by a missing magazine between the magazine arriving
at the labeling head, including the step of:
rejecting the excess magazine to maintain a match between the
number of preprinted labels for the particular sub-group and the
number of magazines for that sub-group arriving at the labeling
head.
moving a dummy beneath the labeling head as the gap arrives at the
labeling head to receive the label for the missing magazine.
4. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
in different subgroups within each group by demographic
characteristic in accordance with predetermined criteria from inown
subscriber information which includes for each subscriber at least
his name and address and one item of demographic information, the
system comprising:
a gathering machine having a plurality of pockets adapted to
contain different sets of signatures, said gathering machine
operating in cycles, each cycle of operation of said gathering
machine causing successive feeding of signatures from at least some
of said pockets to make up each magazine,
each said gatherer pocket having connected therewith;
pocket instruction means for instructing the associated said pocket
to feed or not feed during each gathering machine cycle,
file means for storing information in machine readable form
identifying for each different subgroup in each different group (1)
a predetermined combination of at least some of said gatherer
pockets to be instructed to feed during a gathering machine cycle
to provide a predetermined combination of signatures constituting
the appropriate combination of signatures constituting the
appropriate magazine for that subgroup and (2) the number of
subscribers in that subgroup,
reading means connected with said pocket instruction means, said
reading means reading said control file means in timed relation to
the cycle of operation of said gathering machines for instructing
feeding of said gatherer pockets, in the predetermined different
combinations corresponding to the different subgroups to produce
for each subgroup a number of magazines of the appropriate
predetermined signature combination equal to the number of
subscribers in that subgroup,
labeling means connected with said gathering machine adapted to
apply a preprinted stock of subscriber name and address labels
arranged by a group and subgroup in the same order as said groups
and subgroups are arranged in said subscriber file means to the
magazines,
a plurality of monitoring means associated with said gatherer
pockets, said monitoring means monitoring the feeding of signatures
at each said gatherer pocket to detect a feed error at each pocket
instructed to feed during each machine cycle,
memory means connected with said monitoring means for storing
information identifying any magazine rendered defective by a feed
error,
reject means connected with said memory means for rejecting the
defective magazine after it leaves said gathering machine,
disabling means connected with said gatherer pockets and with said
monitoring means for preventing feeding from all said gatherer
pockets downstream from the gatherer pocket where a feed error
occurs, as the defective magazine passes each pocket, total count
means connected with said gathering machine for maintaining a
cumulative count of all the magazines produced by said gathering
machine,
error count means connected with said monitoring means for
maintaining a cumulative count of all the feed errors,
comparing means connected with said error count means and total
count means for deriving an error rate,
predicting means connected with said comparing means for applying
the error rate to the number of magazines to be produced for each
subgroup to derive for that subgroup a predicted number of
defective magazines, and
ordering means connected with said predicting means for operating
said gathering machine for each subgroup for an additional number
of defective magazines, and
ordering means connected with said predicting means for operating
said gathering machine for each subgroup for an additional number
of cycles in excess of the number of subscribers in that subgroup
to produce an additional number of magazines equal to the predicted
number of defective magazines.
5. The system as defined in claim 4 further including:
sub-total means connected with said monitoring means for counting
the actual number of defective magazines produced during the
production of magazines for a particular sub-group, and
second comparing means connected with said sub-total means and with
said predicting means for comparing, for each sub-group, the actual
number of defective magazines produced with the predicted number of
defective magazines for the same sub-group.
6. The system as defined in claim 5 further including:
second rejection means connected with said second comparing means,
said second rejection means rejecting the excess magazines produced
when the predicted number of defective magazines is in excess of
the actual number of defective magazines.
7. The system as defined in claim 5 further including:
dummy means for receiving the excess labels for a particular
sub-group whenever the actual number of defective magazines
produced for the sub-group exceeds the predicted number of
defective magazines.
8. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
groups of subscribers classified in accordance with predetermined
criteria from known subscriber information, the system
comprising:
a gathering machine having a plurality of pockets adapted to
contain different sets of signatures, said gathering machine
operating in cycles, each cycle of operation of said gathering
machine causing successive feeding of signatures from at least some
of said pockets to make up each magazine,
each said gatherer pocket having connected therewith pocket
instruction means for instructing the associated said pocket to
feed or not feed during each gathering machine cycle;
file means for storing information in machine readable form
identifying the different subscribers with different predetermined
combinations of at least some of said gatherer pockets to be
instructed to feed during a gathering machine cycle to provide a
predetermined combinations of signatures constituting the
appropriate magazine for each subscriber,
means connected with said pocket instruction means for reading said
file means and instructing feeding of the gatherer pockets in the
predetermined combinations required to provide the different
magazines appropriate for the corresponding subscribers,
the information stored in said file means including at least the
name and address of each subscriber in machine readable form, and
the system further including:
label printing means responsive to reading of said file means for
automatically printing labels bearing the name and address of each
subscriber; and
label application means connected with said gathering machine for
applying a printed label for each subscriber to a magazine
constituted of the predetermined signature combination appropriate
for that subscriber's group,
sensor means for sensing the presence and absence of a magazine and
generating a signal in response to the sensed condition, and
means responsive to a signal from said sensor means when a
subscriber.div.s magazine is absent for storing for a reuse the
information pertinent to that subscriber.
9. The system as defined in claim 8 and further including label
reject means operative upon sensing of an absent magazine to remove
the printed label for said subscriber from said label application
means.
10. A system as defined in claim 8 and further comprising means
responsive to said signal from said sensor means when a
subscriber's magazine is absent for actuating said pocket
instruction means to produce a magazine to replace the absent
magazine.
11. A method for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers grouped in accordance with predetermined criteria from
known subscriber information, utilizing different sets of
signatures located in different pockets of a gathering machine of
the type in which each cycle of operation of the gathering machine
causes successive 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 during a
gathering machine cycle to provide the predetermined combinations
of signatures constituting the appropriate magazines for the
subscribers,
progressively machine reading the file,
wherein the step of machine reading the file is followed by the
step of storing the information from the file in a memory,
reading the information in the memory to instruct feeding of the
gatherer pockets,
retaining the information in the memory for each subscriber whose
magazine is defectively produced, and
re-instructing feeding of the gatherer pockets in the predetermined
combinations required to provide the different magazines for the
subscribers whose information was retained in the memory.
12. A method for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
different subgroups within each group by demographic
characteristics in accordance with predetermined criteria from
known subscriber information which includes for each subscriber his
name and address and at least one item of demographic information,
utilizing different sets of signatures located in different pockets
of a gathering machine of the type in which each cycle of the
gathering machine causes successive 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 cycle, the method comprising the steps
of:
preparing a machine readable file identifying each subgroup in each
different group with; (1) the corresponding number of subscribers
within the subgroup, and (2) a predetermined combination of at
least some of the gatherer pockets to be instructed to feed during
a gathering machine cycle to provide the predetermined combination
of signatures constituting the appropriate magazine for that
subgroup,
preparing a preprinted stock of subscriber name and address labels
arranged by group and subgroup in the same order as the groups and
subgroups are arranged in the file,
progressively machine reading the file in timed relation to the
cycles of operation of the gathering machine, in accordance with
the reading of the file, instructing feeding of the gatherer
pockets in the predetermined combinations to produce, for each
subgroup, a number of magazines of the appropriate predetermined
signature combination equal to the number of subscribers in that
subgroup,
feeding the preprinted stock of labels to a labeling head operating
in timed relation to the gathering machine with the labels for each
subgroup being timed to coincide with the arrival at the labeling
head of the particular magazines produced for that subgroup,
monitoring the feeding of signatures at each gathering pocket to
detect a misfeed or nonfeed at each pocket instructed to feed
during each machine cycle,
whenever an error is detected, tracking the defective magazine
affected by the error in its subsequent passage through the
gathering machine,
rejecting the defective magazine after it leaves the gathering
machine,
preceding the step of labeling at the labeling head, of
binding each magazine at a binding station, and subsequent to
binding, trimming each magazine at a trimming station,
detecting erroneously bound magazines subsequent to the binding
step,
rejecting each erroneously bond magazine,
making a cumulative count of errouneously bond magazines,
making a cumulative count of all magazines passing through the
binding station,
comparing the cumulative total of the erroneously bound magazines
with the cumulative total of magazines passing the binding station,
and deriving a binding error rate,
for each subgroup, applying the binding error rate to the number of
magazines for that subgroup to estimate a predicted number of
defective magazines, and
operating the gathering machine for an additional number of cycles
in excess of the number of subscribers in that subgroup to produce
an additional number of magazines for that subgroup equal to the
predicted number of defective magazines.
