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Description  |
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BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to the field of magazine printing systems,
and more particularly to an automated system for defining the presets for
the folder used, so that set-up and conversion of the folder from job to
job to accommodate differing signature sizes, paper sizes and page
make-ups can be facilitated.
II. Discussion of the Prior Art
In the printing industry, offset presses are used to print inked images
onto a web of paper moving through the press at high speeds. The web may
then be slit into plural ribbons and the ribbons are then routed through a
folder where the signatures are formed in an appropriate order so that
when cut and assembled on a bindery line, the pages of the magazine will
be in proper order. Typical of the type of equipment on which the present
invention finds use is the Harris Model M1000B which may incorporate a
double former folder and/or a combination folder. It should be understood,
however, that the present invention is not limited only to this particular
equipment, but may find application on any web press incorporating turn
bars and compensation rollers in its folder station.
Typical folders may have a plurality of levels where each level is equipped
with a turn bar and an associated compensation roller. The turn bars and
compensation rollers are movable by servomotor driven lead screws. The
turn bars are moved to adjust the lateral positioning of the ribbons
passing there over while the compensation rollers are used to adjust the
advance or retard of the ribbons longitudinally, so that when passing
through a cutter, the cut will provide appropriate margins at the
beginning and end of each page and will not be cut in mid-page.
In the past, in setting up a job, the press operator would first determine
for each folder level which holes the turn bars on that level should be
inserted into. If the particular job had been run before, the operator
would typically have recorded the hole positions and the paper path route
in a notebook or the like for future reference. Once the turn bars are
properly assembled into the appropriate positioning holes, it is still
necessary for the operator to "fine tune" the positions of those turn bars
as well as those of the compensation rollers. This is done by jogging
manual push-buttons to apply current to the lead screw drive motors to
drive the screws in the forward or reverse direction, while noting the way
in which the signatures are folded and cut. When folding and cutting is as
desired, normal operation can resume. Since this must be done for each of
the plural folder levels in use at the time, the setup operation can be
relatively time consuming, even for an experienced operator. For a novice
operator, the task tends to be quite formidable. If the setup takes a
relatively long time to accomplish, there is an attendant waste of paper
taking place until the proper positioning of the turn bars and
compensating rollers has been attained.
As an example, it has been found that for successive different runs, a
trained operator may take typically 15-20 minutes in reconfiguring the
folder between successive job changes. Considering that the rate of paper
flow through the press is approximately 700 feet per minute, 14,000 feet
of paper may typically flow through the system before the folder is
properly adjusted to produce usable copy.
In that a printing company commonly prints a variety of publications in
accordance with a predetermined time schedule, there is real value in
being able to preset the folder section of the press to a specific
configuration associated with a previously run job after it has been
operated for other publications so that valuable time and materials will
be saved.
The preset system of the present invention is universally modifiable to any
two nose double former folder and any ribbon decks of four or six levels.
The configuration can be set in a password protected screen.
SUMMARY OF THE INVENTION
It is accordingly a principal object of the present invention to provide an
improved, automated system for facilitating the set-up of a folder section
of an offset printing press.
A more specific object is to provide a microprocessor based control system
which functions to return the folder's turn bars and compensation rollers
to pre-established positions earlier created at a time that a particular
setup was made for running a job whenever it is desired to rerun that job
or a job with the same page, width and page layout following the running
of a different job.
In accordance with the invention, the apparatus for facilitating the setup
of a folder section of a web printing press to carry out a particular
specified job where the folder is of the type having a plurality of
motor-driven turn bars for adjusting the lateral position of a print
ribbon flowing through the folder section and a plurality of motor-driven
compensation rollers for adjusting the advance and retard of the ribbons
relative to a page cutting device has a linear transducer associated with
each of the plurality of motor-driven turn bars and motor-driven
compensation rollers used in the multi-level folder. The linear transducer
produces an electrical current signal whose amplitude is proportional to
the displacement of the turn bars and compensation rollers from
predetermined reference locations. A microprocessor, including a memory
means, is included for storing data corresponding to a desired target
position for each of the plurality of turn bars and compensation rollers
for a plurality of job names. A programmable controller is coupled to
receive the electrical signals from the linear transducer, as well as the
data from the memory of the microprocessor. The programmable controller
operates to generate motor drive signals related to the extent of
displacement of each of the turn bars and compensation rollers from their
desired target positions associated with the specified job configuration.
