U.S. patent number RE32,690 [Application Number 06/898,359] was granted by the patent office on 1988-06-07 for collating and binding system and method with postage indication.
This patent grant is currently assigned to R. R. Donnelley & Sons Company. Invention is credited to Did-Bun Wong.
United States Patent |
RE32,690 |
Wong |
June 7, 1988 |
Collating and binding system and method with postage indication
Abstract
A collating and binding system for producing customized versions
of books includes means for detecting a defective book, means
responsive to the detecting means for rejecting the defective book
and means for reordering the rejected book at a point in an
original production sequence determined in accordance with a
comparison of the postal information of the rejected book with the
postal information of a book currently being produced. An
indication of the postage required to mail the produced books is
derived from an amount calculated before the books are produced and
from indications of postage increases for those books which were
reordered at subsequent portions in the original production
sequence.
Inventors: |
Wong; Did-Bun (Glen Ellyn,
IL) |
Assignee: |
R. R. Donnelley & Sons
Company (Chicago, IL)
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Family
ID: |
27072052 |
Appl.
No.: |
06/898,359 |
Filed: |
August 20, 1986 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
559398 |
Dec 8, 1983 |
4500083 |
Feb 19, 1985 |
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Current U.S.
Class: |
270/52.05;
705/402; 705/406 |
Current CPC
Class: |
B07C
1/00 (20130101); B65H 43/04 (20130101); B42C
19/00 (20130101); B65H 2301/4311 (20130101) |
Current International
Class: |
B07C
1/00 (20060101); B42C 19/00 (20060101); B65H
43/04 (20060101); B65H 039/02 () |
Field of
Search: |
;270/55-58,1,4,12,18,20,52 ;364/464 ;101/2 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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15112 |
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Sep 1980 |
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EP |
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2066734 |
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Jul 1981 |
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GB |
|
2066735 |
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Jul 1981 |
|
GB |
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Primary Examiner: Eickholt; E. H.
Attorney, Agent or Firm: Wood, Dalton, Phillips, Mason &
Rowe
Claims
I claim:
1. A method of operating a collating system, comprising
producing a series of books in an original sequence, such original
sequence being determined in accordance with postal information
relative to such books;
checking for a defective book;
generating a signal when a defective book is detected;
reordering the defective book in response to the generated signal
at a point in the original sequence determined in accordance with
the postal information relative to the rejected book and another
book to produce the series of books in a revised sequence; and
deriving an indication of postage for the nondefective produced
books in accordance with the revised sequence.
2. The method of claim 1, wherein the step of producing is carried
out on a conveyor and wherein the point in the original sequence at
which the defective book is reordered is determined by comparing
the postal information of the defective book with the postal
information of a book on the conveyor.
3. The method of claim 1, wherein the point in the original
sequence at which the defective book is reordered is determined by
comparing the postal information relative to the defective book
with the postal information relative to the most recent book being
produced.
4. The method of claim 1, wherein the step of deriving includes the
steps of calculating the postage required for the books if produced
in the original sequence and revising the calculated postage in
dependence upon the revised sequence.
5. The method of claim 4, wherein the step of revising includes the
steps of generating an indication of the increase of postage for
each reordered book and adding to the calculated postage the
increase in postage for such reordered books.
6. The method of claim 1, wherein the step of reordering includes
the steps of comparing the postal information of the defective book
with that of the most recent book being produced, determining which
parts of the postal information of the defective and most recent
books match and reordering the defective book at a point in the
original sequence prior to a change in one of the matching parts of
the postal information for books to be produced.
7. The method of claim 1, wherein the postal information includes
designations of 5-digit zip code and carrier route, and wherein the
step of reordering includes the steps of comparing the postal
information of the rejected book with that of the most recent book
being produced to determine whether any of such informatiokn
matches and immediately reordering the defective book only if the
carrier route and 5-digit zip code designations of both books
match.
8. The method of claim 7, wherein the step of reordering includes
the further step of reordering the defective book immediately
preceding a change in 5-digit zip code for books to be produced if
the 5-digit zip code of the defective book matches that of the most
recent book being built but the carrier route designations do not
match.
9. The method of claim 7, wherein the step of deriving includes the
steps of calculating the postage required for the books is produced
in the original sequence, generating an indication of the increase
in postage for a defective book if such book is not immediately
reordered and adding to the calculated postage the increase in
postage to derive the indication of postage.
10. The method of claim 7, wherein the step of reordering includes
the further step of reordering the defective book immediately
preceding a change in the first three digits of the zip code for
books to be produced if neither the 5-digit zip code nor the
carrier route designation of the defective book matches that of the
most recent book being built but the first three digits of the zip
code match.
11. The method of claim 10, wherein the step of deriving includes
the step of calculating the postage required for the books assuming
such books are produced in the original sequence, generating an
indication of the increasing in postage for the reordered book over
the calculated postage required for the defective book and adding
the increase in postage to the calculated postage.
12. A collating system, comprising:
means for producing a series of books in an original sequence, such
original sequence being determined in accordance with postal
information relative to such books;
means for detecting a defective book;
means responsive to the detecting means for generating a signal
when a defective book is detected;
means for reordering the defective book in response to the
generated signal at a point in the original sequence determined in
accordance with the postal information relative to the rejected
book and another book to produce the series of books in a revised
sequence; and
means for deriving an indication of postage for the non-defective
produced books in accordance with the revised sequence.