13. A method for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
different subgroups within each group by demographic
characteristics in accordance with predetermined criteria from
known subscriber information which includes for each subscriber his
name and address and at least one item of demographic information,
utilizing different sets of signatures located in different pockets
of a gathering machine of the type in which each cycle of the
gatering machine causes successive 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 cycle, the method comprising the steps
of:
preparing a machine readable file identifying each subgroup in each
different group with; (1) the corresponding number of subscribers
within the subgroup, and (2) a predetermined combination of at
least some of the gatherer pockets to be instructed to feed during
a gathering machine cycle to provide the predetermined combination
of signatures constituting the appropriate magazine for the
subgroup,
preparing a preprinted stock of subscriber name and address labels
arranged by group and subgroup in the same order as the groups and
subsgroups are arranged in the file,
progressively machine reading the file in timed relation to the
cycles of operation of the gathering machine, in accordance with
the reading of the file, instructing feeding of the gatherer
pockets in the predetermined combinations to produce, for each
subgroup, a number of magazines of the appropriate predetermined
signature combination equal to the number of subscribers in that
subgroup,
feeding the preprinted stock of labels to a labeling head operating
in timed relation to the gathering machine with the labels for each
subgroup being timed to coincide with the arrival at the labeling
head of the particular magazines produced by that subgroup,
monitoring the feeding of signatures at each gathering pocket to
detect a misfeed or nonfeed at each pocket instructed to feed
during each machine cycle,
whenever an error is detected, tracking the defective magazine
affected by error in its subsequent passage through the gathering
machine,
rejecting the defective magazine after it leaves the gathering
machine,
preceding the step of labeling at the labeling head, of
binding each magazine at a binding station, and subsequent to
binding, trimming each magazine at a trimming station,
detecting erroneously trimmed magazines subsequent to the trimming
step,
rejecting each erroneously trimmed magazine,
making a cumulative count of the erroneously trimmed magazines,
making a cumulative count of all magazines passing through the
trimming station,
comparing the cumulative total of erroneously trimmed magazines
with the cumulative total of magazines passing the trimming
station, and computing a trimming error rate,
for each subgroup, applying the trimming error rate to the number
of magazines for that subgroup to estimate a predicted number of
defective magazines, and
operating the gathering machine for an additional number of cycles
in excess of the number of subscribers in that subgroup to produce
an additional number of magazines for that subgroup equal to the
estimated number of defective magazines.
14. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
groups of subscribers classified in accordance with predetermined
criteria from known subscriber information, the system
comprising:
a gathering machine having a plurality of pockets adapted to
contain different sets of signatures, said gathering machine
operating in cycles, each cycle of operation of said gathering
machine causing successive feeding of signatures from at least some
of said pockets to make up each magazine,
each said gatherer pocket having connected therewith pocket
instruction means for instructing the associated said pocket to
feed or not feed during each gathering machine cycle;
file means for storing information in machine readable form
identifying the different subscribers and associating the
subscribers with different predetermined combinations of at least
some of said gatherer pockets to be instructed to feed during a
gathering machine cycle to provide the predetermined combinations
of signatures constituting the appropriate magazine for each
subscriber,
means connected with said pocket instruction means for reading said
file means and instructing feeding of the gatherer pockets in the
predetermined combinations required to provide the different
magazines appropriate for the corresponding subscribers,
the information stored in said file means including at least the
name and address of each subscriber in machine readable form, and
the system further including:
label printing means responsive to reading of said file means for
automatically printing labels bearing the name and address of each
subscriber; and
label application means connected with said gathering machine for
applying a printed label for each subscriber to a magazine
constituted of the predetermined signature combination appropriate
for that subscriber's group.
15. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
in different subgroups within each group by demographic
characteristic in accordance with predetermined criteria from known
subscriber information which includes for each subscriber at least
his name and address and one item of demographic information, the
system comprising:
a gathering machine having a plurality of pockets adapted to
contain different sets of signatures, said gathering machine
operating in cycles, each cycle of operation of said gathering
machine causing successive feeding of signatures from at least some
of said pockets to make up each magazine,
each said gatherer pocket having connected therewith;
pocket instruction means for instructing the associated said pocket
to feed or not feed during each gathering machine cycle,
file means for storing information in machine readable form
identifying for each different subgroup in each different group (1)
a predetermined combination of at least some of said gatherer
pockets to be instructed to feed during a gathering machine cycle
to provide the predetermined combination of signatures constituting
the appropriate magazine for that subgroup and (2) the number of
subscribers in that subgroup,
reading means connected with said pocket instruction means, said
reading means reading said control file means in timed relation to
the cycle of operation of said gathering machine for instructing
feeding of said gathering pockets in the predetermined different
combinations corresponding to the different subgroups to produce
for each subgroup a number of magazines of the appropriate
predetermined signature combination equal to the number of
subscribers in that subgroup,
labeling means connected with said gathering machine adapted to
apply a preprinted stock of the subscriber name and address labels
arranged by a group and subgroup in the same order as said groups
and subgroups are arranged in said subscriber file means to the
magazines,
binding means connected with said gathering machine for binding the
signatures constiting each magazine after leaving said gathering
machine,
triming means connected with said binding means for trimming each
magazine subsequent to binding,
detection means connected with said binding means for detecting
erroneously bound magazines leaving said binding means,
rejection means connected with said detection means for rejecting
erroneously bound magazines,
binder error count means connected with said detection means for
making a cumulative count of erroneously bound magazines,
binder count means for counting all magazines passing said binding
means,
comparison means connected with said binder error count means and
with said binder count means for deriving a binding error rate,
prediction means for applying the binding error rate to the number
of magazines for each subgroup to estimate a predicted number of
defectively bound magazines for that subgroup, and
ordering means connected with said prediction means for operating
said gathering machine for an additional number of cycles in excess
of the number of subscribers in that subgroup to produce an
additional number of magazines for that subgroup equal to the
predicted number of defectively bound magazines.
16. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different geographic groups by region and
in different subgroups within each group by demographic
characteristic in accordance with predetermined criteria from known
subscriber information which includes for each subscriber at least
his name and address and one item of demographic information, the
system comprising:
a gathering machine having a plurality of pockets adapted to
contain different sets of signatures, said gathering machine
operating in cycles, each cycle of operation of said gathering
machine causing successive feeding of signatures from at least some
of said pockets to make up each magazine,
each said gatherer pocket having connected therewith;
pocket instruction means for instructing the associated said pocket
to feed or not feed during each gathering machine cycle,
file means for storing information in machine readable form
identifying for each different subgroup in each different group (1)
a predetermined coombination of at least some of said gatherer
pockets to be instructed to feed during a gathering machine cycle
to provide the predetermined combination of signatures constituting
the appropriate magazine for that subgroup and (2) the number of
subscribers in that subgroup,
reading means connected with said pocket instruction means, said
reading means reading said control file means in timed relation to
the cycle of operation of said gathering machine for instructing
feeding of said gathering pockets in the predetermined different
combinations corresponding to the different subgroups to produce
for each subgroup a number of magazines of the appropriate
predetermined signature combination equal to the number of
subscribers in that subgroup,
labeling means connected with said gathering machine adapted to
apply a preprinted stock of subscriber name and address labels
arranged by a group and subgroup in the same order as said groups
and subgroups are arranged in said subscriber file means to the
magazines,
binding means connected with said gathering machine for binding the
signatures constituting each magazine after leaving said gathering
machine,
trimming means connected with said binding means for trimming each
magazine subsequent to binding,
detection means connected with said trimming means for detecting
erroneously trimmed magazines leaving said trimming means,
rejection means connected with said detection means for rejecting
erroneously trimmed magazines,
trim error count means for making a cumulative count of erroneously
trimmed magazines,
trimmer count means for counting all magazines passing said
trimming means,
comparison means connected with said trim error count means and
with said trimmer count means for deriving a trimming error
rate,
prediction means for applying the trimming error rate to the number
of magazines for each subgroup to estimate a predicted number of
defectively trimmed magazines for that subgroup; and
ordering means connected with said prediction means for operating
said gathering machine for an additional number of cycles in excess
of the number of subscribers in that sugroup to produce an
additional number of magazines for that subgroup egual to the
predicted number of defectively trimmed magazines.
17. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different groups in accordance with
predetermined criteria from known subscriber information which
includes for each subscriber at least his name and address, the
system comprising:
a gathering machine having a plurality of pockets adapted to
contain different signatures, said gathering machine operating in
cycles, each cycle of operation of said gathering machine causing
successive feeding of signatures from at least some of said
pockets,
each said gatherer pocket having connected therewith;
pocket instruction means for instructing the associated said pocket
to feed or not feed during each gathering machine cycle,
file means for storing information in machine readable form
identifying for each different group (1) a predetermined
combination of at least some of said gatherer pockets to be
instructed to feed during a gathering machine cycle to provide the
predetermined combination of signatures constituting the
appropriate magazine for that group and (2) the number of
subscribers in that group,
reading means connected with said pocket instruction means, said
reading means reading said control file means in timed relation to
the cycle of operation of said gathering machine for instructing
feeding of said gathering pockets in the predetermined different
combinations corresponding to the different groups to produce for
each group a number of magazines of the appropriate predetermined
signature combination equal to the number of subscribers in that
group,
binding means connected with said gathering machine for binding the
signatures constituting each magazine after leaving said gathering
machine,
detection means connected with said binding means for detecting
erroneously bound magazines leaving said binding means,
rejection means connected with said detection means for rejecting
erroneously bound magazines,
binder error count means connected with said detection means for
making a cumulative count of erroneously bound magazines,
binder count means for counting all magazines passing said binding
means,
comparison means connected with said binder error count means and
with said binder count means for deriving a binding error rate,
prediction means for applying the binding error rate to the number
of magazines for each group to estimate a predicted number of
defectively bound magazines for that group before the group is
finished and
ordering means connected with said prediction means for operating
said gathering machine for an additional number of cycles in excess
of the number of subscribers in that group to produce an additional
number of magazines for the group equal to the predicted number of
defectively bound magazines.
18. A system for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers classified in different groups in accordance with
predetermined criteria from known subscriber information which
includes for each subscriber at least his name and address, the
system comprising:
a gathering machine having a plurality of pockets adapted to
contain different signatures, said gathering machine operating in
cycles, each cycle of operation of said gathering machine causing
successive feeding of signatures from at least some of said pockets
to make up each magazine,
each of said gatherer pockets having connected therewith;
pocket instruction means for instructing the associated said pocket
to feed or not feed during each gathering machine cycle,
file means for storing information in machine readable form
identifying for each different group (1) a predetermined
combination of at least some of said gatherer pockets to be
instructed to feed during a gathering machine cycle to provide the
predetermined combination of signatures constituting the
appropriate magazine for that group and (2) the number of
subscribers in that group,
reading means connected with said pocket instruction means, said
reading means reading said control file means in timed relation to
the cycle of operation of said gathering machine for instructing
feeding of said gathering pockets in the predetermined different
combinations corresponding to the different groups to produce for
each group a number of magazines of the appropriate predetermined
signature combination equal to the number of subscribers in that
group,
trimming means connected with said binding means for trimming each
magazine,
detection means connected with said trimming means for detecting
erroneously trimmed magazines leaving said trimming means,
rejection means connected with said detection means for rejecting
erroneously trimmed magazines,
trim error count means for making a cumulative count of erroneously
trimmed magazines,
trimmer count means for counting all magazines passing said
trimming means,
comparison means connected with said trim error count means and
with said trimmer count means for deriving a trimming error
rate,
prediction means for applying the trimming error rate to the number
of magazines for each group to estimate a predicted number of
defectively trimmed magazines for that group; and
ordering means connected with said prediction means for operating
said gathering machine for an additional number of cycles in excess
of the number of subscribers in that group to produce an additional
number of magazines for that group equal to the predicted number of
defectively trimmed magazines.
19. A method for producing different magazines, composed of
different predetermined combinations of signatures, for different
subscribers grouped in accordance with predetermined criteria from
known subscriber information, utilizing different sets of
signatures located in different pockets of a gathering machine of
the type in which each cycle of operation of the gathering machine
casues successive 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 during a
gathering machine cycle to provide the predetermined combinations
of signatures constituting the appropriate magazines for the
subscribers,
progressively machine reading the file,
in accordance with the reading of the file, instructing feeding of
the gatherer pockets in the predetermined combinations required to
provide the different magazines approproate for the corresponding
different subscribers,
providing at least the name and address of each subscriber in
machine readable form,
responsive to reading of the file, automatically printing labels
bearing the name and address of each subscriber,
utilizing a labeling head to apply the label for each subscriber to
a magazine constituted of the predetermined signature combination
appropriate for that subscriber's group as the magazine arrives at
the labeling head, and
removing a particular subscriber's label from the labeling head if
that subscriber's magazine fails to reach the labeling head.
Description
BACKGROUND OF THE INVENTION
This invention relates to a method and apparatus for producing
magazines, books, catalogs or the like by automatically assembling
signatures in different combinations to provide differently
constituted magazines for different groups of subscribers.
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 increasingly significant desire
of advertisers to direct their advertising at particular subscriber
groups within a magazine's total national subscription. Such groups
may be selected in accordance with predetermined arbitrary criteria
from known subscriber information, and may include geographic
groupings by region and demographic groupings such as by income,
occupation, or interests. Furthermore, such subscriber groups may
have combined geographic and demographic characteristics. For
example, a surfboard manufacturer advertising in a magazine of
national circulation may wish his advertisement to appear only in
those issues of the magazine sent to subscribers living in the
southeast with incomes below $10,000 a year, while by contrast, a
snowmobile manufacturer may wish to reach only subscribers living
in the northwest with incomes above $15,000 a year. The magazine
publisher is thus faced with a problem of providing different
issues of the magazine containing different combinations of
advertising for different subscriber groups.
Using present methods, most magazines are assembled on gathering
machines comprising a plurality of gatherer pockets containing
different sets of signatures, spaced above a moving conveyor chain.
On each cycle of the gathering machine, a signature is fed from
each pocket in turn to make up an issue of the complete magazine on
the underlying conveyor. A labeling machine may be positioned
downstream to apply preprinted subscriber name and address labels
to the magazines.
With the arrangement described, whenever, it is desired to change
the particular combination of signatures making up the magazine in
order to provide a differently constituted magazine for a different
group of subscribers, it is necessary to shut down the gathering
machine and the labeling machine to permit the various signatures
in the pockets to be changed and a different set of subscriber
labels to be placed in the labeling machine.