The motor drive signals are then fed to the motor-driven turn bars and the
motor-driven compensation rollers to effect repositioning thereof to the
desired target position of each.
In order to obtain and store the desired target locations for the turn bars
and compensation rollers, means are provided for manually actuating the
motor-driven turn bars and motor-driven compensation rollers to reposition
same until the operator is satisfied that the margins on the printed page
are as they should be. The programmable controller includes a means for
receiving the electrical signals from the transducing means and producing
digital data words representative of these electrical signals when the
turn bars and compensation rollers are at their desired target position.
Once so formatted, the memory of the microprocessor can be used to store
the digital data words for subsequent readout whenever it is again desired
to run that particular job.
DESCRIPTION OF THE DRAWINGS
The foregoing features, objects and advantages of the invention can best be
understood from the following detailed description of a preferred
embodiment of the invention, especially when explained in conjunction with
the accompanying drawings in which:
FIG. 1 is a schematic diagram of an offset printing press and folder
assemblies used therewith;
FIG. 2 is a schematic diagram of the system of the present invention;
FIG. 3 illustrates the display screen layout;
FIG. 4 is a software flow diagram of the steps used in initially creating a
display screen used by the operator in creating the necessary data for
defining a particular job;
FIG. 5 is a software flow diagram useful in understanding the cursor
movements when the display screen is created:
FIG. 6 is a software flow diagram of the preset system control; and
FIG. 7 is a further software flow diagram of the programmable controller
operation for either a compensation roller or turn bar for a single level.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there is indicated generally by numeral 10 an offset
printing press and folder assemblies used therewith. Two paper webs, which
are superimposed, are identified by numeral 12 and they are arranged to
enter a four-level, double former folder station 14 which, in turn, feeds
into a combination folder 16. Either folder may be used depending upon the
size configuration and necessary page count of the product being produced.
The press as well as the double former folder and combination folder are
all standard apparatus, well known to those having ordinary skill in the
art. Using this setup, the operator has the option of creating a tabloid
fold, a combination quarter fold and a double former fold.
While not shown in FIG. 1, a slitter is generally provided for dividing the
webs 12 into at least two ribbons which are then routed over appropriate
turn bars and compensation rollers disposed at the different levels of the
folder assemblies so as they are brought together and folded, the
resulting signatures will be in a proper order to be assembled as
magazines when the signatures are processed in a bindery line (not shown).
Depending upon the type of fold desired, the page size and the flow path of
the ribbons, and further depending on whether the web is used standard or
reversed, different magazine runs vary from one to the other.
While not specifically illustrated in the plan view of FIG. 1, those
skilled in the art appreciate that the press and folder are comprised of a
plurality of levels (six or less) and associated with each level is a turn
bar and a compensation roller for controlling the movement of the ribbons
through the former and folder. The turn bars at each particular level are
adapted to span between two parallel, spaced-apart blocks having a
plurality of equally spaced holes extending along the length of the
blocks. The blocks are, in turn, coupled via a fine threaded lead screw,
to drive motors whereby the relative position of the two blocks and
therefore the position of the angled turn bar supported between them can
be adjusted. Movement of the turn bars results in a shift of the ribbon in
a direction transverse to the direction of flow of the paper thereover.
Likewise, motor-driven lead screws associated with the compensation
rollers can impart precise movement to those compensation rollers, whereby
the ribbon can be advanced or retarded in the longitudinal direction
allowing it to be cut midway between two successive pages on the ribbon
rather than through the middle of a page.
