Print media manufacturing system

Abstract

A print media manufacturing system including a print media conveyor, a plurality of print media processing machines adapted to dispense print media components to the print media being conveyed on the print media conveyor, an automated storage and retrieval machine including a shuttle, and a storage rack that stores reserve supply of print media components used by the plurality of print media processing machines. The storage and retrieval machine is operable to position the shuttle along the storage rack, and the shuttle is operable to enter the storage rack to retrieve the reserve supply of print media components stored therein, and to deliver the retrieved reserve supply to the print media processing machines.

Description

[0001] This application claims priority to U.S. Provisional Application No. 60 / 668,978, filed Apr. 7, 2005, the contents of which are incorporated herein by reference.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The present invention relates to print media manufacturing systems. In particular, the present invention relates to systems for manufacturing magazines, catalogs, books, newspapers, and collation of print media. [0004] 2. Description of the Related Art [0005] Presently, manufacturing of various print media such as magazines, catalogs, and books, as well as collation of print media, are attained in print media manufacturing systems. Typically, print media such as magazines, catalogs, and books, are assembled from print media components which are pre-printed by the printers. These pre-printed sections are referred to as “signatures” in the print media industry. These signatures are typically 8 or 16 pages, and are typically just over 8.5″×11″ in size. Th...

AI Technical Summary

Benefits of technology

[0016] In view of the above, one advantage of the present invention is in providing a print media system that reduces the need for a separate warehouse facility and operations for retrieving the print media components.

[0017] In addition, another advantage of the present invention is in providing a print media system that reduces costs associated with such a separate warehouse facility and operations, including amount of manual labor required.

[0018] In accordance with one embodiment of the present invention, a print media manufacturing system is provided, the system including a print media conveyor for conveying print media thereon, a plurality of print media processing machines positioned along the print media conveyor, the print media processing machines being adapted to dispense print media components to the print media conveyor, and at least one supply rack positioned proximate to the plurality of print media processing machines, the supply rack receiving supplies of print media components used by the plurality of print media processing machines. The system also includes a rail positioned substantially parallel to the supply rack, an automated storage and retrieval (S / R) machine including a shuttle that is operable to move in a direction perpendicular to the rail, the S / R machine engaging the rail to allow the S / R machine to travel substantially parallel to the supply rack, and a storage rack that stores reserve supply of print media components used by the plurality of print media processing machines, the storage rack being positioned adjacent to the rail so that the rail is positioned between the supply rack and the storage rack.

[0019] Furthermore, in accordance with the present invention, the S / R machine is operable to position the shuttle along the storage rack, and the shuttle is operable to enter the storage rack to retrieve the reserve supply of print media components from the storage rack. In this regard, the S / R machine is operable to position the shuttle along the supply rack, and the shuttle is operable to deliver the retrieved reserve supply of the print media components.

[0020] In accordance with another embodiment of the present invention, the shuttle preferably includes drive wheels and a means for lifting the reserve supply of print media components onto the shuttle, the drive wheels being operable to move in a synchronized manner with the means for lifting. In accordance with another embodiment, the system further includes a programmable controller that controls the operation of the S / R machine and the shuffle in the manner described.

[0021] In another embodiment of the present invention, the storage rack includes a plurality of vertically arranged storage bays for storing the reserve supply of print media components. In this regard, the S / R machine may be implemented to include a vertically extending mast and a vertically movable carriage to elevate the shuttle for entry into the plurality of vertically arranged storage bays to allow retrieval of the print media components stored therein. The plurality of vertically arranged storage bays include a plurality of overhead storage bays positioned above the supply rack, the shuttle being operable to enter into the plurality of overhead storage bays to retrieve the print media components stored therein. Preferably, the plurality of overhead storage bays are also positioned above the plurality of print media processing machines and the print media conveyor.

Problems solved by technology

The space requirements of the various print processing machines and binding machines of the print media manufacturing system are very high.

Most, if not all newspapers, tend to purchase all or a portion of these inserts from other printing companies, since their presses are usually not designed to print these smaller pages using a different paper stock.

However, such collation operations require the various different magazine titles to be retrieved from a warehouse using fork-trucks which require significant amount of manual labor and resources, thereby reducing the cost savings that can be realized by the collation operations.

Correspondingly, a separate warehouse facility and operations for retrieving the print media components require substantial amount of real estate and facilities, and thus, are very expensive.

Moreover, the retrieval of such print media components from such warehouses using fork-trucks require significant amount of manual labor and resources, thereby further increasing costs.

Therefore, there exists an unfulfilled need for a print media system that reduces the need for a separate warehouse facility for storing the print media components, and operations for retrieving the print media components.

In addition, there also exists an unfulfilled need for a print media system that reduces cost associated with such a separate warehouse facility and operations, including amount of manual labor required.

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