13. The collating system of claim 12, wherein the producing means
includes a conveyor and wherein the reordering means includes means
for comparing the postal information of the defective book with the
postal information of a book on the conveyor to determine the point
in the original sequence at which the defective book is
reordered.
14. The collating system of claim 12, wherein the reordering means
includes means for comparing zip code and carrier route
designations of the defective book with zip code and carrier route
designations of the most recent book being produced to determine
the point at which the defective book is reordered.
15. The collating system of claim 12, wherein the deriving means
includes means for providing a precalculated indication of the
postage required for the books if produced in the original sequence
and means for revising the precalculated indication in dependence
upon the revised sequence.
16. The collating system of claim 15, wherein the revising means
includes means for developing an indication of the increase in
postage for each reordered book and means for adding the increase
in postage to the precalculated indication of postage.
17. The collating system of claim 12, wherein the reordering means
includes means for comparing the postal information of the rejected
book with that of the most recent book being built, means for
determining which parts of the postal information of the defective
and most recent books match and means for reordering the defective
book at a time prior to a change in one of the matching parts of
the postal information for books to be produced.
18. The collating system of claim 12, wherein the postal
information includes designations of zip code and carrier route,
and wherein the reordering means includes means for comparing the
postal information of the rejected book with that of the most
recent book being produced to determine whether any of such
information matches and first means for immediately reordering the
defective book only if the carrier route and zip code designations
of both books match.
19. The collating system of claim 18, wherein the reordering means
further includes second means for reordering the defective book
immediately preceding a change in zip code for books to be produced
if the zip code of the defective book matches that of the most
recent book being built but the carrier route designations do not
match.
20. The collating system of claim 18, wherein the deriving means
includes means for providing a precalculated indication of postage
required for the books assuming such books are produced in the
original sequence, means for developing an indication of the
increase in postage due to reordering of a defective book and means
for adding the increase in postage to the precalculated indication
of postage.
21. The collating system of claim 18, wherein the reordering means
further includes second means for reordering the defective book
immediately preceding a change in the first three digits of the zip
code for books to be produced if only the first three digits of the
zip code of the defective book matches the first three digits of
the zip code of the most recent book.
22. The collating system of claim 21, wherein the deriving means
includes means for providing a precalculated indication of postage
required for the books assuming such books are produced in the
original sequence, means for developing an indication of the
increase in postage for the reordered book over the precalculated
indication of postage for the defective book and means for adding
the indication of the increase in postage to the precalculated
indication of postage.
23. A collating system comprising:
A plurality of signature feeders for delivering signatures to a
plurality of stations along a conveyor;
means controlling the signature feeders for progressively building
different groups of signatures on the conveyor to thereby build a
series of books in an original sequence;
means for providing a precalculated indication of the postage
required for the books being built on the conveyor;
means disposed along the conveyor for detecting a defective
book;
means responsive to the detecting means for rejecting the defective
book;
means for reordering the rejected book at a point in the sequence
determined in accordance with a comparison of the postal
information of the rejected book with the postal information of a
book on the conveyor; and
means for revising the precalculated indication of the postage
required in accordance with the point in the sequence at which the
rejected book is reordered.
24. The collating system of claim 23, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories comprising lowest, intermediate and highest rate
categories, and wherein the revising means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for increasing the
precalculated indication of postage by a particular amount if the
rejected book had been classified in the lowest postal rate
category and is reordered at a point in the sequence such that it
can be grouped with other books having the same zip code but not
the same carrier route designation.
25. The collating system of claim 23, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories comprising lowest, intermediate and highest rate
categories, and wherein the revising means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for increasing the
precalculated indication of postage by a particular amount if the
rejected book had been classified in the lowest postal rate
category and is reordered at a point in the sequence such that it
is grouped with other books not having the same zip code and
carrier route designations.
26. The collating system of claim 23, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories, comprising lowest, intermediate and highest rate
categories, and wherein the revising means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for increasing the
precalculated indication of postage by a particular amount if the
rejected book had been classified in the intermediate postal rate
category and is reordered at a point in the sequence such that it
is grouped with other books not having the same zip code and
carrier route designations.
27. A collating system, comprising:
a plurality of signature feeders for delivering signatures to
stations along a conveyor;
means coupled to the signature feeders for individually controlling
the signature feeders to build a series of customized books in a
particular sequence, such particular sequence being determined in
accordance with postal information relative to each book to be
built so that the books are produced in an order which permits
groups of books having common postal information to be bundled
together and thereby receive a postal discount;
means adjacent the conveyor for detecting a defective book;
means responsive to the detecting means for reordering the
defective book at a point in the particular sequence dependent upon
a comparison of the postal information relative to the defective
book and the most recent book being built on the conveyor; and
means for deriving an indication of the difference in postage, if
any, for the reordered book over the defective book.
28. The collating system of claim 27, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories comprising lowest, intermediate and highest rate
categories and wherein the deriving means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for generating an
indication of a particular postage difference if the rejected book
had been classified in the lowest postal rate category and is
reordered at a point in the sequence such that it can be grouped
with other books having the same zip code but not the same carrier
route designation.