The lost time involved in shutting down the machine usually imposes
severe limits on the degree to which the total subscription list
may be refined into separate groups because an increased number of
groups necessarily requires a greater number of shutdowns between
groups and the aggregate shut down time may soon become so high as
to render the overall printing time prohibitively long. This
technical difficulty runs directly counter to marketing
requirements which seek ever more specialized groupings and
sub-groupings within the total subscription list in order to
attract advertisers. This conflict poses a very serious problem for
magazine publishers utilizing conventional equipment of the type
previously described.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for producing
differently constituted magazines tailored to the characteristics
of particular subscriber groups within the total magazine
subscription, which is intended to avoid problems of the type
previously discussed. In particular, the invention provides for the
continuous production of differently constituted magazines for
different groups of subscribers classified into different groups in
accordance with predetermined criteria utilizing known subscriber
information, without requiring repeated shutting down of the
equipment.
More particularly, a gathering machine is utilized having different
sets of signatures located in different pockets of the machine. The
gathering machine is of a type in which each cycle of operation of
the gathering machine causes successive 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. A machine readable file
identifies the different subscribers with different predetermined
combinations of at least some of the gatherer pockets to be
instructed to feed during a gathering machine cycle to provide the
predetermined combinations of signatures constituting the
appropriate magazines for subscribers in the different groups. The
file is then machine read and, in accordance with the reading of
the file, the gatherer pockets are instructed to feed in the
predetermined combinations required to provide the different
magazines appropriate for the corresponding different
subscribers.
As an additional refinement of the invention, a labeling machine is
associated with the gathering machine to apply subscriber name and
address labels to the magazines with each subscriber label being
timed to coincide with the arrival at the labeling machine of a
magazine constituted by the appropriate combination of signatures
required for the subscriber whose label is to be applied.
In one embodiment of the invention, the labeling machine applies
pre-printed labels in a predetermined sequence while in another
embodiment, an on-line label printer is employed to print the label
for each subscriber as the magazine for that subscriber is being
made up.
BRIEF DESCRIPTION OF THE DRAWINGS
A system for producing magazines in accordance with the principles
of the invention, is illustrated in the accompanying drawings in
which:
FIG. 1 is a simplified schematic view of a system for producing
magazines including a gathering machine, binder, trimmer and
labeling head, assembled in accordance with the preferred
embodiment of the invention;
FIG. 2 is a side view of the system shown in FIG. 1;
FIG. 3 is a block diagram illustrating the manner in which a
magazine subscription list may be classified into groups and
sub-groups according to geographic region, Zip Code and demographic
characteristic as an example of one application to which the system
shown in FIG. 1 may be applied;
FIG. 4 is a block diagram providing a pictorial representation of
certain steps performed in classifying subscriber information in
some initial stages of operation of the system shown in FIG. 1;
FIG. 5 is a block diagram providing a pictorial representation of
certain steps performed to provide a control file, in some
intermediate stages of operation of the system;
FIG. 6 is a schematic block diagram of the operating sections of
the process computer and the manner in which they are connected to
the gathering machine;
FIGS. 7-10 illustrate magazines arriving at the labeling head shown
in FIG. 1, showing the relation between the magazines and the
address labels under different conditions of operation of the
system;
FIG. 11 is a side view of an error detection system associated with
each pocket of the gathering machine shown in FIG. 1;
FIGS. 12-18 show, in schematic form, a defective cover detection
sub-system forming a part of the system shown in FIG. 1, for
detecting defectively applied magazine covers;
FIG. 19 is a schematic diagram of the process control system for an
alternative form of the system for producing magazines;
FIG. 20 is a schematic diagram of an on-line label printing system
used with the system of FIG. 19;
FIG. 21 schematically illustrates one form in which data may be
stored on the drum memory in the system of FIG. 19.
DETAILED DESCRIPTION
System Components
Referring to FIGS. 1 and 2, a system for producing magazines,
constructed in accordance with the invention, is there shown.
The system includes a gathering machine 20 having a plurality of
gathering pockets 22a-22n adapted to contain different sets of
signatures, spaced above a conveyor 24. During a cycle of operation
of the gathering machine 20, signatures are fed successively from
the gatherer pockets 22 one at at time to build up a magazine on
the underlying conveyor 24. The conveyor 24 carries the magazines
to a binder 26 where the signatures are secured together and the
covers applied. From the binder 26 the conveyor 24 taken the
magazines to a trimmer 28 where the edges of the magazines are
trimmed, and thus on to a labeling machine 30 where a mailing label
bearing a subscriber's name and address is applied to the magazine.
Thereafter, the conveyor 24 takes the magazine to a stacking and
unloading station (not shown). The operation of the gathering
machine is coordinated with the motion of the conveyor 24 by a
cycle timer 32 which arranges that the pockets 22 feed as the
magazine is passing beneath the pockets.
The assembly of system components thus far described comprises a
conventional system well-known to those skilled in the art of
magazine production and detailed description of the structure,
functioning and operation of the gatherer 20, conveyor 24, binder
26, trimmer 28, labeler 30, and cycle timer 32 is not deemed
necessary, except in respect of certain modifications to the
conventional structure to be described in more detail
hereinafter.
It is to be noted that the system is equally applicable to perfect
binding and saddle binding. As is well known, in saddle binding,
the gathering machine is an inserter gathering and the binder is a
saddle stitcher.
Subscriber Breakdown
Of particular interest in the present invention is the adaptation
of the just described assembly of system components for the
production of different magazines, constituted by different
combinations of signatures, for different groups of
subscribers.
Operating on information provided by the subscribers including
their names and mailing addresses and such items of demographic
information as may be provided, e.g., age, income, occupation,
etc., the subscribers may be broken down into groups and sub-groups
according to predetermined arbitrary criteria. Thus, using the
exemplary application shown in FIG. 3, the subscribers may be
broken down into groups by geographic region (for example, the
Southeast, the Midwest, Pacific region, etc.) and by Zip Code
within each region, with a further breakdown into a number of
demographic sub-groups (e.g., by age, income group, occupation, or
other arbitrary criteria) within each group. In the example shown,
four sub-groups A,B,C,D, are considered, although it will be
appreciated that other numbers of sub-groups may be chosen.
For the subscribers in the different groups and sub-groups it is
intended to provide differently constituted magazines, carrying
combinations of signatures arbitrarily determined to be appropriate
for the characteristics of each group and sub-group. Much of the
magazine may constitute signatures which are common for all groups.
In addition, there are other signatures and various combinations of
these other signatures which are intended to be received only by
different groups and sub-groups.
For the purpose of description hereafter, a magazine will be
discussed in which the various editions are made up from ten
standard signatures I-X which remain the same for all editions of
the magazine plus four variable signatures XI-XIV which are to be
provided in different combinations and sub-combinations for the
different sub-groups. It will be realized that the numbers of
standard and variable signatures are entirely arbitrary and may be
varied.
The magazine make up appropriate for each particular subscriber
group is predetermined using arbitrary criteria. Thus, for example,
it may be predetermined that a subscriber in region 1, sub-group B
is to receive a magazine comprising signatures I-X, XII, and XIV
while a subscriber in regional group 2, sub-group A should receive
a magazine comprising signatures I-X, XI, XII, and XIII.
The Gathering Machine
The sets of signatures to make up the various editions of the
magazine are placed in the various pockets 22a-22n of the gathering
machine 20. Using the previously mentioned example of a magazine
constituted by ten standard signatures I-X and various combinations
and sub-combinations of four variable signatures, XI-XIV, the
pockets containing the standard signatures are shown as unmarked in
FIG. 1 while the pockets containing the variable signatures are
marked with a cross.
