Control system for pre-setting and operation of a printing press and collator

Abstract

Process and apparatus for manufacturing multi-part forms uses web presses having printing stations and processing stations at which operations are performed on webs in registry with a series of printed images, and uses a collator to assemble related webs from said presses, and to perform additional operations on assembled webs in registry with images thereon. A digital job description of a form is created, including location of printed images on several parts of the form and location of process items, e.g. perforations, holes, or cuts on parts of the form. This job description is stored in the memory of a computer [PR-2] with a job identifying code. Also, a digital description is created of images to be printed on the form, and stored in memory with the job identifying number. The image descriptions are recalled from memory and used to create printing plates for the presses and to pre-set printing and processing sections of a press for each part of the form. The parts of the form are then produced on the presses and supplied to the collator. The job description is recalled from memory and used to pre-set stations of the collator to assemble and complete processing of the multi-part forms. The computer also gathers and stores management data as the presses and collator operate, keeps a record of supplies/tools needed for each job and makes this information available to operators through terminals, and maintains records of jobs entered, work in process, and jobs shipped.

Claims

What is claimed is:

1. A process for manufacturing multi-part forms using at least one web press having one or more printing stations and one or more processing stations at which operations are performed on webs in registry with a series of printed images produced at a printing station,;

the steps comprising

(a) creating a digital job description of a form including the location and content of printed images on the several parts of the form and/or the location of process items such as perforations, holes, cuts or other markings on one or more parts of the form,

(b) storing said job description in a digital memory with a job identifying number,

(c) using the job number from the memory to pre-set the printing sections and processing sections of a press for each part of the form,

(d) producing the several parts of the form on the press or presses, and

(e) assembling and completing the processing of the several parts into a quantity of multi-part forms sufficient to complete the job.

2. A process for manufacturing multi-part forms using at least one web press having one or more printing stations and one or more processing stations at which operations are performed on webs in registry with a series of printed images produced at a printing station, and also using a collator having a collating station at which job related webs from said press or presses are assembled in registry and having one or more processing stations at which additional operations are performed on the assembled webs in registry with a series of printed images thereon;

the steps comprising

(a) creating a digital job description of a form including the location and content of printed images on the several parts of the form and/or the location of process items such as perforations, holes, cuts or other markings on one or more parts of the form,

(b) storing said job description in a digital memory with a job identifying number,

(c) creating a digital description of the images to be printed on the parts of the form,

(d) storing said image descriptions in the memory associated with the job identifying number,

(e) using the digital job description from the memory to pre-set the printing sections and processing sections of a press for each part of the form,

(f) producing the several parts of the form on the press or presses and supplying the parts to the collator,

(g) using the digital job description to pre-set the processing stations of the collator, and

(h) assembling and completing the processing of the several parts on the collator into a quantity of multi-part forms sufficient to complete the job.

3. A process as defined in claims 1 or 2, including the further step of

using the digital descriptions from the memory to make printing plates for use in the printing stations of a press.

4. A process as defined in claim 3, including the further step of

gathering production data during the steps of creating the job description, making the printing plates, pre-setting the press and producing the form parts, or pre-setting the collator and completing processing of the forms, and

storing the gathered production data in a digital memory.

5. In a forms plant including

a first terminal for generating data describing the composition and arrangement of a business form,

a computer receiving data from said first terminal and having at least one data output line,

said computer functioning to prepare job instructions from the data,

a data processor communicating with one of said data output lines and functioning to store makeready data, and

a microprocessor controller receiving the makeready data from said data processor and transmitting the makeready data to a plurality of power operated adjustors on a web processing machine upon command of the operator.

6. A forms plants as defined in claim 5, also including

means including a photocomposing device receiving data from said computer and functioning to produce one or more printing plates to provide a press with print information to complete part of a job.

7. A printing system comprised of:

at least one machine having a plurality of stations along a path through which web material is transported, said stations including apparatus for operating on said material to produce printed matter and related physical changes on the web material, adjustment means at certain of said stations for changing the lateral or circumferential position of the apparatus relative to the path of movement of said materials;

computer means including a memory,

input means including at least one terminal and a display for inputting information including the identification of certain job parameters concerning operations to be performed on the web material and for storing the parameters in said memory;

means for storing a job number in said memory in association with the job parameters;

adjustment control means coupled to said adjustment means for controlling the position of said adjustment means in response to control signals derived from information stored in said memory; and

machine control means coupled to said computer means and said adjustment control means for associating a machine with a job number and for applying the control signals to said adjustment control means for presetting the adjustment means at the machine in accordance with the job parameters in memory associated with the job number.

8. A printing system as defined in claim 7 further comprising:

production control means interfaced with said computer means for monitoring the production of printed material produced by said machine, including

(a) means for receiving information concerning production runs of said machine and for determining a production run has been completed by a machine, and

(b) means for supplying production run information to said computer means for storage in said memory in association with a job number.

9. A printing system as defined in claims 7 or 8 further including:

input means for supplying storeroom information, machine tooling information, material information and print color information to said computer means for storage of such information in memory in association with the job number; and

output means coupled to said computer means for providing a visual display of such information for the machine crew along with the associated job number prior to application of the control signals to said adjustment control means.

