Device and method for assembling printed sheets on a per-order basis for the production of book blocks for photo books

Abstract

The invention relates to a device and method for assembling printed sheets for the production of book blocks for photobooks from a stack (2) comprising several orders, each with at least one printed sheet (20), the device (1) comprising a control unit (100), a sheet counting unit (13) with a separating element (130) that can be inserted into the stack (2), wherein the sheet counting unit (13) can be operated by means of the control unit (100) to count a number of printed sheets (2) according to an order (22) and to separate the number of printed sheets (2) of the order (22) from the stack (2) at least partially by means of the separating element (130), a collection station (14) and a transfer device (15), wherein the transfer device (15) is configured to transfer the order separated from the stack (2) at least partially by means of the separating element (130) to the collection station (14).

Description

FIELD OF APPLICATION AND STATE OF THE ART

[0001] The invention relates to a device and method for assembling printing sheets for producing book blocks for photo books from a stack.

[0002] In the context of the registration, a photo book refers to a digitally printed book whose content can be individually designed. It is also known that the format and / or number of pages of a photo book can be individually selected, at least within defined frameworks.

[0003] Photo books usually consist of a book block and a cover, although the cover can also be freely designed depending on the application.

[0004] In the context of this application, a book block refers to a unit comprising several printed and trimmed, interconnected printed sheets. In some embodiments, the book block additionally has an upper and / or lower cover sheet.

[0005] The printing blocks (and possibly the cover sheets) are bound together using a binding device. In the context of this application, a binding device refers to a device by which a number of aligned and trimmed printed sheets are bound. The binding device is designed, for example, as an adhesive binding machine for producing an adhesive binding. However, other binding devices are also known.

[0006] A number of printed sheets to be combined into a book block is referred to as an order in the context of the application. It is common practice to process multiple orders of the same format in a stack (also called a batch). The stack can contain several orders that differ in content and / or page count, as well as several orders that are identical in content and page count.

[0007] Batch processing is usually done manually. It is common practice to assign a job sheet to the batch.

[0008] To process the stack, an operator uses the order sheet to record the page numbers of the jobs in the stack and manually counts and picks off the corresponding number of printed sheets from the stack. The operator then adds a top and bottom cover sheet to the counted and picked-off printed sheets of a job. The assembled job is manually inserted into a binding device and bound to form a book block. Before inserting the job into the binding device, it is common practice to perform a thickness check. TASK AND SOLUTION

[0009] The objects of the invention are to provide a device and method for assembling printed sheets for producing book blocks for a photo book, which allows an at least partially automated, order-by-order assembly of printed sheets from a stack comprising several orders.

[0010] According to a first aspect, a device is provided for assembling printed sheets for producing book blocks for photo books from a stack comprising a plurality of jobs, each with at least one printed sheet. The device comprises a control device and a sheet counting unit with a separating element insertable into the stack, wherein the sheet counting unit is operable by means of the control device to count a number of printed sheets corresponding to a job and to separate the number of printed sheets of the job from the stack at least in regions by means of the separating element. The device further comprises a collecting station and a transfer device, wherein the transfer device is configured to transfer the job, which has been separated from the stack at least in regions by means of the separating element, to the collecting station.

[0011] The terms "a," "an," or similar are used in the context of this application merely as indefinite articles and not as number pronouns. The terms "first," "second," etc., serve merely to distinguish between the elements and do not indicate a sequence. Likewise, the use of the term "first" does not necessarily require the presence of a second element or component.

[0012] In some embodiments, the control device comprises several decentrally arranged units that operate in a hierarchical architecture or in parallel. In other embodiments, a central control device is provided.

[0013] The stack contains at least one job, preferably several jobs. Each job contains at least one printed and preferably pre-cut sheet. Depending on requirements, several identical or different jobs are grouped together in a stack. The jobs in a stack can differ in both content and page count.