At its lower end, each gather pocket 22 is provided with a shaft
driven, rotary drum feed out mechanism, which may be of the type
disclosed in U.S. Pat. Nos. 2,621,039 and 2,020,321, both assigned
to the assignee herein, and which feeds one signature onto the
underlying conveyor for each cycle of the gathering machine 22. As
described in the aforesaid patents, after feeding of the first
pocket in line, each downstream pocket feeds its signatures as the
bundle of signatures move into registry beneath the pocket, thereby
making up the magazine.
In the present invention, the feed mechanism has interposed therein
a pocket instruction mechanism 34 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 gathering
machine cycle when that the pocket is due to feed. Inhibiting the
feed from selected pockets may be controlled in various ways such
as by inhibiting the vacuum and calipering at the selected pockets
on through use of clutches which, when actuated, would disengage
the drive to the selected pockets.
For the pockets containing the standard signatures I-X which are to
be fed for every edition of the magazine, the associated pocket
instruction mechanisms 34 are instructed to feed with each cycle so
that each pocket feeds one of its signatures at the appropriate
point during each gathering machine cycle. For the gatherer pockets
containing the variable signatures XI-XIV, the associated pocket
instruction mechanisms 34 are selectively instructed to enable or
prevent feeding from the associated pockets 22 in accordance with
instruction signals supplied by a process computer 36.
The process computer is provided with information relating
subscribers to the particular combinations of gatherer pockets to
be instructed to feed (as will be described in more detail
hereafter) to provide the combination of signatures appropriate for
each subscriber's group. Responsive to this information, the
process computer 36 controls the feeding or non-feeding of each of
the pockets 22 containing the variable signatures XI-XIV of the
gathering machine 20 during each cycle of gathering machine
operation so that the different subscribers receive appropriate
different magazines which include different combinations and
sub-combinations of the variable signatures.
Organization of Data
In the practice of this invention, it is necessary at several
points to store information concerning subscribers in machine
readable form. The preferred method is by the storage of binary
coded information on reels of magnetic tape, a technique which is
sufficiently well known not to require further detailed
description. However, systems based on other conventional methods
of data storage such as, for example, punched paper tape, punched
card systems or removable elements may alternatively be
utilized.
Referring to FIG. 4, information concerning each subscriber,
including his name and address and at least one item of demographic
information, such as age, income, occupation, etc., is stored in
machine readable form on a magnetic tape, subscription list 40.
The order in which subscribers appear on the subscription list 40
is usually random with the most recent subscribers, for example,
being added on at the end. It is necessary to process this
information in accordance with predetermined criteria in order to
sort the subscribers into groups by geographic region and Zip Code
and sub-groups within each group classified demographically.
For this purpose, the subscription list 40 is processed through a
general purpose computer 42, such as for example, IBM 360,
manufactured by International Business Machines of New York, N.Y.,
operating in accordance with a predetermined sort program contained
on a sort instruction tape 44. Sorting the information in
accordance with the program, the computer 42 produces a label print
file 46 on magnetic tape containing in machine readable form the
names and addresses of all subscribers sorted into groups by
geographic region and Zip Code and by demographic sub-groups within
each region. The groups and sub-groups are arranged in a
predetermined order. The order in which this information appears is
pictorially represented in FIG. 3.
Concurrently, the computer 42 produces a magnetic tape subscriber
file 48 containing, in machine readable form, a listing of the
groups by region and Zip Code and of the demographic sub-groups
within each Zip Code in the same predetermined order as the label
print file 46. In addition, file 48 identifies each sub-group with
the corresponding number of subscribers in the sub-group.
The label print file 46 is then processed, for example, through the
computer 42 in a separate run without the sort instruction tape 44,
using the computer as a label printer to produce a pre-printed
stack or roll 50 of labels bearing each subscriber's name, address
and Zip Code, in the same predetermined order of groups and
sub-groups.
Prior to commencing assembly of the magazines, a determination is
made as to which particular sets of signatures are to be contained
within which particular pockets 22a-22n of the gathering machine
20. Thus, using the previous example, it might be decided that the
variable signatures XI - XIV are to be put into gatherer pockets
22a, 22c, 22g and 22h (FIG. 1), respectively, with the standard
signatures I-X being put in the other pockets 22 of the gathering
machine. This information must be combined with the previously
determined relations between the various predetermined combinations
of signatures for the various sub-groups.
Thus, using the previous example of the group 1, sub-group B
subscribers which are to receive a magazine comprising variable
signatures XII and XIV and the ten standard signatures I-X, it will
be necessary on each cycle of the gatherer machine to instruct
feeding only of pockets 22c and 22g (containing signatures XII and
XIV respectively) and the other pockets 22, which contain the
standard signatures I-X. For each sub-group of each group, it is
similarly determined in advance what predetermined combination of
gatherer pockets is to be instructed to feed. It is apparent that,
for a magazine containing twelve signatures, twelve cycles of the
machine will be required to produce a completed magazine.
A magnetic tape instruction file 54 (FIG. 5) is then prepared
identifying in machine readable form for each different sub-group
in each different group, a different predetermined combination of
at least some of the gatherer pockets to be instructed to feed
during a gathering machine cycle. The predetermined combination of
pockets to be instructed to feed for each sub-group is the
combination which will provide a magazine constituted by the
signatures predetermined to be necessary for that particular group
and sub-group.
The instruction file 54 and the subscriber file 48 are then
processed through the previously mentioned computer 42 and the
information contained on those files is combined on a magnetic tape
control file 56 produced by the computer. The control file 56
contains information in machine readable form identifying each
sub-group of subscribers in each group with (i) the number of
subscribers in that sub-group, and (ii) the predetermined
combination of gatherer pockets to be activated to produce the
appropriate magazine for that sub-group. The groups and sub-groups
are arranged in the control file 56 in the same order as the groups
and sub-groups are arranged on the roll 50 of the pre-printed
labels.
The computer may also be used to produce a fan-folded, print-out
sheet 58 containing the same information in printed form, if
desired.
The Process Computer
The previously mentioned process computer 36, which may comprise
any standard, commercially available process computer, includes
separate electrical output connections 70 (FIG. 1) to each of the
separate pocket instruction mechanisms 34 associated with the
gatherer pockets 22a-22n. Each of the pocket instruction mechanisms
34 may thus be individually instructed to enable or prevent feeding
from the associated gatherer pocket 22 during a gathering machine
cycle, by a separate electrical signal from the process computer
36.
The operating sections of the process computer 36 are illustrated
schematically in FIG. l6, although it will be appreciated by those
skilled in computers that other internal computer arrangements to
achieve the results about to be described, may be employed.
The previously mentioned control file is interrogated by a tape
reader 72 and an advance unit 74 advances the tape incrementally
past the tape reader upon instruction. As a particular sub-group
moves into registry with the tape reader 72, the information
concerning the predetermined combination of gatherer pockets to be
activated for that sub-group is read and fed to a pocket selector
register 76. Operating on this information, the pocket selector 76
instructs the necessary pocket instruction mechanisms, via the
connections 70, to engage so that during each gathering machine
cycle, a signature is fed from each of the pockets 22 instructed to
feed. The tape reader 72 also reads the number of subscribers in
the sub-group and the information is fed to an add unit 78 where an
additional number of predicted defective magazines for the
sub-group is added (as will be described hereinafter) to provide a
total number of magazines to be produced for the sub-group. The
total number from the add unit 78 is passed to a store total unit
80.
On successive gathering machine cycles, successive magazines are
produced constituted by the predetermined combination of signatures
necessary for that sub-group. Each cycle is counted by a cycle
count unit 82 connected with the previously mentioned cycle timer
32. The cumulative total in the cycle count unit 82 is compared
with the total in the store total unit 80 by a comparison unit 84.