10. A printing system as defined in claims 7 or 8 wherein said machine is a web press, and further including:

a collator having a plurality of stations through which a plurality of webs are adapted to be transported including a first station at which the webs are collated and subsequent stations including apparatus for operating simultaneously on said webs to produce physical changes therein;

said apparatus including collator adjustment means at certain of said stations for changing the lateral or circumferential position of the apparatus relative to the path of movement of the webs;

collator adjustment control means coupled to said collator adjustment means for controlling the position of the adjustment means and responsive to control signals derived from information stored in said memory;

means for supplying information concerning the operation of said collator for storage in said memory in association with a job number; and

said machine control means being coupled to said collator adjustment control means for associating the collator with the job number and for applying control signals for presetting the collator adjustment means in accordance with job parameters in said memory associated with said job number.

11. A printing system as defined in claim 10 including:

means for supplying information concerning collator tooling to said computer means for storage in said memory means in association with said job number, and

output means coupled to said computer means for providing visual display of such information along with the associated job number prior to the application of control signals to said collator adjustment control means.

12. A forms production system comprising:

data input means for determining in digital form certain parameters of the layout of a form to be produced including a computer, and a memory for storing information pertaining to the parameters concerning the content of a form and for supplying information to produce the form;

means for supplying a job number to said computer for storage in said memory in association with form content parameters stored in said memory,

a machine for receiving at least one portion of said information for producing the form, including a plurality of stations arranged along a path and having apparatus for operating on web form material to be moved through the machine along such path;

said stations including adjustment means for positioning parts of the apparatus laterally or circumferentially relative to the path the material travels through the machine;

control means responsive to makeready position signals for controlling the settings of said adjustment means, and

means for generating makeready position signals from said stored information and supplying such signals to said control means to preset said adjustment means in accordance with the parameters of the form to be produced.

13. A forms production system as defined in claims 12 also including:

production monitoring means for monitoring the production of printed material produced by said machine including means for receiving information concerning production runs and for terminating the production runs when they have been achieved; and

means for supplying production run information to said computer for storage in said memory in association with the job number.

14. A forms production system as defined in claim 12, including

production monitoring means for gathering data from said data input means and from said machine during setting of said adjustment devices, and for supplying the data to said memory in association with the job number.

15. A forms production system as defined in claim 12 including:

means for supplying storeroom information, press tooling information, material information and print color information to said computer for storage of such information in memory in association with said job number, and

output means coupled to said computer for providing a visual display of information concerning press tooling, material and color, and storage information concerning supplies and/or material needed for the job along with the associated job number prior to the application of the makeready position signals to said control means.

16. Apparatus for producing forms comprising:

a machine for producing forms including means for transporting material along a given path and a plurality of stations along the path for consecutively performing repetitive operations on the material, said stations including means for operating repetitively on the material as a step in the production of a form and said stations including adjustment means for laterally and/or circumferentially adjusting the operation of the mechanisms relative to the path of travel of the material;

forms composing means for identifying certain parameters of a form to be produced relative to said adjustment means and the path of travel of the material and a memory receiving and storing such parameters from said forms composing means;

said forms composing means including a digital processor communicating with said memory,

means for supplying a job number to said processor for storage in said memory in association with the parameters stored in said memory,

control means for positioning the adjustment means; and

computer means, responsive to a command signal, for generating position signals from the parameters stored in said memory and applying the position signals to said control means for automatically positioning the adjustment means in accordance with the specified form to be produced.

17. Apparatus for producing forms as set forth in claim 16 including:

production control means associated with said computer for monitoring and controlling the production of printed material produced by said machine including means for receiving information concerning production runs of said machine in association with a job number.

18. Apparatus for producing forms as set forth in claim 17 wherein said machine is a forms printing press and includes;

means for supplying storeroom information, press tooling information, material information and print color information to said computer for storing such information in memory in association with said job number, and

output terminal means coupled to said computer for providing a visual display of information concerning press tooling, material and color, along with the associated job number prior to the application of the control signals to said adjustment control means.

19. Apparatus for producing forms as set forth in claim 16 wherein said machine is a collator in which a plurality of printed webs are to be collated;

means for supplying information concerning printed material on the webs and collator tooling information to said computer for storage in said memory in association with a job number, and

output terminal means coupled to said computer for providing visual display of information concerning collator tooling and printed material to be collated along with an associated job number prior to the application of position signals to said adjustment control means.

20. Apparatus for producing forms as set forth in claim 16 including:

production control means associated with said computer for monitoring and controlling the production of printed material produced by said machine including means for receiving information concerning the operation of said forms composing means, and means for storing such information in said memory.

21. A printing system comprising:

a plurality of printing presses, each having a plurality of stations along a predetermined path through which web material is transported, each of said stations including mechanism for operating repetitively on the material to produce printed matter or related physical changes on the material, certain of said stations including adjustment means for locating the lateral or circumferential position of the mechanism relative to the predetermined path of movement of said material;

a plurality of adjustment control means, a separate one of each of said adjustment means, each of said adjustment control means being responsive to control signals for controlling the position of its connected adjustment means;

a plurality of processors, a separate one for each of said printing presses, coupled to each of the adjustment control means on its respective press for providing control signals thereto to position the associated adjustment means;

editing means having a visual display for designing the layout of information to be printed and including means for identification of certain parameters for use in presetting said press adjustment means according to a desired layout, which parameters along with the information to be printed and an associated job identification number are adapted to be stored;

circuit means coupled to said editing means for supplying said print information in digital form for use in plate making;

a central computer including a memory, coupled to said editing means for receiving and storing the parameters in the memory with the associated job number;

terminal means coupled to said central computer for supplying information concerning production, supply and tooling for storage in said central computer memory in association with the corresponding job number; and

circuit means coupling said central computer to each of said plurality of press processors for supplying the parameters from memory to a selected press and to enable said press processor to automatically preset said adjustment means in accordance with said parameters.