29. The collating system of claim 27, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories comprising lowest, intermediate and highest rate
categories and wherein the deriving means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for generating an
indication of a particular postage difference if the rejected book
had been classified in the lowest postal rate category and is
reordered at a point in the sequence such that it is grouped with
other books not having the same zip code and carrier route
designations.
30. The collating system of claim 27, wherein the postal
information includes a carrier route designation, a zip code
designation and a postal rate category for each book, the postal
rate categories comprising lowest, intermediate and highest rate
categories and wherein the deriving means includes means for
determining the postal rate category for the rejected book and
means responsive to the determining means for generating an
indication of a particular postage difference if the rejected book
had been classified in the intermediate postal rate category and is
reordered at a point in the sequence such that it is grouped with
other books not having the same zip code and carrier route
designations.
31. The collating system of claim 27, wherein the series of
customized books includes a plurality of versions of such books and
wherein the deriving means includes means for generating an
indication of the difference in postage for each version.
32. The collating system of claim 31, wherein the developing means
includes means for storing in a table an indication of the increase
in postage for each version.
33. A collating system, comprising:
a plurality of signature feeders for delivering signatures to
stations along a conveyor;
means coupled to the signature feeders for individually controlling
same to build customized books in a particular sequence, such
particular sequence being determined in accordance with postal
information including carrier route and zip code designations
relative to each book so that groups of books having common postal
information can be bundled together and receive a postal
discount;
means for providing a precalculated indication of postage required
for the books if produced in the original sequence;
means for detecting a defective book on the conveyor;
first means responsive to the detecting means for immediately
reordering the defective book if the carrier route and zip code
designations of the defective book are the same as the carrier
route and zip code designations of the most recent book being
produced;
second means responsive to the detecting means for reordering the
defective book at a subsequent point in the particular sequence if
the carrier route designation of the defective and most recent
books do not match; and
means responsive to the second means for revising the precalculated
indication of postage by an amount dependent upon the point in the
particular sequence at which the defective book is reordered.
34. The collating system of claim 33, wherein the second means
includes means for determining whether the zip code designations of
the defective and most recent books are the same and third means
responsive to the determining means for reordering the defective
book immediately prior to a change in zip code designation for
books to be produced if the zip codes of the defective and most
recent books are determined to be the same.
35. The collating system of claim 34, wherein the second means
includes fourth means responsive to the determining means for
reordering the defective book after the zip code designation for
books to be produced has changed from that of the most recent book
if the zip codes of the defective and most recent books are found
to not be the same.
36. The collating system of claim 33, wherein the revising means
includes means for indicating whether the rejected book was to have
been grouped in the original sequence with at least a predetermined
number of other books having the same carrier route and zip code
designations, means for determining whether the rejected book is
reordered so that it can be grouped with other books having the
same zip code but not the same carrier route and means responsive
to the indicating means and the determining means for increasing
the precalculated indication of postage by a particular amount.
37. The collating system of claim 33, wherein the revising means
includes means for indicating whether the rejected book was to have
been grouped in the original sequence with at least a predetermined
number of other books having the same carrier route and zip code
designations, means for determining whether the rejected book is
reordered so that it cannot be grouped with other books having
either the same carrier route or zip code designations and means
responsive to the indicating means and the determining means for
increasing the precalculated indication of postage by a particular
amount.
38. The collating system of claim 33, wherein the revising means
includes means for indicating whether the rejected book was to have
been grouped in the original sequence with at least a predetermined
number of other books having the same zip code but not the same
carrier route, means for determining whether the rejected book is
reordered so that it cannot be grouped with other books having
either the same carrier route or zip code designations and means
responsive to the indicating means and the determining means for
increasing the precalculated indication of postage by a particular
amount.
39. A collating system, comprising:
a plurality of signature feeders for delivering signatures to
stations along a conveyor;
means coupled to the signature feeders for individually controlling
same to build customized books in a particular sequence, such
particular sequence being determined in accordance with postal
information including carrier route and zip code designations
relative to each book so that groups of books having common postal
information can be bundled together and receive a postal
discount;
means for detecting a defective book on the conveyor;
first means responsive to the detecting means for immediately
reordering the defective book if the carrier route and zip code
designations of the defective book are the same as the carrier
route and zip code designations of the most recent book being
produced;
second means responsive to the detecting means for reordering the
defective book at a subsequent point in the particular sequence if
the carrier route designation of the defective and most recent
books do not match; and
means responsive to the first and second means for generating an
indication of the postage for the books based upon the point in the
particular sequence at which the defective book is reordered.
40. The collating system of claim 39, wherein the second means
includes means for determining whether the zip code designations of
the defective and most recent books are the same and third means
responsive to the determining means for reordering the defective
book immediately prior to a change in zip code designations for
books to be produced if the zip codes of the defective and most
recent books are determined to be the same.
41. The collating system of claim 40, wherein the second means
includes fourth means responsive to the determining means for
reordering the defective book after the zip code designation for
books to be produced has changed from that of the most recent book
if the zip codes of the defective and most recent books are found
to not be the same. .Iadd.