It will be appreciated that as a sub-group run is being concluded,
the pockets upstream of the last magazine being produced should
stop feeding for that run but the gatherer must, of course,
continue cycling to complete production of the last magazine. Thus,
when enough magazines have been started in process, that is, when
pocket 22a has made its last feed for the particular sub-group, the
gathering machine will have performed enough cycles for the totals
in the units 80 and 82 to be equal but the gatherer has yet to
complete producing all of the required magazines. Accordingly, when
the totals in the unit 80 and 82 are equal, the compare unit 84
sends a signal to a pocket disable unit 120 which sequentially
disables the gatherer pockets behind the last magazine in the
gatherer for the sub-group.
Moreover, it is necessary that the last magazine be at least
through the gatherer before the file 56 is advanced and a new set
of pocket instructions are sent to the gatherer. To this end, an
additional store total unit 81 is employed to receive the total
number from add unit 78. However, the store unit 81 is preset at a
number equal to at least the number of gatherer pockets. For
example, if the gatherer has fifteen pockets, unit 81 would be
preset at fifteen and the number from unit 78 would be added to
fifteen. The number in unit 81 is compared with the cycle count
unit 82 in a compare unit 83. When the totals in the two units are
equal, the last magazine in the run will have cleared the gatherer
and a signal is sent to a set zero unit 86 to which it is
connected. The set zero unit 86 is connected with the store total
units 80, 81 and the cycle count unit 82, and upon being signalled
by the compare unit 83 sets the units 80 and 82 back to zero and
unit 81 back to its pre-set total. At the same time, the compare
unit 83 instructs the advance unit 74 to advance the control file
56 so that the next sub-group is interrogated by the tape reader
72. The process is then repeated for the next sub-group.
Error Detection
Using a gathering machine of the type disclosed in the previously
mentioned U.S. Pat. No. 2,621,039, each of the gatherer pockets
22a-22n is provided with an associated caliper device 90 for
detecting a feed error from the associated pocket. The caliper
device 90 includes pivot arm 92 having a roller 94 at its lower end
biased by a spring 95 towards a calipering cam E. Signatures being
fed from the associated pocket pass between the roller 94 and the
cam E. The pivoted lever 92 carries a projecting electrical contact
arm 96 having its upper end spaced between two opposed electrical
contacts 98. A single signature between the roller 94 and the cam E
positions the contact arm 96 midway between the contacts 98 out of
contact with either. In the event of a double feed, the increased
signature thickness moves the roller 94 further away from the cam E
bringing the contact arm 96 into electrical contact with the lower
of the contacts 98 to complete an appropriate error electrical
circuit. Conversely, if no signature is fed, the roller 94 moves
relatively closer to cam E so that the electrical contact arm 96
makes contact with the upper electrical contact 98, thus also
completing the error circuit.
Whenever a feed error is detected at any of the gatherer pockets
22a-22n, the error signal produced by the associated caliper unit
90 is fed to a pocket disable unit 120 (FIG. 6) within the
previously mentioned process computer 36. The pocket disable unit
100 which is connected with the pocket instruction mechanisms 34,
thereupon instructs all the pockets 22 downstream of the pocket at
which the error occurred, not to feed for the remainder of the
gathering machine cycle in which the error occurred. This offers
the considerable advantage that good signatures do not continue to
be fed from the pockets on to a defective magazine, thereby
significantly reducing the loss of signatures due to errors. One
technique by which the downstream pockets may be disabled is
disclosed in U.S. Pat. No. 3,519,264 to Beacham et al. and U.S.
Pat. No. 3,525,516 to Bushmell et al.
The pocket disable unit 120 also triggers a reject mechanism 121
(FIG. 1) positioned downstream of the gathering machine 20 to
automatically remove the defective magazine from the conveyor 24 as
the defective magazine leaves the gatherer 20.
For detecting an erroneously bound magazine leaving the binding
station 26, a binding error detection system is provided (FIGS.
12-18). The binding error detection system includes two
longitudinally spaced potocells 100a and 102a positioned above the
conveyor 24 at a fixed location downstream of the binding station
26. The photocells are aligned with light sources 100b and 102b.
The photocells 100a and 100b control (by conventional circuitry not
shown) switches 106 and 108 arranged in series with an error
detecting circuit. With light beams uninterrupted, each photocell
maintains its associated switch open to break the error detection
circuit. The longitudinal spacing betwen the photocells (100 and
102) is such that a magazine with correctly applied covers will not
cause closing of more than one of the switches 106 and 108 at a
time (FIG. 16). If, however, the covers are incorrectly applied to
a magazine, parts of the magazine may project longitudinally beyond
the cover (FIG. 15). If a book with such defectively applied covers
passes the photocells 100 and 102, it will, at some stage of its
progress, simultaneously obscure both photocells thus closing
simultaneously both switches 106 and 108 (FIG. 18) and completing
the error detection circuit.
To detect incorrect lateral application of the covers, a photocell
110a and corresponding light source 110b are provided adjacent the
open edge of the magazine. If the cover is properly applied, the
beam is uninterrupted. If, however, the cover extends too far
beyond the open edge of the magazine because of mis-application,
the beam between the photocells 110 is interrupted closing another
switch 114, in parallel with the switches 106 and 108, to complete
the error detection circuit (FIG. 17).
A similar photocell error detection system is employed downstream
of the trimming station to detect erroneously trimmed books.
Both the binding error detection system and the trimming error
detection system would be connected to suitable reject mechanisms
for rejecting the defective magazines.
Allowance For Defective Magazines
If there were no errors, the system thus far described would
provide, for each subscriber sub-group, a number of magazines equal
to the number of pre-printed subscriber name and address lables for
that sub-group on the pre-printed roll 50. Rejected defective
magazines, however, create a mismatch and it is a significant
feature of the present invention that the number of defects is
predicted and an extra number of magazines made up in order to
minimize the degree of mismatch between the number of magazines for
a particular sub-group and the number of subscriber name and
address labels to be applied for that sub-group.
To this end, each gatherer pocket 22a-22n has associated with it a
prediction sub-system 122 within the process computer 36 (FIG. 6).
Each prediction sub-system 122 for each pocket 22 includes an error
count unit 124 connected with the caliper device 90 associated with
the pocket which maintains a cumulative count of the feed errors
occurring at that pocket. Each prediction sub-system 122 also
includes a cumulative count unit 126 associated with each pocket
maintaining a cumulative count of each actuation of the pocket. The
total of errors from the error count unit 124 is compared with the
total from the cumulative count unit 126 in a predicted error rate
unit 128 which derives a predicted error rate for that gatherer
pocket. The prediction sub-systems 122 for the other gatherer
pockets derive corresponding predicted error rates for them.
Similar prediction sub-systems 130 and 132 for errors occurring at
the binder 26 and trimmer 28, derive predicted binder and trimmer
error rates.
The various predicted error rates thus derived, are added in an
adding unit 134 to provide a cumulative predicted error rate. The
cumulative predicted error rate is applied to the number of
subscribers in the sub-group currently being interrogated by the
read tape unit 72 in a multiply unit 136, to derive a predicted
number of defective magazines for that sub-group. The predicted
number of defective magazines is then added to the number of
magazines for that subgroup in the previously mentioned add unit
78, and the total of magazines for the sub-group plus the predicted
number of defects is transferred to the store units 80 and 81 as
previously discussed. The predicted number of defective magazines
is also stored in a predicted defects store unit 137, for a purpose
to be discussed.