22. A printing system as defined in claim 22 including:

production control means for each of said presses connected to monitor the production of printed material produced by said presses, including means for receiving information concerning production runs for said presses and for terminating a production run which has been achieved by a press; and

means for supplying production run information to said central computer means for storage in the memory of a press computer in association with a job number.

23. A printing system as defined in claim 23 including:

wherein said production control means at said press includes means subject to command for determining the status of the press including madeready, stop, maintenance and time to complete production run and providing information concerning the press status to said central computer, and

wherein said central computer analyzes the press status information in selecting the press for a job.

24. In a machine for performing processing operations on a web of material, said machine comprising

a plurality of stations arranged to define a path along which the web is transported,

rotary mechanisms at said stations functioning to perform repetitive operations on the passing web,

a drive for operating said rotary mechanisms in synchronism, including means defining a rotary zero position of the drive,

means for connecting said rotary mechanism to said drive and providing for limited rotary displacement of selected ones of said rotary mechansims relative to the rotary zero position,

means for establishing a lateral zero position relative to said web path,

adjustable mounting means for supporting at least some of said rotary mechanisms for lateral displacement relative to said lateral zero position;

the improvement comprising

first power operated adjustment means incorporated in said means for connecting,

second power operated adjustment means incorporated in said adjustable mounting means,

control means for receiving makeready adjustment information and connected to both said adjustment means to cause predetermined displacements of the rotary mechanisms relative to the rotary and lateral zero positions;

a layout device coordinated to said adjustment means and including means for locating the layout of a form or forms to the available operating area of the rotary mechanisms,

means in said layout device operable to generate parameters of a form layout as digital displacment instruction signals compatible to said control means, and

means for transmitting such instruction signals to said control means during makeready operation of said machine.

25. A machine as defined in claim 24, including

digital indicator means driven from said adjustment means and operable to display a numerical indication of lateral and rotary displacement of said adjustment means.

26. In a forms plant including departments for production supervision, sales/estimating, composition, accounting, a manufacturing department having at least one forms press and one collator, a supply department tor storing ink, paper, and other supplies and including a receiving area, and a shipping department; the improvement comprising

a computer including a CPU, a memory providing means for storing an integrated data base for jobs, and a plurality of terminals for use by the departments to enter order and design information, job instructions, and the like under a job identification code;

an interactive control for the press and the collator including an operator console, a mcroprocessor controller, power operated adjustors on the press and the collator and drivable by said controller, and means on the press and the collator providing feedback data to said controller; and

means providing data communication between said computer and said controller, whereby a unique data base may be created in said memory for each form manufacturing job and may be utilized and/or added to by each department as the job progresses through the plant.

Description

BACKGROUND OF THE INVENTION

This invention pertains to web processing machines in general and more particularly to making ready printing presses and collators. Depending upon the type of press and the type of printed matter produced, makeready time (i.e. press set up time) becomes an important overall cost factor. There is a segment of the printing industry that is devoted primarily to the design, manufacturing and sale of business forms, and there are corresponding types of equipment which are unique to the business forms industry. The problems associated with making ready a business forms press are significantly amplified over those associated with other types of presses, primarily because of additional operations performed by such business forms presses. Since the makeready functions associated with the business forms press are the most complex, the invention will be described in the context of a makeready press, but will also have application to other type of presses. Many of these makeready functions are also present in preparation of a collator, which assembles the webs printed on these presses, and often performs mechanical operations alternately with the press. In the United States, there is an association devoted to this business known as the National Business Forms Association, located in Alexandria, Virginia, which has published a handbook known as The Business Forms Handbook (2nd Ed., copyright 1979), which is devoted to various aspects of the business forms industry.

In general, a form is designed to facilitate the handling and recording of various business transactions, internal or external to a company, with a view to prompt the user to accumulate and record whatever information is necessary for the transaction involved, and, if necessary, to duplicate this information on a number of copies for routing or record keeping purposes. The design of forms is covered in detail in the aforementioned handbook, and as is commonly known in the industry, there are also certain standard forms which have been developed and are used by many manufacturers and suppliers in this industry for particular job applications.

Business forms typically are categorized into two general types, unit sets and continuous forms. Unit sets are individual form sets with parts held together by a detachable glued stub or edge which is designed for easy separation. Styles of unit sets are divided into stock forms, custom printed forms and tabulating card sets. At this time, the most common are the custom manufactured unit sets. These forms have the advantages of saving handling, and reducing non-productive labor, they may be written either by hand or machine, or both, and they have many construction features which may be utilized, for example the forms of the set, or parts of them, may be sectioned, parts may be removable as single parts or portions thereof, etc. Unit sets are convenient and clean to handle, since if interleaved carbon paper is used the forms can be snapped apart without touching the carbon. Of course, if no-carbon paper is used this is not a problem. Unit sets are useful both for intermittent and regular work, and they have the advantage of not needing any special feeding attachments for typewriters, printers or other machinery used in entering on the forms. Also, a special part can be included in the sets, e.g. a duplicating master, safety paper, and transparent or translucent parts. The unit set form provides accurate registration within the set, it is easy to use, and thus training in its use is fast and simple.