After being cut, the paper is delivered on conveyors 17 or 19 to a stacker
where the sections are assembled in a "brick" form to be pelletized,
either manually or by a robot.
Turning now to FIG. 2, there is shown a schematic electrical and mechanical
diagram of the apparatus employed in implementing the folder preset scheme
of the present invention. As is shown in this drawing, and as those
skilled in the art appreciate, the typical folder used with a web printing
press may include a plurality of levels and disposed at each level is a
ribbon turn bar as at 20 and 22 and a compensation roller as at 24 and 26.
In such typical prior art folder, the turn bars are supported at each end
in a slide block (not shown) slidably mounted to a frame member where each
of the slide blocks includes a plurality (typ. 8) holes which are
generally equally spaced along the longitudinal dimension of the slide
blocks. The shaft of the turn bar can be fitted into any one of the holes
on one slide block and into the corresponding hole on the corresponding
slide block. Thus, the position at which the angled turn bar is disposed
can be selected.
To provide a fine adjustment of the turn bar position, one of the two slide
blocks for the turn bar is coupled to the traveling nut of a lead screw as
at 28 and 30 in FIG. 2. The lead screw is, in turn, adapted to be driven
by a servo motor, such as motors 32 and 34, in FIG. 2. Depending upon the
direction of rotation of the motor, the turn bar associated with it can be
finely adjusted to cause the paper ribbon traversing it to be moved to the
right or left by jogging the normally open push-button switches 36, 38
associated with motor 32 and the similar switches 40 and 42 associated
with motor 34.
The compensation rollers 24 and 26 for levels 1 through 6, respectively,
are also arranged to be driven by a motor-driven lead screw. More
particularly, as shown in FIG. 2, compensation bar 24 is operatively
coupled to a lead screw arrangement 44 coupled to a servomotor 46 having
manual push button switches 48 and 50 interposed between a voltage supply
(not shown) and the associated motor. Depression of the push button switch
48 operates to advance the web while operation of the push button switch
50 serves to retard it. Those familiar with known prior art press folders
understand that the compensation bars are driven at each end thereof by a
single motor operating through an appropriate differential gear mechanism
to drive a pair of lead screws which, in turn, drive frame-mounted slide
blocks to which the opposed ends of the compensation rollers are
journaled.
The description of the preferred embodiment thus far presented concerns a
conventional commercially-available folder. In implementing the present
invention, there is further provided a programmable controller module 54
that is operatively coupled to the servomotors such as motors 32, 34, 46
and 52.
Furthermore, in accordance with this invention, associated with the lead
screw of each of the turn bars and compensation rollers on each level is a
linear transducer which is operative to output a voltage or current signal
(analog) proportional to the extent of displacement of a traveler element
relative to a predetermined reference point. In FIG. 2, the linear
transducer associated with turn bar 20 and its lead screw 28 is identified
by numeral 56 and its traveler is identified by numeral 58. As the lead
screw 28 is rotated by motor 32 to reposition the turn bar 20, the
traveler 58 moves along the transducer's shaft 60. A typical transducer
which may be employed is that produced by the Magnetek Company as its
Model No. 950. It produces a voltage output that varies linearly between
about 1 volt DC and 5 volts DC for the full length movement of the
traveler 58 along its shaft 60.
In a similar fashion, a linear transducer is associated with each of the
other turn bars and compensation rollers employed in the folder. As such,
the actual position of each turn bar and roller is fed as an analog signal
through the cable 62 to the programmable controller 54.
Also coupled to the programmable controller 54 is a personal computer, such
as an IBM PS-2 or one of the clones of that machine now available through
several companies. It includes a keyboard 64 for providing manual inputs
to a computer 66. Also associated with the computer is a display module
68. The computer 66 includes a semiconductor memory (not shown) for
storing the applications program yet to be described as well as data
defining a desired position for each of the turn bars and compensation
rollers included in the press folder and with variables associated with a
plurality of jobs.