42. A method of operating a collating system, comprising the steps
of:
producing a series of books in an original sequence, such original
sequence being determined in accordance with postal information
relative to such books;
providing an indication of an amount of postage required to mail
the books if produced in the original sequence;
checking for a defective book;
generating a signal when a defective book is detected;
reordering the defective book in response to the generated
signal;
determining for each reordered book whether an incremental increase
in postage is required to mail the books due to the reordering of
such book; and
revising the indication of the amount of postage required to mail
the books by the incremental increases determined for the reordered
books. .Iaddend.
Description
DESCRIPTION
Background of the Invention
The present invention relates generally to collating and binding
systems and methods, and more particularly to a system for
collating signatures into individual books, arranging the books for
efficient mailing and generating an indication of postage
therefor.
One prior type of collating and binding system is disclosed in
Riley at al U.S. Pat. No. 4,121,818, assigned to the assignee of
the instant application. This collating and binding system
discloses a plurality of signature feeders disposed adjacent a
conveyor, the signature feeders being individually operated by a
programmable controller so that customized books are built in
accordance with information contained on a magnetic tape. Means are
provided along the conveyor to detect defective books. These
defective books are removed from the conveyor by a diverter which
is operated by the programmable controller.
The above system disclosed in Riley et al is useful to permit
customized information and/or signatures to be placed in books
produced during a single production run. In other words, each book
can be customized for the person to whom it is to be sent.
These books are then collated and bound in a sequence such that the
resulting books can be easily bundled to take advantage of postal
discounts or to meet Post Office requirements.
The assembling of customized books in a particular sequence to
permit bundling according to postal regulations is difficult to
achieve in an optimal fashion in the event a defective book is
detected, rejected and reordered by the system. In such a case, the
Riley et al system compares the mailing information of the
defective book with the mailing information of the book adjacent
the first signature feeder (or the "most recent book") to determine
the optimal time to reorder the book. For example, if the defective
book and the most recent book have the same zip code, the defective
book can be immediately reordered and grouped with other books
having the same zip code to obtain postal discounts. However, if
the zip code of the most recent book is different than that of the
defective book, then the defective book is reordered following the
last book within the same sectional center facility, or SCF,
destination. As these examples illustrate, the time for reordering
is determined in accordance with a comparison of the mailing
information of the defective book with the mailing information of
the most recent book on the conveyor.
In some cases when a book is found to be defective and is
reordered, the book may no longer qualify for a certain postal
discount and may instead be subject to a higher postal rate. For
example, a book may be originally classified in a discount
classification along with other books to be delivered to the same
five digit zip code area. If this book is found to be defective and
is reordered at a time such that it no longer is grouped with other
books of the same zip code, then this book could not qualify for
the discount postage rate previously applicable. The Riley et al
system noted above is not capable of generating an indication of
the change in postage, if any, caused by the reordering of the
defective book.
SUMMARY OF THE INVENTION
In accordance with the present invention, a collating and binding
system includes means for deriving an indication of postage
increase caused by the rejection and reordering of defective
books.
The collating system of the present invention includes a plurality
of signature feeders for delivering signatures to a plurality of
stations along a collating conveyor. A computer controls the
signature feeders to progressively assemble different groups of
signatures on the conveyor and thereby build a series of defective
books in an original or predetermined sequence to take advantage of
postal discounts. Means are disposed along the conveyor for
detecting a defective book and means responsive to the detecting
means reject the defective book at a point downstream from the
signature feeders.
The collating system further includes means for reordering the
rejected book at a point in the sequence determined in accordance
with a comparison of the postal information of the rejected book
with the postal information of a book on the conveyor, typically
the current or most recent book being assembled by the system. The
computer generates an indication of the incremental increase in
postage for the reordered book based upon the point in the sequence
at which the defective book was reordered and adds this increase to
a precalculated indication of such postage computed before the
collating and binding has begun.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a signature collating and binding
system according to the present invention;
FIG. 2 is a generalized block diagram of the control program stored
in the computer shown in FIG. 1;
FIGS. 3A and 3B, when joined along similarly lettered lines,
comprise a flow chart of the book reordering control program stored
in the computer shown in FIG. 1;
FIGS. 4, 5A and 5B are flow charts of the postage revision control
program stored in the computer of FIG. 1;
FIG. 6 is a flow diagram of steps for generating an indication of
postage due to the reordering of defective books, such steps being
implemented either manually or in the computer shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a signature collating and binding system
14 is disclosed, such system being preferably of the type disclosed
in Riley et al U.S. Pat. No. 4,121,818, assigned to the assignee of
the instant application and the disclosure of which is hereby
incorporated by reference. The description of the Riley et al
system in this application is limited to those portions which are
pertinent to an understanding of the present invention, it being
understood that a more complete description may be had by reference
to the above-identified patent.
The system 14 includes a conveyor 16 having a plurality of
stations, such as station 18, each station being separated from
other stations by pusher pins shown schematically at 20. The
station 18 is illustrated as being positioned to receive a
signature 21 stored in a first signature feeder box 22. The feeder
box 22 includes feeder apparatus 24 selectively operated by a main
computer 25 through a distribution network 26. The feeder apparatus
24 is disclosed in the above-mentioned Riley et al patent and
reference may be had thereto for a full description. At this point,
it need only be mentioned that the signature 21 may or may not be
placed on the conveyor 16 at the station 18 depending upon the
state of a signal on a line 28 from the distribution network
26.