Continuous forms are also sometimes known as "strip forms", and encompass continuous tabulating cards, fanfold forms and autographic register forms. The types of continuous forms are generally divided into stock forms, imprinted forms and custom design forms. They are traditionally designated by a measurement which states first the width and then the length, e.g., WxL. Continuous forms provide accurate part-to-part, line-to-line, and set-to-set registration. Controlling the handling of continuous forms with line holes, as is usually the custom, avoids the slipping out of registration of the various parts. Continuous forms are easy to use, can be written faster, particularly by continuous printers or the like, and consecutive numbering is preserved; sets can't be mixed accidentally. Also, continuous forms are capable of being manually or mechanically decollated and burst.

Thus, a typical forms manufacturing plant will have the capability to manufacture and merchandise both unit sets and continuous forms, with a predominance in one or the other type depending upon the types of business that the plant serves and the desires, to some extent of its customers.

The typical forms manufacturing plant involves functions not unlike a commercial printing plant. For example, the cycle may commence with a sales person contacting a customer and making an estimate to that customer. As part of the estimate, the nature and design of the form will be identified, and if the form is not a standard one, or a variation of a standard one, in most instances the estimate will include some example or layout. Following submission of the estimate there may be interaction between the sales person and the customer possibly including modification of the form design, or the quantity involved, but if all goes well the company will be given an order by the customer, at which time the job will be assigned a job number.

From the beginning of this process, there are certain types of information already available that will be pertinent to the job throughout the manufacturing and shipping portions of the job cycle. For example, the name and address of the customer, the shipping address if different, identification of the sales person and of the contact person at the customer, size and configuration of the form, color of parts, any special art work, etc. all are identified and can be recorded early in the process. This data can best be utilized if it is thereafter available quickly for checking, reuse, or addition to it, without repeated entry of the information.

Once an order is entered, the plant personnel must then schedule the job, make certain that the proper supplies are available, or order whatever additional supplies are needed, and prepare a schedule and routing of the job through the various departments (and their functions) within the plant.

This will usually involve the use of a form, and perhaps a folder or envelope, which moves through the departments as the job progresses. A typical job will require the preparation of one or more printing plates, and thus one of the first tasks to be performed will be typesetting and photocomposition, the product of which is then passed to the plate making department where the necessary printing plates are manufactured. Alternately the plates can be made directly through laser plate making apparatus.

The plates then are grouped with a job instruction sheet which identifies for the press operator the various measurements and settings that he needs to run the job. He will use these for setting up the press, but first it is necessary to assure that the proper type and supply of paper, ink, and related equipment such as perforating or slitting blades, numbering machines, possibly special punches and dies, are all available to the press operator. Then, with all of this information and material gathered, the press operator begins the job first by setting up the press, normally called makeready, following which he may run a small number of impressions, have them checked by his foreman for accuracy and compliance with the order requirements, after which the press will proceed in the running or productive mode until the required number of forms have been prepared. Because of a trend toward shorter run lengths, minimizing waste in this makeready procedure becomes more important. Depending upon the size or design of the form, the required number may either equal, or be a sub-multiple of the number of impressions performed by the press.

If the job requires a multi-part form, normally the product of the above described run will be rewound onto a roll, and the next part or parts of the form for the particular job will be printed, either subsequently on the same press, or perhaps on another press if it is available. There may be three or four different such rolls required, depending upon the number of parts of the form. In the case of a multi-part form, the finished rolls will then be transported to a collator where they will be assembled, perhaps further mechanical work may be done on the assembled forms such as cross-perforating or slitting, and the end product multi-part form will be folded in zig-zag fashion or batched, packaged, and delivered to the shipping department for addressing and shipment to the customer.

In the case of single part forms, the end product of the press, as mentioned above, may be folded, or divided into sheets, as it is delivered from the press, and then taken to the shipping department.

During all of this procedure, much of the job information will follow the order through the plant, will be recalled all or in part at various stages of the manufacturing procedure, even at the final shipping function where it will be necessary to prepare a shipping label, perhaps prepare an invoice, and instruct the shipper as to routing or delivery

As can be seen, the documentation included in progressing a job from beginning to end can be significant, and is subject to errors, resulting in possible waste or unnecessary time delay or missed delivery schedules, or cost overruns. A significant portion of job costs result from makeready time along with paper waste in setting the press or collator for final production. Further delays are possible in the event that materials or tools are not available or mislaid etc. when a job is scheduled for production, further costing undesirable down time. All of these factors impact the profitability of a printing press. Improved efficiency can be achieved if misinterpretation or errors in the job identification are minimized. The ability of a computer to store, recall, display on a terminal, to modify or expand upon the job data base is particularly useful in assuring smooth and properly scheduled handling of the entire sales, manufacturing, accounting, and shipping functions which all are necessary to the prompt and profitable completion of jobs in a business forms manufacturing establishment. Further efficiency can be achieved by automation in the press and collator to reduce labor cost, down time and errors. All of this can be combined with the other functions required of a printing operation to provide a smooth transition of jobs from beginning to end.