Assuming that a particular printing job had earlier been run and the manual
switches 36, 38, 40, 42, 46 and 48 had been used by the operator to set
the positioning of the turn bars and compensation rollers so as to produce
signatures with appropriate margins at the top, bottom and each side, the
analog signals from each of the linear transducers are fed over the cable
62 to an analog to digital converter (not shown), forming a part of the
programmable controller 54, and the resulting digital data pertaining to
the actual position of each of the turn bars and compensation rollers is
fed, via cable 70, to be stored in the memory of the computer 66. At a
later time, when it is desired to run the same job, the press operator may
call up a program which presents a menu on the display 68. The menu
contains a number of prompts which causes the operator to enter in
operands and addressing information for reading out the previously stored
desired positions for the turn bars and compensation rollers associated
with that job, with the positional information being fed over the cable 72
to the programmable controller 54. The programmable controller is
operative to then compare the desired position information with the
existing actual position information coming from the linear transducers
for then generating drive signals for the motors 32, 52, 34 and 46,
whereby those motors are driven until the error signal between the actual
position and desired position is reduced to zero. In this fashion, the
turn bars and compensation rollers will be moved to their appropriate
positions which theretofore had resulted in satisfactory margins when that
job had been previously run.
Referring next to FIG. 3, there is shown the screen layout for the display
68 when the folder preset system of the present invention is being used.
This operator interface screen has a top title portion 74, a middle
application "work area" 76, and at the very bottom are lines 78 for
indicating system status. In the application work area, there are three
side-by-side sections that comprise the application screen layout. The
left section contains all of the input system set-up information, the
middle section gives a description for each input, and the right section
has the selection for the product size ranges. All inputs are indicated in
the lower left corner of the application area. The status of each level to
be used in producing the particular signature is displayed to the right of
the input line.
In use, the operator turns on the system and when the screen of FIG. 3 is
presented on the display, at the left side of the middle portion of the
screen, it can be seen that the first input selects the type of fold to be
used. A "1" selects "double former fold", a "2" selects "combination
quarter fold", and "3" selects "tabloid fold".
Input lines 2 through 5 or 2 through 7 (depending on the number of levels
on the folder) contain the turn bar placement and path routing
information. For each level, the operator inputs the hole number that the
turn bar has been placed at. Also, for each level, when using a double
former fold, a "F" is entered if the ribbon on this level uses the front
nose or a "B" if the back nose is used. If a quarter fold or tabloid fold
is involved, a "O" is entered if the ribbon on the particular level exits
out the operator side or a "G" is entered if the ribbon exits the level on
the gear side. For any level that is not used, a "O" is entered for the
turn bar hole number.
The final setup input line on the screen calls for the width size of the
untrimmed signature product. The possible selection for this input are
found on the right hand side of the application portion of the screen in
FIG. 3. The hole for a double former fold setup and the path routing for
the quarter and tabloid fold setups on each particular level automatically
indicate if the web is used standard or reversed. Accordingly, the setup
information outlined above is all that is necessary for all possible run
combinations.
After all the setup information has entered, the bottom line on the left
hand portion of the screen prompts the operator to look for presets.
Entering a "Y" will start the search for the defined setup. The level
number for any found preset will be displayed to the immediate right (the
lower center portion of the application area). If no presets are found, a
message stating that fact will be displayed and the operator will need to
manually preset the folder using the push button switches, all as has been
previously described. There are no algorithms incorporated in the
controller to calculate turn bar and compensation rollers for first-time
setup configurations. If no presets are found, the cursor automatically
prompts "Save Preset" but if presets are found, it will continue with the
"Start Preset" operation.