The signature feeder box 22 also includes a detector 30 which
detects when a signature has been placed on the conveyor 16. The
output from the detector 30 is coupled to the computer 25 through
the network 26.
Second through nth signature feeder boxes are also disposed along
the conveyor 16, only the nth box 32 being shown schematically for
purposes of simplicity. Each of the second through nth signature
feeder boxes is essentially identical to the first feeder box 22,
the feeding of signatures by the boxes being individually
controlled by the main computer 25. The computer 25 in turn
receives information from a magnetic tape reader 36 which senses
information stored on a magnetic tape 37 regarding the particular
signatures to be assembled for each book. As noted in the
above-mentioned Riley et al patent, different versions of books may
be built at different stations of the conveyor 16 by controlling
the feeding of signatures by each of the feeder boxes.
A programmable controller 27 is also coupled to the distribution
network 26 and is capable of controlling various book-processing
apparatus noted more specifically below.
The conveyor 16 is driven by a chain motor 38 and information
regarding the position of the stations of the conveyor 16 is
developed by an encoder 39 and is coupled to the distribution
network 26.
A non-contact printer, such as an ink jet printer 40, is disposed
between the first and nth signature feeder boxes at a point which
permits ink jet printing of customized information under control of
the computer 25 on one or more signatures. The ink jet printer 40
includes a detector 41 which detects whether the printer is
operating correctly. A microcomputer 42 controls the printer 40 in
response to commands from the computer 25.
Alternatively, the ink jet printer 40 may be located at another
point, as desired.
Also disposed along the length of the conveyor 16 is means for
detecting a defective book. One of these means is the detector 41
in the ink jet printer 40 described above. Other means include a
long book detector 43, a hanging signature detector 44, a missing
book detector 46 and a square book detector 47, the last two being
located farther downstream adjacent the conveyor 16. A caliper 48
may additionally be utilized to check the thickness of each book on
the conveyor 16. The caliper 48 is adjusted to provide a defective
book indication to the distribution network 26 and the computer 25
when the thickness of the book measured thereby is outside of a
predetermined range.
A stitcher 50 binds the assembled books after measurement by the
caliper 48. A diverter 52, under control of the programmable
controller 27 rejects defective books by removing same from the
conveyor 16. A trimmer 54 then cuts the bound books to size and a
label printer 56, which may be a second ink jet printer, operated
by the computer 25 and a microcomputer 57, prints mailing
information on the outside of the completed book. The label printer
56 may also have a detector 58 incorporated therein to determine
whether the printer is operated satisfactorily.
Following the label printer 56, additional processing may be
performed as desired.
The computer 25 includes a random access memory, or RAM 62 and a
central processing unit, or CPU 64. The RAM 62 contains the control
program described in later portions of this specification and may
additionally store incremental postal rates, as later noted. The
RAM 62 also stores various intermediate results of calculations
performed by the CPU 64 and information from the magnetic tape
reader 36 indicating the makeup of each book to be produced during
a production run, the address to which the completed book is to be
sent and other information.
An operator console 66 acts as an interface between an operator and
the collating system. The computer 25 may also operate printer 68
to inform a user of various operating conditions in the collating
system. For example, the computer 25 may operate the printer 68 to
print a postage report for the assembled books, as noted more
specifically below.
The collating system may include additional elements, such as a
replacement book feeder which replaces missing books with a
standard book, or other elements as desired. The replacement book
feeder is disclosed in Abram et al. U.S. Pat. No. 3,899,165 and in
the above-noted Riley et al patent and reference should be made
thereto for a full description.
The order in which the books are to be produced is derived from
mailing lists provided by the customer so that advantage is taken
of discounts offered by the Postal Service. The postage is then
calculated and this precalculated indication of total postage and
the rate category for each book to be produced is stored on the
magnetic tape 37. The current postal rate structure for bulk
business mail and the postal bundling requirements, some of which
result in discounts for second and third class mailings is as
follows:
______________________________________ 2nd Class 3rd Class Postal #
of Pieces Postal # of Pieces Rate or Weight Rate Category Required
Level Required Level ______________________________________ Carrier
6 or more C 10 or more CAR RT Route (lowest pieces (lowest rate)
rate) 5 Digit 6 or more B 50 pieces 5-DIGIT Zip Code (intermed- or
10 lbs. (intermed- iate rate) iate rate) 3 Digit 6 or more A 10 or
more BASIC Zip Code (highest pieces (highest rate) rate) SCF 6 or
more A 10 or more BASIC (highest pieces (highest rate) rate) Common
6 or more A 10 or more BASIC State (highest pieces (highest rate)
rate) Mixed left over A left over BASIC States (highest (highest
rate) rate) ______________________________________
A typical second class piece of mail is a magazine while a typical
third class item is a catalog.
In terms of second class mailings, a bundled group of 6 or more
pieces to the same carrier route qualifies for the lowest postal
level rate C, while a group of six or more pieces bundled together
and having the same 5-digit zip code qualifies for an intermediate
postal rate level B. The remaining groupings, for example the
3-digit zip code category (referring to the first three digits of
the 5-digit zip code) where six or more books are grouped together
each having a common 3-digit zip code prefix, qualify for the basic
(or highest) postal rate A.