SUMMARY OF THE INVENTION

The present invention provides a process and apparatus for manufacturing multi-part forms using web presses having printing stations and processing stations at which operations are performed on webs in registry with a series of printed images, and using a collator to assemble related webs from said presses and to perform additional operations on assembled webs in registry with images thereon. A digital job description of a form is created, including location of printed images on several parts of the form and location of process items, e.g. perforations, holes, or cuts on parts of the form. This job description is stored in the memory of a computer with a job identifying code or number, and includes a digital description of images to be printed on the form, stored in memory with the job identifying number.

The image descriptions are recalled from memory and used in conjunction with an editing terminal and appropriate software to create printing plates for the presses and to pre-set printing and processing sections of a press for each part of the form. The parts of the form are then produced on the presses and supplied to the collator. The job description is recalled from memory and used to pre-set stations of the collator to assemble and complete processing of the multi-part forms. The computer also gathers and stores management data as the presses and collator operate, keeps a record of supplies/tools needed for each job and makes this information available to operators through terminals, and maintains records of job entered, work in process, and jobs shipped.

On each press, and on the collator, microprocessors are provided with communication links to the computer. The consoles of these machines include controls for receiving messages containing makeready information and other data in the job description. Thus the operators have available to them, in addition to plates and printouts of parts of the job descriptions, the content of the stored job description and the ability to pre-set their machine during makeready operations merely by calling up the job description message to the microprocessors and related equipment. The various elements of the press are pre-set automatically, although under operator supervision. However, the operators have the ability, through appropriate manual inputs, to modify the setting as necessary.

Digital displays are driven from the microprocessor controls, and are located adjacent the various machine stations as well as at the control console, to inform the operator as to the settings of adjustable elements of the machines with respect to predetermined circumferential and lateral reference (zero) positions.

In a more comprehensive aspect, the invention is directed to a forms printing plant incorporating computer control and management with an integrated data base and terminals located throughout the plant to bring information related to any job quickly to the attention of appropriate personnel. Typical locations of such terminals are in different areas devoted to management, sales and estimating, accounting, composition, manufacturing including plate making, printing and collating, and stores related to these for supplies and tooling, and in receiving and shipping. Personnel can call up the same description and related information pertaining to any job from the integrated data base. This minimizes chances for error in transcription and considerably smoothes the flow of work through the plant.

The primary object of the invention, therefore, is to provide a forms manufacturing process and apparatus as above set forth; to provide such a process and apparatus in a plant where job descriptions are created and stored in an integrated data base of a computer, and used to produce printing plates, makeready the machines, specify supplies and/or tooling required, monitor the progress of the job through the plant, produce management data (including scheduling) relating to the above, and in general unify the forms manufacturing operation, minimize waste of time and materials, thereby improving productivity of the plant.

Other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan layout of a business forms manufacturing plant;

FIG. 2 is a schematic diagram of the data processing and control system for the plant;

FIG. 3 is a drawing of a continuous three-part form, the quantity production of which is representative of a job to be performed in the plant;

FIG. 4 is a block diagram of the functions of a typical plant;

FIG. 5 is an amplified diagram showing data paths and material flow;

FIG. 6 is a block diagram of the data entry and handling system together with the forms composing apparatus;

FIGS. 7A and 7B show a typical forms on which press and collator makeready data is printed;

FIG. 8 and 9 are block diagrams showing greater detail of the parts of the system for control of a press, and a collator, respectively;

FIG. 10 is an overall view of a typical web press for printing business forms;

FIG. 11 is a diagrammatic view of one printing section with its circumferential and lateral adjustement devices;

FIG. 12 is a diagrammatic showing of parts of typical circumferential and lateral adjustment devices and encoders for a single element station;

FIG. 13 is a schematic view of adjustors and encoders in a dual element station such as the file punch in the processing section;

FIG. 14 is a schematic diagram of the circumferential adjustment controls and readouts for a press;

FIG. 15 is a timing diagram for some of the press controls;

FIG. 16 is a drawing of a press control panel, omitting the associated terminal;

FIG. 17 is a block diagram illustrating the interfacing of the microprocessor controller with two adjustment motors on a press or collator;

FIG. 18 is a program diagram for a typical controller;

FIG. 19 is a diagram of the program for the display controls;

FIG. 20 is a diagram of a typical circumferential measurement program;

FIG. 21 is a diagram of a typical lateral measurement program;

FIG. 22 is an overall side view of a typical collator for multi-part forms;

FIG. 23 is a detail view of a section of the collator;

FIG. 24 is a schematic diagram of the circumferential adjustment controls and readouts for a collator; and