[0014] The sheet counting unit, also referred to as a counting machine, allows a number of printed sheets to be counted corresponding to a job and the counted printed sheets, i.e. a job, to be separated from the stack at least in sections by means of the separating element for transfer to a collecting station. In some embodiments, the separating element is a rotating disc, wherein upon rotation of the disc a corner or edge of a printed sheet lying on a flat side is transported to the opposite side, and in the process a counting signal is generated. In some embodiments, the counting disc is positioned on the top side of the stack in order to count the printed sheets sheet by sheet, starting from the top side of the stack.

[0015] In some embodiments, the device further comprises a storage area on which the stack can be provided.

[0016] In some embodiments, the sheet counting unit is moved vertically relative to the stack during the counting process. In other embodiments, the tray is designed as a lifting table, wherein the lifting table can be vertically adjusted relative to the separating element in a timed manner by means of the control device in order to deliver the printed sheets individually to the separating element in a timed manner.

[0017] In some embodiments, the stack is positioned manually. For improved automation, other embodiments provide a first manipulator configured to transfer a stack to the storage location and to position the stack on the storage location. In the context of the application, a manipulator refers to a kinematic system with two or more axes that enables physical interaction with the environment, wherein the manipulator has an end effector suitable for the respective interaction. In some embodiments, the manipulator is a three-, four-, five-, six-, or seven- to eight-axis robot arm.

[0018] For the production of photo books in print shops, it is known to place stacks containing multiple jobs on a carriage downstream of a printing device and to use the carriage to transport the stacks to subsequent stations, such as a cutting station and / or a binding device. In one embodiment, the stack is transferred from a carriage to the stacking station.

[0019] In other embodiments, the device further comprises a feed device for feeding the stack to the storage unit. The feed device can be suitably designed by a person skilled in the art depending on the application. In some embodiments, the feed device is designed as an air table.

[0020] In embodiments, the control device comprises a human-machine interface by means of which a user can transmit information concerning the orders present in a stack to the control device.

[0021] Alternatively or additionally, in some embodiments, the control device comprises a reading unit configured to read jobs combined in a stack from a job sheet. The job sheet is generated in some embodiments at the printing device and deposited on the stack. Information relating to the stack is stored on the job sheet in coded form, for example, as a barcode or a two-dimensional code, in particular as a QR code, with the reading unit configured accordingly to read the information.

[0022] Typically, a top and bottom cover sheet are added to the printed sheets of a book block production order. In some cases, the cover sheets are added manually.

[0023] For further automation, the device in some embodiments comprises a dispensing device configured to remove an upper and / or lower cover sheet from a cover sheet supply and deposit them at the collection station. In some embodiments, the cover sheets are identical and can be removed from a common supply. In other embodiments, separate devices are provided for the upper and lower cover sheets.

[0024] In embodiments, the transfer device and the dispensing device can be operated in a coordinated manner by means of the control device in order to deposit the separated, removed order at the collection station between an upper and a lower cover sheet.

[0025] In some embodiments, the order, possibly supplemented by the upper and / or lower cover sheet, is manually removed from the device and fed to a binding device. For further automation, in some embodiments the device comprises a second manipulator which is configured to feed the order - possibly supplemented by the upper and / or lower cover sheet - to the binding device. In some embodiments the second manipulator comprises for this purpose an end effector designed as a gripper. In some embodiments the gripper can be controlled by the control device in accordance with the order in order to adapt a gripping width and / or a gripping force to a page number and thus a thickness of the order. In some embodiments the binding device comprises a thickness measuring device, wherein the second manipulator is operable to feed the order first to the thickness measuring device and then, for example, to an adhesive unit of the binding device.

[0026] To align the job, possibly supplemented by the top and / or bottom cover sheet, before it is fed to the binding device, a format alignment is provided downstream of the collecting station in some embodiments. Additionally or alternatively, a control device, in particular a thickness measuring device, is provided downstream of the collecting station in some embodiments. The control device serves to control the sheet counting unit so that an incorrectly compiled job can be detected before binding. In an alternative embodiment, the control device is provided at the collecting station and / or a thickness measuring device of the binding device is used as the control device.