Similarly, for third class mailings, ten or more pieces bundled
together by carrier route qualifies for the lowest postal rate
level CAR RT, while groupings of 50 or more books, or 10 pounds or
more of books, having a common 5-digit zip code qualifies for the
intermediate rate 5-DIGIT. The remaining categories qualify for
BASIC (or highest) rates, similar to that described with respect to
second class.
As noted above, the magnetic tape 37 contains for each book to be
produced information as to the makeup of the book in terms of which
signatures are to be included therein and information regarding the
person and mailing address to which the book is to be sent. This
information may be arranged sequentially on the magnetic tape 37 so
that the finished books exit the conveyor ready to be bundled into
groups which qualify for the postal rate discounts.
This grouping of books can result in substantial postal savings to
the customer. However, when a book originally qualifying for a
postal discount is found to be defective on the conveyor and is
rejected by the diverter 52, and it is too late to reorder the same
book so that it can be grouped with its original grouping, then the
reordered book may not qualify for the discount. Accordingly, the
precalculated indication of postage required may become
erroneous.
Furthermore, a defective book which cannot be reordered so that it
is still grouped with its original grouping of books may cause the
entire original grouping to drop below the minimum level necessary
to quality at a particular postal rate. For example, if a defective
book in a second class mailing was originally grouped with five
other books all addressed to the same 5-digit zip code and if the
defective book could not be reordered to maintain its grouping with
the remaining five books, then all six of the books (i.e. the
defective book plus the five other books with which it was
grouped), cannot qualify for postal rate level B instead must be
mailed at the higher postal rate level A.
The above problems can be particularly acute where the books are
"customized" in the sense that not all of the books produced during
a single production run are identical. Customization can result
from different signatures being included in some books but not in
others, ink-jet printing of specialized messages (such as addressee
name) on one or more signatures, insertion of subscription cards in
some books but not others or any other manufacturing step which is
selectively performed on less than all of the books in a production
run so that not all books are alike. In fact, two or more different
publications might be produced during the course of a single
production run, and hence these books are appropriately considered
"customized" as well.
Where a customized book is found to be defective and is rejected,
the next book in the collating sequence cannot simply be
substituted therefor to make up the deficiency since the two books
are most likely not identical. Therefore, the customized book must
be reordered.
In order to generate an indication of postage for a defective book
which is reordered, the computer 25 is programmed to reorder the
defective book at an appropriate point in the original collating
sequence to take advantage of postal discount rates. An indication
of the increase in postage, if any, for the reordered book is then
generated by the computer 25 based upon the point in the collating
sequence at which the book was reordered.
Referring also to FIG. 2, the book reorder and postage revision
program stored in the computer 25 is accessed by any one of a
number of interrupts generated by the computer 25 of the
programmable controller 27. The computer or controller generates an
interrupt whenever a signal is generated by one of the defective
book detecting means. For example, if a failure has occurred in an
ink jet such that the printer 40 fails to print a satisfactory
message on a signature, the computer 25 receives the signal from
the detector 41 in the printer 40 and generates the interrupt to
cause the computer 25 to reorder the book at an appropriate time
and generate an indication of the increase in postage for that
piece of mail.
In a similar fashion, an indication of a defective book provided by
the detectors 30,43,44,46,47 and a thick/thin-book indication from
the caliper 48 causes an interrupt to be transmitted to the
computer 25.
Referring now to FIGS. 3A and 3B, there is illustrated a portion of
the programming in the computer 25 which determines the appropriate
point in the original sequence to reorder a book found to be
defective. The postal information of the defective book is compared
with the postal information of the most recent books on the
conveyor to determine which parts of the postal information for
these books match and the defective book is immediately reordered
or is reordered later in the sequence prior to a change in one of
the matching parts of the postal information.
The "most recent" book is that book in the process of being
assembled which is currently adjacent the first signature feeder
box 22. In other words, the most recent book as seen in FIG. 1 is
typically that book which is eventually assembled on the station
18.
As seen in FIG. 3A, following the receipt of a defective book
interrupt generated as previously noted, a block 80 determines the
version of the defective book. As previously noted, each book may
be different from or the same as other books in the production run
depending upon the makeup of the book in terms of which signatures
are fed to the appropriate station on the conveyor. As previously
noted, this book makeup information is initially stored on the
magnetic tape 36. During production the information for each book
is read into the RAM 62 of the computer 25 in a fashion identical
to that disclosed in connection with FIGS. 10 and 11 of the Riley
et al patent. For purposes of discussion in this application, it
will be assumed that the version may be any one of N versions to be
produced by the collating and binding system.
A block 82 then compares the 3-digit carrier route and 5-digit zip
code designations of the defective book with the same information
of the most recent book being assembled on the conveyor. If the
carrier routes and zip codes of these books are the same, then a
block 86 stores the book information for the defective book in the
RAM 62 so that this book is assembled immediately following the
most recent book. The defective book is therefore reordered so that
it can be grouped with the other books having the same carrier
route and zip code mailing information.