FIG. 25 is a drawing of a collator control panel.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 is a floor plan of a typical single floor manufacturing plant devoted primarily to the production of business forms. The front of the building includes office space for management, accounting, a conference area for dealing with customers, a sales and estimating department, the office of the production manager and office space for supporting clerical staff, and office equipment, as well as the floor space for much of the data processing equipment which is part of the present invention. Immediately behind this frontal space the central area of the plant is divided into two relatively smaller rooms, one devoted to the composing staff and its equipment, the other devoted to the plate making staff and equipment, and the major part of the central area which houses the printing production department. In the typical arrangement shown, there are three forms presses arranged side by side designated Press I, II, and III, and one collator C arranged opposite the presses. The presses are shown in FIG. 2 and are provided with re-wind apparatus at their delivery, but can be fitted optionally with a zig-zag folder or a sheeter-delivery stacker. A typical such press is shown in U.S. Pat. No. 4,177,730. The collator is provided alternatively with a folder for producing zig-zag folded output of multi-part continuous forms, or a batch delivery apparatus which is used to deliver unit set forms from the collator. A typical folder is shown in U.S. Pat. No. 4,082,259 issued Apr. 4 1978 or 3,912,252 issued Oct. 14 1975, and a typical batch delivery apparatus is shown in U.S. Pat. No. 3,998,141 issued Dec. 21 1976, all of which are assigned to the assignee of this application.

The rear area of the plant is devoted to stores, e.g. supplies, tools, paper stock, ink, and all the other materials and consumable type items which are required in the forms manufacturing process. The rear area is also subdivided into a receiving area and a shipping area, for each of which there preferably is a loading dock as shown.

FIG. 2 is a schematic diagram of the overall arrangement of a data processing and control system for the plant, as provided by the present invention. At the upper corner of the diagram there are shown a number of video terminals with the general designation "CT", these terminals being connected to a first electronic processor PR-1, for example a microcomputer such as DEC PDP 11/23, provided with a printer P1 which can be used, among other things, for the production of hard copy job instructions which are also so designated on the diagram. Also inputting the microprocessor PR-1 is a digitizing apparatus DT1 which can function to reduce art work and the like into digital information for input to the composition processor PR-1. This information consists of a digital description of the form and makeready data necessary to preset the press and collator on which the form is to be manufactured. The processor PR-1 has two other outputs, the first of which transmits data to a photocomposing device PC1 which is used in the composition department to produce films (transparencies). These are utilized in the plate making department to manufacture printing plates, usually offset lithographic plates. The output of the photocomposing device is thus shown schematically as a plurality of films which are routed to a plate maker, so designated on the diagram, with the plates resulting from this operation being eventually installed in the lithographic printing units of one or more of the presses, as indicated by the flow lines on the diagram. Optionally, the films can be sent to an outside plate making operation. Also, the output of the photocomposing device can be used to drive a laser plate making apparatus (not shown) to expose the plates directly.

Another output of the processor PR-1 leads to a second larger processor PR-2, which is a multi-purpose electronic data processing device such as a DEC PDP 11/44, or a Harris Model 500. The capacity of this processor PR-2 will depend upon the number of operations that it must perform and attend. Although two computers are shown it should be understood that the operations of both can be accomplished by a single computer depending upon cost considerations and complexity of the system.

An optional unit for the production of press and collator makeready data is a device which functions to digitize the information from an existing form, either a standard form, artwork for a single copy of a job, or a copy of a job previously run. This includes a separate digitizer DT2 and terminal TDT, preferably located in the composition department, which utilizes a printer P2 for generating additional hard copy job instructions, and another output through which certain of the job instructions may be transmitted in digital form to central computer PR-2.

Referring back to FIG. 1, input terminals may be conveniently located, by way of example, in the sales and estimating department (one or more terminals), in the accounting department, in the office of the production manager, in the shipping area, and perhaps in the receiving area (these might share one terminal). The digitizer DT2, the photocomposing apparatus PC1, its digitizer DT1, additional terminals CT and an editing terminal CT-E will be located in the composition department, and of course the plate making apparatus will be physically located in the plate making department.

Additional terminals T-1, T-2 . . . T-N may be located at a convenient point within the manufacturing department, for example somewhere on the press floor where it can be accessed by the press room foreman.

Outputs from the main processor PR-2 are directed via operator consoles to microprocessor controllers at each of the presses and at the collator. The general arrangement is shown in FIGS. 1, 2 and 6, with the consoles designated PMST-I . . . PMST-IV each located at a corresponding piece of apparatus, with associated terminals of the group T-1, T-2, etc. FIGS. 16 and 25 show in greater detail the consoles at one of the presses and at the collator, omitting the associated terminal. With this console the operator is provided controls which permit him to start and stop the press, indicate the beginning of a job, beginning of makeready, the beginning of useful production at the end of makeready, and to enter various code designations which identify reasons for delay, etc. in the operation of a job. The operator console includes an alpha/numeric display device which provides a means for communicating to the operator prompts for his entering of information, and various other messages, as well as a verification display of information which he has entered through the console keyboard. This console is duplicated at each of the presses, and a similar console is provided at the collator, these being part of the microprocessor controller which is connected via a two way data line with the central computer PR-2.

FIG. 4 is a block diagram which shows the relation of the functions of a typical plant, showing the progress of a job from the order entry stage through shipment to the customer. FIG. 5 is a substantially amplified block diagram in which the major systems of (1) estimating and quoting, (2) inventory control, (3) shop loading, (4) job cost or control, (5) finished goods inventory and shipping, and (6) inventory, are listed along with major data paths. Many minor systems are omitted or not shown in detail, including most accounting systems supporting the general ledger, payroll, sales and market analysis, and financial analysis. However, FIG. 5 provides an overview in one sheet of the typical information or data that is processed in a plant of this type. Data is preferably stored in an integrated data base which is accessed by the various programs through a data base management system.