[0027] According to a second aspect, a method is provided for the order-by-order assembly of printed sheets for producing book blocks for photo books from a stack comprising a plurality of orders, each with at least one printed sheet. For at least partially automated assembly of the printed sheets, a sheet counting unit comprising a separating element is operated by means of a control device in order to count a number of printed sheets corresponding to a job from a stack and to separate the number of printed sheets of the job from the stack at least in regions by means of the separating element. Furthermore, a transfer device is operated by means of the control device in order to transfer the job, which has been separated from the stack at least in regions by means of the separating element, to a collecting station.

[0028] In some embodiments, orders grouped together in a stack are read from an order sheet by means of a reading unit of the control device.

[0029] The stack is provided in various configurations on a storage unit.

[0030] In particular, in embodiments, the stack is provided on a storage device designed as a lifting table, wherein the lifting table is adjusted vertically in a timed manner relative to the separating element by means of the control device in order to deliver the printed sheets individually in a timed manner to the separating element.

[0031] In embodiments, the stack is transferred to the storage area by means of a first manipulator and positioned at the storage area by means of the first manipulator.

[0032] In some embodiments, the stack is fed to the storage unit by means of a feeding device, in particular by means of a feeding device designed as an air table.

[0033] In embodiments, an upper and / or a lower cover sheet is removed from a cover sheet supply by means of a dispensing device and deposited at the collection station.

[0034] The transfer device and the dispensing device are operated in a coordinated manner by means of the control device in embodiments in order to deposit the separated, removed order at the collection station between an upper and a lower cover sheet.

[0035] In embodiments, the order - possibly supplemented by the upper and / or lower cover sheet - is fed to a binding device by means of a second manipulator.

[0036] In embodiments, it is further provided that an automated format alignment of the order and / or an automated control of the order, in particular a thickness measurement, takes place downstream of the collecting station. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Further advantages and aspects of the invention emerge from the claims and from the description of exemplary embodiments of the invention, which are explained below with reference to the figure. In this figure: Fig. 1 is a schematic representation of a layout of a plant for producing book blocks for photo books, comprising a device for assembling printing sheets from a stack 2 in a job-by-job manner. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0038] Fig. 1 shows a schematic layout of a system for producing book blocks for photo books, comprising a device 1 for assembling printing sheets 20 from a stack 2 in a job-by-job manner.

[0039] Printed sheets 20 are printed in a printing device (not shown) and each combined into a stack 2. In one embodiment, a stack 2 comprises exactly one job. Typically, stacks 2 each comprise multiple jobs, with all jobs having the same format. Jobs in a stack 2 may differ in terms of content and / or page count. However, it is also conceivable for a stack 2 to contain multiple jobs that are identical in content and page count.

[0040] The printed sheets are then fed to the printing device of a cutting station (also not shown), in which the sheets are cut to the desired format.

[0041] In the illustrated embodiment, the stacks 2 comprising the printed and cut printed sheets 20 are placed on a schematically illustrated carriage 3 and moved by means of the carriage to the device 1 for assembling printed sheets 20 in order. The stack 2 is in Fig. 1 is shown schematically fanned out on the carriage 3. In practice, the printed sheets 20 of a stack 2 are preferably deposited aligned on the carriage 3. Depending on the design, exactly one stack 2 or several stacks 2 are deposited on the carriage 3.

[0042] By means of the device 1, printed sheets 20 are assembled from a stack 2 in a job-by-job manner to form a printed sheet collection. The printed sheet collection is then fed to a binding device 4 for joining to form a book block 5. In some embodiments, the binding device 4 has a thickness measuring device 40. The thickness measuring device 40 can be used to measure the thickness of the printed sheet collection for monitoring and adjusting the binding device 4.