If the predicted number of defective magazines is accurate, then
the number of magazines for a sub-group arriving at the labeling
head for application of labels will be equal to the number of
subscriber labels for that particular subgroup, thereby maintaining
a match as shown in FIG. 7 and FIG. 8. In FIG. 7, for example, with
four remaining labels for subscribers in an A sub-group, there are
four remaining unlabeled A magazines approaching the labeling head,
despite the existence of a gap in the stream of books where a
defective magazine was rejected. The gap is detected by a
photocelllight source pair 138 (FIG. 2) positioned just before the
labeling head 30, which signals the labeling head not to apply a
label as the gap passes underneath. This system reduces to a
minimum the number of subscribers who will not be provided with
magazines due to feed, trimming and binding errors.
For each sub-group, during the production run therefore, the total
of actual defective magazines produced is accumulated by an actual
defect total unit 140 connected with the error detection devices
previously described. At the conclusion of the run, as signalled by
compare unit 83, the total of actual defects in the unit 140 for
that sub-group is compared with the predicted defects stored in
unit 137 in a substract unit 141 and the difference between them is
transferred to a store unit 142. The units 140 and 137 are then set
back to zero by the set zero unit 86 as the control tape file 56 is
advanced to the next subscriber sub-group, in the manner previously
described.
As shown, it is a signal from the set zero unit 86 which first
actuates the subtract unit 141 and then re-sets units 140 and 137.
If desired, the units 137,140 and 141 may operate continuously so
that, at any instant, unit 141 reflects the difference between
units 137 and 140. A gate positioned before store unit 142,
operated by a gating signal from compare unit 83, would, at the
conclusion of the run, receive the difference figure from unit 141
at that moment and a signal from set zero unit 86 would reset units
137 and 140.
If there is an excess of magazines resulting from an actual number
of defects less than the predicted number (the situation
illustrated in FIG. 9) the stored difference figure transferred to
the store unit 142 is used to activate another reject unit 143,
(FIG. 1) positioned just before the labeling head 30 to remove the
excess books from the conveyor 24. After the last excess book is
rejected by reject unit 143, the store unit 142 is cleared in
readiness for the next reject instruction and reject unit 143 is
deactivated.
If the number of actual defects exceeds the predicted number of
defects for a particular sub-group, there will be a deficiency of
magazines arriving at the labeler 30, as shown in FIG. 10. The
deficiency figure, stored in the store unit 142, signals activation
of a dummy book 150. The dummy book 150 comprises a roll of paper
152 wound on two longitudinally spaced, parallel, laterally
extending spools 154. The spools 154 are moved laterally beneath
the labeling head into the position occupied by the missing book to
actuate the photocell 128 and receive the label that would be
applied to the book if it were there. The spools 154 are then
retracted laterally as the conveyor chain 24 moves past the
labeling head. After the last excess label has been applied, store
unit 142 is cleared and the dummy book is deactivated.
In a further refinement, one of the spools 154 may be indexed upon
each withdrawl so that the labels are not applied on top of each
other to the roll of paper 152 and may subsequently be peeled
off.
It is contemplated that the predicted error rate may be updated
with each run. To this end, the predicted error rate from each unit
128 would be re-added before each run so that the number of
additional magazines produced for each run is based on the
immediate past history of the system.
Alternative Embodiment
The preferred embodiment of the invention, heretofore described,
utilizes a pre-printed stock of labels in conjunction with a
process of sorting the subscribers into groups and sub-groups in a
predetermined order. In an alternative embodiment, the labels are
printed concurrently with the production of the magazines by
utilizing the subscription list to prepare a control file
containing information identifying each subscriber with his name
and address, and the gatherer pocket combination to be instructed
to feed for his magazine. Then at the same time the information
from the control file is used to instruct feeding of the
appropriate pockets to constitute the magazine for a particular
subscriber, his mailing label is printed and later applied as the
magazine arrives at the labeling head.
One form which the alternative embodiment may take is illustrated
in FIGs. 19 to 21. Referring first to FIG. 19, a control file 56'
in the form of binary coded information on a reel of magnetic tape
is prepared. The control file 56' may be prepared by processing the
subscriber file and the instruction file through the general
purpose computer 42 in the manner mentioned above. However, the
control file 56' differs from the control file 56 of the first
embodiment in that the complete name and address of each subscriber
is coded on the magnetic tape in machine readable form. In
addition, the control file 56' contains information identifying, in
machine readable form, each individual subscriber with a
predetermined combination of the gatherer pockets to be instructed
to feed during the gathering machine cycle to produce the
predetermined combinations of signatures for that subscriber. Thus,
the control file 56' contains, in machine readable form, each
subscriber's name and mailing address together with information for
controlling operation of the gatherer to make up that particular
subscriber's predetermined combination of signatures. To facilitate
town sorting and mailing, it is preferred that the subscribers be
organized on the control file by region and Zip Code so that runs
by Zip Code can be made.
Since there is no demographic organization of the subscribers on
the control file 56', it is to be understood that with successive
cycles of the gatherer, successive magazines may be composed of
different combinations of signatures.
As illustrated in FIG. 19, the control file 56' is fed into the
process computer 36 which, as in the embodiment of FIG. 1 may be
any commercially available process computer such as a PDP8. Only
the operating sections pertinent to this embodiment are
illustrated, it being understood that other internal arrangements
may be employed.
The name -- address and signature -- pocket information, on the
control file tape is read by the tape reader 72, transferred into a
buffer storage and then, by a suitable write unit 200, transferred
into a drum memory 202. During operation of the system, the
information on the drum memory for each individual subscriber is
subsequently entered into the computer core and used by the
computer 36 to control operation of the gatherer and the printing
of the label for each subscriber.
FIG. 21 illustrates one form in which the information on the
control file may be recorded on the drum, it being understood that
various ways may be employed. As shown, the pocket instruction
information for each subscriber is entered according to a drum
diagonal format. This format provides, for each machine time frame
corresponding to a gatherer cycle, a file of commands which are the
instructions for each pocket during that cycle. In addition, since,
for each cycle of operation of the gatherer, a different
subscriber's magazine is started, the name -- address information
for each subscribers may be stored on the drum in the manner shown
in FIG. 21. Thus, for each machine time frame the name and address
of the subscriber whose magazine will be started in that time frame
together with this pocket instruction information, is entered in
that file of information. For example, as John Doe's pocket
instruction information is entered in the diagonal format shown,
his name, address and pocket instruction information are also
entered in the file of time frame 1 since his magazine will be
started in that cycle. Similarly, John Smith, whose magazine will
be started in time frame 2, is entered in the file corresponding to
that time frame.
A read unit 204 reads the information on the drum by file, that is,
across the drum and transfers this information a few machine time
frames at a time to the core memory of the computer where it is
stored for use in controlling the production process. Thus, the
information read by the read unit 204 is fed to a store instruct
unit 206 which assigns the information to different addresses in
the core for use at the proper time. As shown, the information for
each machine time frame governing the pocket operation is stored in
a cycle instruct store 208. The name and address information is
stored in a name -- address store 210 and the pocket instruction
information is stored in a pocket instruct store 212. It will be
appreciated that each of the store units 208, 210, 212 represents a
block of addresses in the core memory and are illustrated as
separate blocks merely to facilitate an understanding of the
invention.
In operating the bindery system, a core read unit 214 reads the
information stored in the cycle instruct store 208 in the same
squence in which it was entered and, by the output connections 70,
sends separate electrical signals to each of the separate pocket
instruction mechanisms 34 associated with the gatherer pockets
22a-22n. Thus, the signals sent by the read unit 214 during the
first cycle of operation of the gatherer would correspond to the
pocket information illustrated in the file of time frame 1 on the
drum 202. During the next cycle of operation of the gatherer, the
pockets would be instructed to feed or not feed in accordance with
the information corresponding to the information illustrated in
time frame 2 on the drum. In this manner, each of the pocket
instruction mechanisms 34 is individually instructed to enable or
prevent feeding from the associated pocket 22 during each cycle of
the gathering machine.