It should be understood that computer based systems for the handling of management data, including some visual assistance in the area of press makeready are per se known. Harris Corporation, Business Forms System Division, Dayton, Ohio offers a Production Monitor System (PMS) for automatic data gathering and production/time/material reporting, intended specifically for forms presses and collators. Also the Web Press Division of Harris Corporation, Westerly, Rhode Island, offers a more sophisticated such system for large multi-color web presses. This system is disclosed in U.S. Pat. application Ser. No. 133,770 filed Mar. 25, 1980, entitled Management Analysis System for Web Machines and the Like, now U.S. Pat. No. 4,346,446, issued Aug. 24, 1982.

TYPICAL MULTIPART FORM

FIG. 3 shows a typical multipart business form which is the product of such a plant. The material used may be different colors or paper stock, and may be either of the "no carbon" type, or the form parts may have sheets of disposable carbon paper (not shown) interleaved between them. The assembly of the separate parts of the form and the carbon paper (if used) is accomplished on a typical collating machine such as shown in U.S. Pat. No. 3,303,083, and as later described herein.

The typical form comprises three parts, the top or original F1, which may be printed for example on white paper; the first copy F2, which might be printed on a web of colored paper, and might be an instruction copy for a shipping department; and F3, the third part, which may be printed on yet a different color of paper, and may typically be a packing slip. In the form shown, the identification of the addressee on form F3 may be a removable ticket F3a which can be used for a shipping label, being separated from the packing slip F3 when the package to which the form pertains is shipped to a customer.

The continuous forms are separated from each other by cross perforation lines CP, the forms are provided with file holes FH for convenience in filing some or all of the parts of the form according to the preference of the user, and the marginal portions have line holes LH, which may be used to feed and register separate parts of the form through the collating apparatus which assembles them, and also may be used to feed the assembled multipart form through various devices such as computer printers, autographic registers, etc.

The marginal parts of the forms are separated from the body of the form by vertical perforations VP, such that these marginal parts may be removed from the form in its final use. The shipping ticket F3a is outlined on form F3 by partial perforation lines SP and PP, which intersect the cross perforation line CP, and the vertical separation line VP, to define the ticket which may be removed from the form F3. Each form is provided with a unique order number, corresponding on all three parts of the form, and one copy of the form, for example part F3, may be imprinted or overprinted to obliterate information which appears on the other parts, but is unimportant or undesired on one of the form copies. Such imprinting is indicated on form F3 by the darkened mottled area. On any of the parts of the form, areas such as particular columns, particular lettering or designs, etc., may be printed in different colors, either for the purpose of design/appearance, or in order to set out some particular column of information by reason of its importance on the final form.

In a typical forms press 8.5 in..times.11 in. (U.S. correspondence size) forms would be printed two across and two around, e.g. four forms to a single image in the print stations.

FORMS COMPOSING SYSTEM

With reference to FIG. 1, the composition room includes terminals which allow for the entry and checking of information which is processed to prepare the necessary instructions and film transparencies for the manufacture of one or more printing plates used to produce the required form or form set. The computerized forms setting system is per se known, being commercially available from Harris Corporation, assignee of this application, under the name "Digiform Composition System" and trademark Formsetter. An earlier version of the system is disclosed in The Seybold Report, Vol. 8, No. 10, pages 5-11, a publication of SEYBOLD PUBLICATIONS, INC., Media, PA 19063. The entry devices include terminal CT of which there may be more than one, utilized to enter a complete description of the desired form. In addition, a digitizer DT-1 is also available for the purpose of entering form coordinates into the instructions for manufacturing the form. In addition, there is a graphic display terminal CT-E which provides on its display screen a visual representation of the form.

Details such as rule weights, density of screens, type styles and sizes, are provided to the terminal operators who use this information to describe the form to the system. It is possible to utilize more than one input terminal simultaneously, with each terminal operator entering complete form data including all parts, screens, color and typography. The form can be viewed on the display terminal CT-E to verify accuracy and to note any changes which may be required. A hard copy printer P-1 is also available in this area, for the purpose of preparing the physical makeready information forms such as FIG. 7A. The films are produced by a special form of phototypesetting device, which is indicated at PC-1, and which is capable of producing on film the lines, rules, text and other printed matter, that make up the form. The product of the phototypesetter can be positive or negative film, or paper copy, as may be desired.

The principal encoding software program for this system is known as the Digiform program, and is available with the apparatus. It provides for encoding of lines, text characters, and screened areas used in the composition of business forms. It also contains ability to perform many step and repeat functions for increased efficiency, and commonly used techniques such as text justification, underlining, leadering, kerning, reverse leading, and color separation. The language also provides for processing of this encoded information into a machine readable format which can be executed on a specifically designed Formsetter.