[0043] The schematically illustrated device 1 allows a fully automated order-by-order assembly of printed sheets and for this purpose comprises a control device 100, a feeding device 10, a first manipulator 11, a storage device 12, a sheet counting unit 13, a collecting station 14, a transfer device 15, a dispensing device 16, a format alignment device 17, a control device 18 and a second manipulator 19.

[0044] By means of the feed device 10, the printed sheets 20 are transported stack by stack from the carriage 3 to the stacker 12. In some embodiments, the feed device 10 is designed as an air table, with an air cushion being formed between the stacks 2 to be transported and a surface of the air table, enabling gentle transport with minimal effort. In some embodiments, at least one guide device 110 (shown schematically in FIG. 1 ) is provided on the feed device 10, by means of which the stacks 2 are guided during transport.

[0045] The stacks 2 are transferred from the feed device 10 to the storage area 12 and aligned on the storage area 12. In the embodiment shown, the stack 2 is transferred from the feed device 10 to the storage area 12 by means of the first manipulator 11. In some embodiments, the first manipulator 11 has a slider as an end effector, by means of which the stack 2 can be positioned at a defined position on the storage area 12. In some embodiments, the control device 100 can signal to the first manipulator 11 that a stack 2 present on the storage area 12 has been processed and a subsequent stack can be transferred to the storage area 12. In other embodiments, the first manipulator 11 is initialized decentrally, wherein it can be detected decentrally that the storage area 12 is empty and thus ready to receive a subsequent stack 2.

[0046] From the stacker 12, the printed sheets 20 are transferred order by order to the collecting station 14. For this purpose, the sheet counting unit 13 is provided, by means of which a quantity of printed sheets corresponding to a job to be transferred can be recorded.

[0047] The sheet counting unit 13 comprises a separating element 130 which can be inserted into the stack 2 provided on the tray 12. The sheet counting unit 13 can be operated by means of the control device 100 in order to count a number of printed sheets 2 corresponding to a job and to separate the number of printed sheets 2 of the job from the stack 2 at least in regions by means of the separating element 130.

[0048] In the illustrated embodiments, the tray 12 is designed as a lifting table, wherein the lifting table is adjustable in height relative to the separating element 130 by means of the control device 100 in order to deliver the printed sheets 2 individually to the separating element 130 in a timed manner. In other embodiments, the sheet counting unit 13 is mounted so that its height is adjustable in a timed manner.

[0049] The separating element 130 is designed in embodiments as a rotating disc, wherein due to a rotation of the disc, corner regions of the printed sheets 20 are transferred individually from a position below the disc to a position above the disc and are thus separated from the stack 2 in regions.

[0050] The transfer device 15 is configured to transfer the counted order 22, which has been separated at least partially from the stack 2 by means of the separating element 130, to the collecting station 14. The transfer device 15 is designed in some embodiments as a gripping device, which is configured to grip orders with different page numbers and / or different formats and transfer them to the collecting station 14.

[0051] For a partially automated assembly, in embodiments an upper and a lower cover sheet are manually added to the quantity of printed sheets separated according to the order and this unit is then fed to the binding device 4.

[0052] In the illustrated embodiment, the dispensing device 16 is also provided. The dispensing device 16 is configured to remove an upper and / or a lower cover sheet from a cover sheet supply 6 and deposit it at the collecting station 14. In the schematic representation, exactly one cover sheet supply 6 is provided, from which an upper and a lower cover sheet can be removed. In other embodiments, two cover sheet supplies 6 are provided, in which an upper cover sheet and a lower cover sheet are stored. In some embodiments, the dispensing device 16 is designed as a manipulator with a gripping device designed to grip individual sheets. In other embodiments, the dispensing device 16 is designed as a so-called feeder (dispenser) for single sheet feeding.