In particular, when one or more presets are found, the next prompt
presented to the operator will inquire as to whether he wishes to initiate
the preset system. Entering a "Y" here will simultaneously start all
necessary positioning movements of the turn bars and compensation rollers
with no further action required by the operator. The operator is
responsible for positioning the turn bars in the proper holes on the slide
blocks. This may be done either before or after the automatic presets are
made. Technically, the turn bars may be repositioned while the automatic
presets are being made. When the automatic movement of the turn bars and
compensation rollers begins, all manual positioning switches become
disabled and a warning message not to make manual moves appears in the
system status line on the display.
At any time while the automatic moves are being made, the operator may stop
the preset system by answering "Y" to the "Stop" prompt that appears after
the system starts. This may be necessary if the operator notices a mistake
in the setup or a run is aborted at the last minute. Regardless, the
operator does not have to wait for all moves to stop before setup changes
may be initiated.
Also, as was mentioned earlier, the system has the capability of saving
preset data. The "Save Presets" prompt appears under the following
conditions:
1. After search for presets failed to find any presets;
2. After all automatic preset moves are complete;
3. When the operator answers "Y" to the "Stop Preset" prompt; or
4. When the operator answers "N" to the "Start Preset" system.
When the operator answers "Y" to "Save Presets", the exact position of the
turn bar and compensation roller for each level with a hole number greater
than "0" is recorded and saved in a file determined by that particular
setup.
The operator may also scroll through a job name menu and select the desired
job. Such selections would then use a stored look-up table in which all of
the folder preset setup variables would be read out. Should this be a
first time use of a particular job and run configuration, the folder
preset variables will have to be manually entered and subsequently saved
to the job name and run configuration. This permits the operator to know
what holes in the slide blocks the turn bar should be placed as well as
providing automatic fine adjustment of the turn bars and compensation
rollers.
Referring now to FIG. 4, there is illustrated a software flow diagram
defining the software for controlling the cursor movement through the
screen of FIG. 3. Operation starts with the entry of the folder type and
then for each level, the hole number employed for the turn bar is entered
as is the path route for the ribbon at that level. If the ribbon exits the
gear side of the former, a "G" is entered and if it exits the operator
side, a "O" is entered. The cursor then sequentially steps through the
remaining levels 2 through 6 with the hole number and path route being
entered for each. After the path route for level 6 has been entered on the
screen, the prompt moves to highlight Product Size and, as previously
mentioned, the Product Size is read from a list of available sizes
displayed on the right-hand portion of the screen in FIG. 3. Subsequently,
the command lines on the screen are sequentially highlighted and, as is
indicated by the lower-most block in FIG. 4, the commands include "look
up", "start", "stop", and "save".
FIG. 5 illustrates a typical cursor movement flow chart used in entering
the level hole number and path route. For a given level, e.g., level "X",
a hole number for the turn bar is first entered. Then, a test is made to
determine whether the number entered is a valid number. If not, control
returns to the starting point and the process continues until a valid hole
number has been entered. A test is made to determine whether the entry had
been only a cursor move; if not, the entered level number and hole number
are saved and control passes over to the operation where a path route is
now entered for level "X". If the path route so entered is not valid,
control loops back until a valid input has been made. At that point, a
test is made again to determine whether the input is a cursor move only.
If it is not, the path route for level "X" is saved and the series of
steps relating to the entry of the hole number is again repeated.
Had the test "input move cursor only?" been answered in the affirmative, a
further test is made to determine whether it is to move downward. If so,
the next step is to enter the hole number for the next successive folder
level. Had the test shown that the cursor move was not down, a subsequent
test checks to see if it was to be an up cursor move. If so, the cursor
would proceed to the previous level number and hole number that had been
entered. If the cursor move was not up, a test is made to see if it was a
left cursor move. If so, the cursor is moved to the path route for the
proceeding level "X-1".
In a similar fashion, a series of tests are made to determine the direction
of cursor movement for the path route as reflected in the flow diagram.