Several support software programs are also commercially available. These are:

List Program, lists the entire file or selected portions, with the ability to separate text from command codes for proof reading;

Area Move Program, allows interaction with the graphic display terminal CT-E; selected portions of the form composition can be moved about or changed by cursor direction; Archival Program, provides for orderly storage of forms on magnetic discs or the like for future reference;

Optimization Program, organizes the input instructions into the most efficient commands for the form phototypesetter to compose the form using the least number of sets;

Data Transmission Program, is used with telephone data communications in the event that remote input terminals are to be used; and

Digiform Administration Program, provides operating statistics for the forms preparation department. Digiform Makeready Program, provides for entering press and collator makeready data during forms composition.

In a typical such machine it is possible to compose forms up to twenty inches by twenty inches, to provide "rules" in solid, broken, dotted, screened or double lines, and to have the capability to select up to eight text character discs of 448 characters each, available in sizes from 4 point to 32 point.

The films, together with appropriate instructions, are forwarded from the composition department to the plate making department, where the plate or plates necessary to print the visual information of the forms are prepared. It is possible, of course, to obtain the plates from an independent plate making service if the plant does not encompass the equipment and personnel for the plate making function. In any event, the necessary plates along with the job instructions from the printer constitute the physical material which is eventually routed to the production manager and by him to the press operators. The information for pre-registering the press or presses and the collator during makeready is all compiled and stored in memory under the associated job number, where the information is available as a message to the presses or collator.

The digitizer DT-2 may cooperate with the terminals T-DT as shown in FIG. 2, and this device is intended to be used with final art work or with a sample form, as in the case of a form to be duplicated, in order to scan over the art work or form laid out in a predetermined position on a table or the like. The movement of the scanning device and the location of its target causes the generation of digital information in x - y coordinate fashion, which identifies the location of various items on the form. Such a device is disclosed in U.S. Pat. No. 4,177,730 at FIG. 5. The output of the digitizer DT-2 is transmitted to the central computer PR-2, the messages containing this information being the same as the messages from the forms composer PC-1.

The message format contains two parts, a mode code and an optionally attached data string. A typical message will include first a synchronization message which assures that the next message will be accepted by the protocol handler at the receiver (e.g. computer PR-2), followed by makeready data messages for one or more presses and a collator, all related by a common job number. This number can be any appropriate alpha and/or numeric sequence used for job identification. Content of a typical press makeready and collator makeready message is as follows.

    ______________________________________
    Press Makeready Data Message
    ______________________________________
    Job Number (can be alpha/numeric)
    Part Number
    Material descript. (type, weight, no.)
    Infeed tension (control LH punch spacing)
    First offset               around
    Second offset              around
    Third offset (as needed)   around
    Imprint (first numbering)  around
    Second numbering           around
    File punch                 around
    Internal cross perf        around
    Web guide                  across
    Grippers stream 1          across
    Grippers stream 2          across
    Grippers stream 3          across
    Imprint stream 1           across
    Imprint stream 2           across
    Imprint stream 3           across
    Second numbering stream 1  across
    Second numbering stream 2  across
    Second numbering stream 3  across
    File punch stream 1        across
    File punch stream 2        across
    File punch stream 3        across
    Line hole punch stream 1   across
    Line hole punch stream 2   across
    Line hole punch stream 3   across
    Skip perf stream 1         across
    Skip perf stream 2         across
    Skip perf stream 3         across
    Vertical perf gear side stream 1
                               across
    Vertical perf gear side stream 2
                               across
    Vertical perf gear side stream 3
                               across
    Vertical perf op. side stream 1
                               across
    Vertical perf op. side stream 2
                               across
    Vertical perf op. side stream 3
                               across
    Vertical slitter (gear side)
                               across
    Vertical slitter internal #1
                               across
    Vertical slitter internal #2
                               across
    Vertical slitter (operator side)
                               across
    Fold length
    Fold width
    Fold phase
    ______________________________________


______________________________________
    Collator Makeready Data Message
    ______________________________________
    Glue Nozzle #1 (etc.)   on/parked
    Glue valve #1 (etc.)    on/off
    Crimp wheels            on/parked
    Crimp wheels            around
    Impact wheels           on/parked
    Impact wheels           around
    Crash numbering         around
    File punch              around
    Cross-perf/cut-off      around
    Roll #1                 across
    Roll #2                 across
    etc.
    Grippers                across
    Pin band                across
    Glue nozzle #1          across
    Glue nozzle #2          across
    etc.
    Crimp wheel gear side   across
    Crimp wheel op. side    across
    Impact wheels gear side across
    Impact wheels op. side  across
    Numbering               across
    File punch gear side    across
    File punch op. side     across
    Vertical perf gear side across
    Vertical perf op. side  across
    Slitter gear side       across
    Slitter op. side        across
    Folder chute phase
    Folder length
    Folder width
    ______________________________________

• Inventors
  Dessert, Robert A.; Gaspar, Richard A.; Laubach, Richard T.; Punater, Dinesh G.; Barrera, Ralph E.;
• Assignee
  Harris Graphics Corporation (Melbourne, FL)
• Published
  Jan-22-1985
• Current US Classes:
  101/248
  358/1.18
  700/124
  715/515
• Application #
  385181
• International Classes
  B65H 043/00; G06F 015/46
• Field of Search
  364/468 364/469 364/470 364/471 364/518 364/523 101/248
• Examiner
  Ruggiero; Joseph F.
• Agent
  Biebel, French & Nauman
• US Patent References:
  3938437
  3998141
  4082259
  4177730
  4346446
  4366542