[0053] The transfer device 15 and the dispensing device 16 can be operated in particular by means of the control device 100 such that the order 22 separated from the stack 2 and removed from the stack 2 is deposited at the collecting station 14 between an upper and a lower cover sheet.

[0054] In the illustrated embodiment, the second manipulator 19 is also provided for fully automated processing. By means of the second manipulator 19, the order 22, optionally supplemented by the upper and lower cover sheets, can be removed from the device 1 and fed to the binding device 4 for producing the book block 5.

[0055] In embodiments, the second manipulator 19 removes the order 22, possibly supplemented by the upper and lower cover sheets, from the collection station 14.

[0056] In the illustrated embodiment, the format alignment device 17, in which the individual layers of the order 22 are precisely aligned for subsequent binding, and the inspection device 18 are provided downstream of the collecting station 15. In some embodiments, the order 22 is guided along the format alignment device by means of a linear drive (not shown). In other embodiments, the format alignment of the order 22 is performed by means of the second manipulator 19 or by means of an additional manipulator.

[0057] Furthermore, a control device 18 is provided for the sheet counting unit 13. At least one page count of the job 22 is checked at the control device 18. For this purpose, the control device 18 is designed in some embodiments as a thickness measuring device with a gap (not shown), wherein the job 22, possibly supplemented by the top and bottom cover sheets, can be inserted into a gap for a thickness measurement. In other embodiments, the job is checked for weight.

[0058] If the control device 18 detects a deviation, the order 22 and / or the entire stack 2 from which the order 22 was taken is ejected.

[0059] If the result of a completed inspection reveals no defects, the order 22 can be picked up by the manipulator 19 and fed to the binding device 4 for stapling the layers to the book block 5. The manipulator 19 can be operated in embodiments such that, by means of the manipulator 19, the order 22 is fed to a new thickness measurement on the thickness measuring device 40 provided on the binding device 4.

[0060] In order to transmit information about the order(s) present in a stack 2 to the control device 100, the control device 100 in the illustrated embodiment comprises a reading unit 101 which is configured to read orders summarized in the stack 2 from an order sheet 7. In some embodiments, the order sheet 7 is a paper document on which, for example, the information is stored in a barcode. The paper document is stored, for example, as the top layer on stack 2 fed to the device 1 by means of the carriage 3. In some embodiments, the reading unit 101 is configured to read the information from the order sheet 7 before the stack 2 is transferred to the feed device 10, during transport of the stack 2 along the feed device 10 and / or during transfer of the stack 2 to the storage device.Order sheet 7 is automatically removed after the information in the configurations has been read out.

[0061] In one embodiment, the reading unit 101 is arranged on the first manipulator 11, wherein the end effector provided on the first manipulator 11 is designed to remove the order sheet 7 and to transfer a stack 2 from the feed unit 10 to the storage unit 12. Depending on the application, the order sheet 7 is removed before or after the stack 2 is transferred to the storage unit 12.

[0062] In other embodiments, the order sheet 7 is a reprogrammable radio tag (also referred to as a transponder) provided on the carriage 3, wherein the reading unit 101 is configured to read the radio tag before or during a transfer of the stack 2 to the feeding device 10.

[0063] The device 1 shown is merely exemplary, and numerous modifications are conceivable. The elements of the device 1 are shown only schematically, and the figure is not to scale.