In the event that the carrier route and zip code information are
not identical, then a block 88 compares only the 5-digit zip code
of the defective book with the most recent book zip code. If it is
found that the 5-digit zip codes are identical, a block 92 causes
version X to be reordered immediately preceding the first book
having a zip code different than the zip code of the books
currently being assembled. Following the block 92, control passes
to a block 120 in FIG. 4 where the indication of increase in
postage for the defective book is generated. This is necessary
since the book can no longer be grouped with other books having the
same carrier route and zip code information, and hence this book
cannot be mailed at postal rate C (for second class) or at the CAR
RT rate (for third class mail). Instead this book must be shipped
at postal level B, if second class or at the 5-DIGIT rate, if third
class.
If the 5-digit zip codes of the defective and most recent books are
not the same, a block 94 compares the first three digits of the zip
codes of these books to determine whether the books should be
grouped in the 3-digit category. If these first three digits are
identical, a block 98 causing version X to be reordered immediately
preceding a change in the first three digits of the current zip
code.
Following the block 98, control passes to a block 130, FIG. 5,
which generates the indication of postage increase, if any, for
this book. This is necessary since this book now qualifies for the
highest postal rate whereas it previously may have qualified for a
lesser rate.
If it is determined that the first three digits of the zip code are
not the same, then a block 100 determines the sectional center
facility, or SCF, of the defective book and the most recent book.
This is accomplished by utilizing the zip code information for each
book to access a lookup table containing SCF identifications. A
block 102 then compares the SCF designations for the defective book
and most recent book. If the SCF designations are identical, a
block 104 causes version X to be reordered immediately preceding a
change in the SCF from that associated with the books currently
being produced.
If it is found that the designations are not identical, a block 106
compares the state information of the defective book with that of
the most recent book. If the books are to be mailed to the same
state, a block 108 causes version X to be reordered immediately
preceding a change in such state.
If the block 106 determines that the books are not to be mailed to
the same state, then the book is to be grouped with books from
other states, and hence version X is reordered at a later point in
the sequence such as at the end of the production run.
Control from each of the blocks 104,108,110 passes to the block
130, FIG. 5, previously mentioned.
It should be noted that a change in 5-digit zip code, 3-digit zip
code, SCF or state may be indicated by flags contained within the
mailing information stored on the magnetic tape and placed in the
RAM 62 or may be accomplished by other means, as desired.
The net result of the program shown in FIGS. 3A and 3B is to cause
the original collating sequence to be changed to a revised sequence
due to the reordering of defective books. Control then passes to
the postage revision program shown in FIGS. 4 and 5.
It should be noted that the point at which the defective book is
reordered may be determined in accordance with a comparison of the
postal information of the defective book with another book on the
conveyor not the most recent book. For example, assume that there
are 23 signature feeders positioned adjacent the conveyor at
positions 1-11 and 13-24 such that position 1 is occupied by the
box currently feeding to the most recent book and, position 24 is
occupied by the last box to feed signatures to the conveyor
stations. Also assume that an ink jet printer occupies position 12
and that a series of customized books are to be produced wherein
the customization is due solely to the message printed by the ink
jet printer (i.e. all books have the same signature makeup). If a
detector downstream of the jet ink printer determines that no
signature was fed by one or more of the boxes at positions 13-24
where a signature should have been fed, then the postal information
of the defective book is compared against that of the book adjacent
the box at position 11. If the zip code and carrier route
designations of these two books match, then the message for the
defective book is applied on the book currently adjacent position
11 so that the defective book is reordered. This is possible since
each book will eventually have the same signatures contained
therein. The customized messages for the remaining books in the
production sequence are applied on later books after the message
for the defective book has been printed.
On the other hand, if the carrier route and zip code designations
for the defective book and the book adjacent position 11 are not
both the same, the postal information of the defective book might
be compared against that of all or only some of the books adjacent
positions 1-10 to determine the optimal reorder time.
Referring now to FIG. 4, following the block 92 of FIG. 3A, the
block 120 determines whether the defective book was originally
classified in lowest postal level C or CAR RT. In other words, the
block 120 determines whether the defective book which was
originally classified with either more than six (if second class)
or ten (if third class) other books having the same carrier route
and zip code designations. If this is not the case, then the book
was originally classified in the intermediate postal level B or the
5-DIGIT classification and hence no adjustment to postage need be
made. Accordingly, control passes through a block 121 to a block
122 if the run is not yet complete where control pauses until the
next defective book interrupt is received.
If it is determined that the defective book was originally
classified in postal level C or in the CAR RT classification, then
a block 124 checks to determine whether the defective book was
previously reordered and classified in either postal level B or the
5-DIGIT classification. This is accomplished by checking a flag in
the RAM 62, as noted more specifically below. If this is the case,
then the defective book was originally classified in the lowest
postal rate classification, and subsequently was reordered in the
intermediate postal rate classification and the indication of
postage increase already generated. Accordingly, no further postage
revision is required and hence control passes to the block 121.
If the block 124 determines the defective book has not been
previously reordered and that it has been reclassified in the
intermediate postal level, then a postal change counter designated
"C-to-B" for version X is incremented, such counter being contained
within the RAM 62 shown in FIG. 1. There is a different "C-to-B"
counter for each version to be produced in the run.