The read unit 214 also is used to instruct printing of the
subscriber's labels ini the same sequence in which the subscriber's
magazines are produced. Thus, the read unit 214 reads the
information stored in the name -- address store 210 in the same
sequence in which it was entered and transmits this information to
a label printer 216. The label printer may be a conventional
high-speed computer printer such as is commercially available from
Di/An Control Inc, Boston, Mass.. In accordance with the
instructions from the process computer, the label printer 216
prints a label on a continuous roll 218 of labels. The roll of
labels 218 then enter a conventional labeling head 220 which
applies each subscriber's label to that subscriber's magazine as it
arrives at the label head. As in the emboidment of FIG. 1, a
photocell 138 positioned just before the labeling head may be used
to actuate the labeling head to apply the labels to the magazines.
It will be appreciated that since the labels are printed in the
same sequence as the magazines are produced, and assuming no feed,
trimming or binding errors, each uniquely tailored magazine
arriving at the label head should correspond to the correct
subscriber's label.
In the event there is an ewrror in the system and the uniquely
tailored magazine for a particular subscriber is rejected, a
potential mismatch situation is presented in which the uniquely
tailored magazine arriving at the label head would not correspond
to the printed label. It is an important aspect of this embodiment
of the invention to provide an arrangement which not only avoids
mismatches but which also is capable of reordering that particular
subscriber's magazine as the run is being made.
To this end, a conventional photoelectric sensor 222 is positioned
adjacent the conveyor 24 and between the trimmer and the label head
220. The photoelectric sensor 220 is operative to inspect the
conveyor 24 at predetermined intervals to sense the presence or
absence of the magazines. This inspection by the sensor 222 is
timed in its operation to coincide with the spacings of the
conveyor 24 so that for each space on the conveyor where a magazine
should be present, a photoelectric inspection is made. With each
inspection where a magazine is present, a signal is sent by the
sensor 222 to the process computer so that the information
concerning the particular subscriber, which has been held in the
computer core, may be removed from the core. Should an error occur
at the gatherer, the trimmer or the binder resulting in rejection
of the defective magazine, a space will occur on the conveyor 24.
As this space passes beneath the sensor 222, the absence of a
magazine will be detected and a signal will be sent to the process
computer which indicates that a particular subscriber's magazine is
not present. As this space on the conveyor then moves beneath the
label head 212, a label reject mechanism 224, activated by a signal
from the sensor, receives the label of the particular subscriber
whose magazine was rejected. At the same time, the process computer
transfers the information concerning the particular subscriber
whose uniquely tailored magazine has been rejected, from the core
into a reserve section of the drum memory 202. At the conclusion of
a run, preferably at the end of the particular Zip Code sub-group,
the information stored in the reserved section of the drum is
transferred back into the computer core and uniquely tailored
magazines for each of these subscribers are again produced.
It should be understood from the foregoing that, at any given
moment in a continuous production run, the links or spacings on the
conveyor 24 contain uniquely tailored magazines for a plurality of
different subscribers. For example, the conveyor may have eighty
spaces from the first gatherer pocket to the sensor 222 nd there
would, therefore, be eighty magazines for eighty different
subscribers in process simultaneously. Since an error may occur at
various points from the first gatherer pocket up to the sensor 222,
it is necessary that the information for each subscriber whose
magazine is in process be retained at least until the sensor 222
has made its inspection. Thereafter, if no errors occurred and the
subscribers's magazine has passed to the label head, that
subscribers's information may be removed from memory.
However, the computer, upon receipt of an electrical signal from
sensor 222 indicating absence of a magazine, must ascertain which
subscriber's magazine was rejected and, as discussed above, arrange
to have a replacement made.
There are several ways in which the computer can keep account of
the magazines in process so as to be able to ascertain whose
magazine was rejected when an absent magazine is detected by sensor
222. One suitable technique when the information is stored in the
core memory will be described. In storing the information from the
drum in the store units 210, 212, the store instruct unit 206 may
be used to associate a number with each subscriber's name --
address and pocket instruction information. For example, as John
Doe's name and address and pocket instruction information is
entered in the core, a number is assigned to that information. A
different number would be assigned to John Smith, and so on. As
will be more apparent hereinafter, the first number assigned should
correspond to the number n of spacings or link lengths on conveyor
24 with each number being consecutive thereafter. Using the example
of a conveyor with eighty spacings, the first number assigned would
be 80 and that number would be associated with the information
stored for John Doe in both units 210, 212. The number 81 would be
assigned to John Smith, and so on. No number need be associated
with the information stored in unit 208 since that information
pertains to gatherer cycle sequencing and not to any particular
subscriber.
A cycle count unit 226, connected to the master timer 32, counts
each cycle of the gatherer. When the total in the count unit
reaches 80, John Doe's magazine should be at the sensor 222 and
with the next cycle 81, John Smith's magazine should have reached
the sensor. As the first magazine reaches the sensor and for each
cycle thereafter, the computer would then send a signal actuating
the sensor and an inspection would then be made. If no magazine is
present, a gating signal is sent by the sensor to a retrieve unit
228. Upon actuation by the signal from the sensor, retrieve unit
228 takes the current number on the cycle count unit 226 and
instructs the read unit 214 to retrieve from the store units 210,
212 the information associated with that number. That information
is then transferred to a write unit 230 which transfers the
information to a reserved area 232 on the drum 202. For example, if
at the time an inspection was made and an absent magazine detected,
the count on the cycle count unit was at 81, then the information
in the store units 210, 212 assigned the number 81 by the store
instruct unit 206 would be transferred back to the drum memory. In
the example given above, if John Smith's information had been
assigned the number 81, his name and address would be retrieved
from unit 210 and his pocket instruction information from unit 212
and transferred to the drum 202. At the conclusion of the run,
preferably at the end of the Zip Code, John Smith's information
would be transferred back to core and his uniquely tailored
magazine would be re-made in the manner described.
The label reject mechanism 224 may take various forms. For example,
a dummy book arrangement similar to 150 might be used to receive
the label with the lateral movement of the dummy book beneath the
label head being controlled by the signal from the sensor 222.
While the system of FIG. 19 contemplates transfer of the stored
information on the drum memory to the core memory, it will be
appreciated by those skilled in the art that other techniques might
be used. For example, instead of transferring the information to
the core, it may be entered into shift registers from which it is
used by the computer logic to operate the system. Moreover, it is
within the contemplation of this invention to eliminate the drum
memory and use the core memory of the computer both for initial
storage of the information to be used in a run and for storage of
the information for subscribers whose magazines were rejected
during the run.
If shift registers are used, as suggested above, each subscriber's
name -- address and pocket instruction information could be shifted
through a number of shift stages corresponding to the number of
magazines simultaneously in process. For example, and using the
previous example of eighty spacings on the conveyor 24, each
subscriber's data would be shifted through eighty stages. The last
stage would correspond to the inspection step and, depending on the
signal from sensor 222, the data for the particular subscriber
whose magazine is being inspected would exit from the shift
register and be lost or returned to the drum memory.
It is to be noted that, with the embodiment of FIGS. 19 - 21, the
error prediction system of FIG. 6 is eliminated since complete
custody of each uniquely tailored magazine is maintained throughout
the process. In other words, each subscriber's magazine and label
are made on command and if an error occurs, both the magazine and
the label are rejected and re-ordered.
The invention has been described with reference to two specific
embodiments, in both of which information concerning the
subscribers is stored on a file in machine readable form and
subsequently machine read to control the magazine production
process. In the first embodiment, the machine reading of the file
occurs in timed relation to the cycles of operation of the
gathering machine while in the second embodiment the information
read from the file is temporarily stored in a memory and read from
the memory to control the production process. Still further
modifications will occur to those skilled in the art without
departing from the principles of the invention and it is intended
that all such modifications are to be included within the scope of
the invention as defined by the appended claims.
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