Claims

[1] Device for the order-by-order assembly of printed sheets for producing book blocks for photo books from a stack (2) comprising a plurality of jobs, each with at least one printed sheet (20), the device (1) comprising a control device (100), a sheet counting unit (13) comprising a separating element (130) which can be inserted into the stack (2), wherein the sheet counting unit (13) can be operated by means of the control device (100) in order to count a number of printed sheets (2) corresponding to a job (22) and to separate the number of printed sheets (2) of the job (22) from the stack (2) at least in regions by means of the separating element (130), a collecting station (14) and a transfer device (15), wherein the transfer device (15) is designed to transfer the job which has been separated at least in regions from the stack (2) by means of the separating element (130) to the collecting station (14). [2] Device according to claim 1, characterized byin that the device comprises a storage unit (12) on which the stack (2) can be provided, wherein the storage unit (12) is designed in particular as a lifting table, wherein the lifting table is vertically adjustable in a timed manner relative to the separating element (130) by means of the control device (100) in order to deliver the printed sheets (2) individually in a timed manner to the separating element (130), and / or wherein in particular a first manipulator (11) is provided which is designed to transfer a stack (2) to the storage unit (12) and to position the stack (2) on the storage unit (12). [3] Device according to claim 2, characterized by that a feeding device (10) is provided for feeding the stack to the storage device (12), wherein in particular the feeding device (10) is designed as an air table. [4] Device according to claim 1, 2 or 3, characterized bythat the control device (100) comprises a reading unit (101) which is designed to read out orders summarized in a stack (2) from an order sheet (7). [5] Device according to one of claims 1 to 4, characterized by that a dispensing device (16) is provided which is designed to remove an upper and / or a lower cover sheet from a cover sheet supply (6) and to deposit it at the collecting station (14), wherein in particular the transfer device (15) and the dispensing device (16) can be operated by means of the control device (100) in order to deposit the separated, removed order at the collecting station (14) between an upper and a lower cover sheet. [6] Device according to one of claims 1 to 5, characterized by that a second manipulator (19) is provided which is designed to feed the order - optionally supplemented by the upper and / or lower cover sheet - to a binding device (4). [7] Device according to one of claims 1 to 6, characterized by that a format alignment device (17) and / or a control device (19), in particular a thickness measuring device, are provided downstream of the collecting station (14). [8] Method for the order-by-order assembly of printed sheets for producing book blocks for photo books from a stack (2) comprising a plurality of jobs, each with at least one printed sheet (20), wherein a sheet counting unit (13) comprising a separating element (130) is operated by means of a control device (100) in order to count a number of printed sheets (2) corresponding to a job (22) from a stack (2) and to separate the number of printed sheets (2) of the job (22) from the stack (2) at least in regions by means of the separating element (130), and wherein a transfer device (15) is operated by means of the control device (100) in order to transfer the job (22) separated at least in regions from the stack (2) by means of the separating element (130) to a collecting station (14). [9] Method according to claim 8, characterized bythat the stack (2) is provided on a storage device (12), wherein the storage device (12) is designed in particular as a lifting table, wherein the lifting table is adjusted vertically in a timed manner relative to the separating element (130) by means of the control device (100) in order to deliver the printed sheets (2) individually in a timed manner to the separating element (130), and / or the stack (2) is transferred to the storage device (12) by means of a first manipulator (11) and the stack (2) is positioned on the storage device (12) by means of the first manipulator (11). [10] Method according to claim 9, characterized by that the stack (2) is fed to the storage (12) by means of a feeding device (10), in particular by means of a feeding device (10) designed as an air table. [11] Method according to claim 8, 9 or 10, characterized by that orders summarized in a stack (2) are read out from an order sheet (7) by means of a reading unit (101) of the control device (100). [12] Method according to one of claims 8 to 11, characterized by that an upper and / or a lower cover sheet is removed from a cover sheet supply (6) by means of a dispensing device (16) and deposited at the collecting station (14), wherein in particular the transfer device (15) and the dispensing device (16) are operated by means of the control device (100) in order to deposit the separated, removed order at the collecting station (14) between an upper and a lower cover sheet. [13] Method according to one of claims 8 to 12, characterized by that the order - optionally supplemented by the upper and / or lower cover sheet - is fed to a binding device (4) by means of a second manipulator (19). [14] Method according to one of claims 8 to 13, characterized bythat following the collecting station (16) an automated format alignment of the order (22) and / or an automated control of the order (22), in particular a thickness measurement, takes place.

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