Following the block 126, a block 128 sets a flag in the RAM 62
indicating that the defective book has been reordered. This
information is important since it may occur that the reordered book
itself may later be found to be defective, in which case block 124
is again encountered to check the status of this flag.
Referring now to FIGS. 5A and 5B, immediately following the blocks
98,104,108,110 in FIG. 3, the block 130 checks to determine whether
the defective book was originally classified in the lowest postal
rate level. If this is the case, then a block 132 checks to
determine whether the defective book was previously reordered and
classified in postal level B or in the 5-DIGIT classification. This
is accomplished, similar to the block 124 described in FIG. 4 by
checking the reorder flag for the defective book in the RAM 62. If
this is not the case, then a postal change counter designated
"C-to-A" in the RAM 62 is incremented since the defective book
originally qualified for the lowest postal rates, but could not be
ordered in time to quality for either the lowest or intermediate
rates.
Following the block 134, control passes to a block 136, FIG. 5B,
which sets the reorder flag for the defective book. A block 138
then checks to determine whether the entire production run has been
completed, and if this is not the case then control pauses at a
block 140 until the next defective book interrupt is received.
On the other hand, if the block 138 determines that the run has
been completed, a block 142 prints a postage report, to be
described in greater detail in later portions of the
specification.
If the block 132, FIG. 5A, determines that the defective book had
previously been reordered at the intermediate postal rate level,
then a block 144 checks to determine whether the defective book and
the reordered book are both classified in the highest postal rate
classification. In other words, this block checks to determine
whether the book is being reordered at the highest postal rate,
when it was previously reordered also at the highest postal rate.
If this is the case, then no adjustment to postage need be made and
control passes directly to the block 136 previously described.
On the other hand, if the block 144 determines that the defective
book was classified in the intermediate postal rate level and is
now being reordered in the highest postal rate level, then a block
146 decrements the "C-to-B" postal change counter for version X and
a block 148 increments the "C-to-A" postal change counter for
version X. This is necessary since the book has been twice
reordered, each time at a higher rate, i.e. the book originally
qualified for the lowest postal rates, then was reordered at the
intermediate postal rate and finally was reordered at the highest
postal rate. Accordingly, the bookkeeping is kept accurate by
simply noting that the book is subject to an incremental increase
in postage from the lowest to the highest rates and by deleting the
incremental increase from the lowest to the intermediate rates.
Following the block 148, control passes to the block 136 previously
described.
Referring again to FIG. 5A, if the block 130 determines that the
defective book originally did not qualify for the lowest postal
rate, then a block 150 checks to determine whether the defective
book was previously reordered at the intermediate postal rate
level. If this is not the case, then no adjustment to postage need
be made since the defective book originally was classified in the
highest postal rate level and is reordered at the same level.
On the other hand, if the block 150 determines that the book had
been previously reordered at the intermediate postal rate level,
then a block 152 checks to determine whether the defective book had
been previously reordered and classified in the highest postal rate
level. If this is the case, then again no adjustment to postage
indication need be made since the book had previously been
calculated in the highest postal rate level and will again be
ordered at this level.
On the other hand, if the block 152 determines that the book had
not been previously reordered and classified in the highest postal
rate level, then a block 154 increments a "B-to-A" postal change
counter in the RAM 62 for version X since the defective book
orginally qualified for the intermediate postal rates while the
reorder book cannot so qualify.
Control from the block 154 then passes to the block 136 previously
described.
Referring now to FIG. 6, there is illustrated a flow diagram of
steps for calculating an indication of the increase in postage due
to the reordering of defective books. The flow diagram of FIG. 6 is
described under the assumption that the steps are, in the preferred
embodiment, implemented in the computer 25, it being understood
that such steps may be performed manually, if desired.
A block 160 loads a table of postage rates into memory locations in
the RAM 62. Generally, the table is segregated according to version
and according to the incremental postage rate for each change
between postage rate levels. For example, for version X, three
figures are stored representing the dollar increase for a change in
classification for a book between the lowest and intermediate
postage levels, the lowest and highest postage levels and the
intermediate and highest postage levels. These rates are, of
course, determined by the U.S. Postal Service.
Following the block 160, the blocks 80-152, shown in FIGS. 3-5,
reorder the defective book and generate an indication of the
increase in postage for the reordered book. A block 162 then
performs a lookup procedure in the table of postage rates and the
version X postal change counters and multiplies the contents of
each version X counter by the appropriate increase in postage
stored in the table. The block 162 then generates three postal
adjustments which are added to the previously calculated postal
bill for version X by a block 164.
A block 166 then causes the printer 68, FIG. 1, to print out the
adjusted postal level for version X. A block 168 then repeats the
steps of blocks 162-166 for the remaining versions of the
production run.
The programming in the computer can be modified to calculate the
extra postage required when a defective book causes an entire group
of books to change postal rate level. In such a case, it is
necessary to provide on the magnetic tape not only a precalculated
indication of the total postage required, but also the number of
pieces of each version to be mailed according to postal rate level
classification. At the end of the production run, the information
stored in the postal change counters can be combined with this
additional information to derive an indication of total
postage.
Moreover, the programming can be modified to eliminate the need for
a precalculated indication of postage. In such a case, the final
indication of postage would be generated after the production run,
based upon the sequence in which the nondefective books were
produced.
* * * * *