Turning now to FIG. 6, there is set forth a software flow chart for the
preset system control. If there is at least one level with a hole number
greater than zero, a test is made to look for presets and if none are
found, control exits to go to the first entry on the screen which is to
enter the fold type. Where presets are found, look up file names are
created according to the information originally set up. Presets are then
again looked for and if none are found, the display screen displays "no
presets found". If presets were found, then that fact would also be
displayed along with the numbers of the levels where presets had
previously been determined. In addition, a prompt to start the preset
system is displayed. Once the prompt is there, the operator must respond
by entering "Y" or "N". A test is made to determine which entry is made
and if the instruction were to start it, the messages "do not make manual
moves" and "presetting levels - - - " are presented on the screen.
Moreover, a start bit as well as the desired position information is sent
from the PC 66 to the programmable controller 54 (FIG. 2). As already
mentioned, this causes the actual position data obtained from the linear
transducers to be compared digitally to the desired position with any
differences comprising an error signal for driving the servomotors in the
appropriate direction to cause the turn bar and compensation roller to
move to the desired position.
At the same time that the start bit and position information are
transmitted to the programmable controller, the flow chart of FIG. 6
reflects that the operator is provided with a prompt as to whether to Stop
Presets. If a "Y" for "yes" is entered, this fact is detected and a stop
bit is sent to the PLC to immediately disable the affected drive motor. If
no order to stop the preset system is provided by the operator, a test is
made to determine when the repositioning had been completed. When
completed, the statement "Complete Presets Levels (numbers)" is provided
on the display screen.
In either event, control passes to cause the prompt "Save Presets" to be
displayed. If an "N" for "no" is entered by the operator, control returns
to the starting point in FIG. 6. If the instruction is to save the
presets, the message "Saved Presets Levels (numbers)" is entered and, at
the same time, previously stored files are updated in accordance with the
existing setup or, alternatively, a new file is created in accordance with
the existing setup where no previously presets had been stored. The
current positions of the turn bars and compensation rollers is read and
stored in the file that had earlier been located or established.
FIG. 7 is a software flow diagram representing the operations performed by
the programmable controller. When a start bit and position information is
received from the PC 66, a test is made by the microprocessor in the
programmable controller to determine whether a position requested by the
PC is greater than zero. If not, no repositioning is required and a stop
flag is set and no movement of the motors takes place. If a requested
position differed from zero, another test is made to determine whether the
requested position value is greater than the then-existing value being
sensed and relayed to the programmable controller by the linear transducer
involved. If it is, the motor for the turn bar displaces the slide block
to the left or if it is the compensation bar, the retard motor is started.
Then, a test is continually made until it is determined that the desired
position value becomes less than the current value at which point it is
known that the affected turn bar or compensation roller has reached its
target position. At this point, a stop flag is set and control for this
level holds until the same operations reflected by the flow chart of FIG.
7 are carried out for all moves.
It was earlier assumed that the test as to whether the desired position
value was greater than the then-existing position value was true. If it
had not been, the motor associated with the turn bar would be rotated to
move the slide block to the right, and if it were the compensation roller,
its slide would be moved in the "advance" direction. The test as to
whether the desired position value is greater than the existing position
value and when the result is affirmative, a stop flag is set and control
for this level holds until all moves are complete. When all moves are
complete, the programmable controller sends a stop to the PC.
The flow charts of FIGS. 4, 5, 6 and 7 are sufficient to permit a skilled
programmer to write the appropriate instructions for the PC and for the
microprocessor in the programmable controller to execute the steps set out
in the flow chart. Accordingly, it is deemed unnecessary to set out in
this specification the program in either source code or object code.
This invention has been described herein in considerable detail in order to
comply with the Patent Statutes and to provide those skilled in the art
with the information needed to apply the novel principles and to construct
and use such specialized components as are required. However, it is to be
understood that the invention can be carried out by specifically different
equipment and devices, and that various modifications, both as to the
equipment details and operating procedures, can be accomplished without
departing from the scope of the invention itself.
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