Barcode Control for Bookbinding Folding and Sewing
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Solution Overview
Problem
Current combined bookbinding machines require manual and error-prone programming for each job, leading to inefficiencies and defective book production, especially in short-run applications, due to limited control systems that cannot detect sequence errors exhaustively and automatically.
Innovation Solution
Implementing a barcode-based control system that reads configuration information from sheets to automatically manage the folding and sewing of signatures, eliminating the need for manual programming and enabling real-time detection of sequence errors, thereby ensuring accurate book production without a learning phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual programming is used to input job information for each batch of books, then the machine can be operated with simple control systems, but the programming operations are slow, tiresome, and prone to human errors causing defective book production
Solution Approach 1:
The patent uses barcodes printed on sheets as copies of job configuration information. Instead of manually inputting parameters, the system reads pre-encoded barcode data that contains signature and book block information, eliminating manual programming errors and time consumption while maintaining operational simplicity
Solution Approach 2:
The patent replaces manual mechanical programming operations with automatic optical reading systems. Barcode readers optically capture and automatically input job parameters, substituting the manual control process with an automated system that improves both speed and accuracy
2Reliability
If a learning phase is implemented to define expected processing sequences, then exhaustive error detection is possible, but the time required becomes untenable for short-run jobs
Solution Approach 1:
The patent performs preliminary encoding of the expected processing sequence directly into barcodes on the sheets during the printing or preparation stage. This pre-prepared information is then automatically read and verified during production, enabling exhaustive error detection without requiring a time-consuming learning phase during operation
Solution Approach 2:
The sheets themselves carry the configuration information through barcodes, making them self-descriptive. The system reads information directly from the sheets rather than requiring external programming or learning phases, allowing the material to serve its own identification and sequencing functions
Data Source
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AI summary
A solution is proposed for controlling a bookbinding folding/sewing combined machine. A corresponding method (500) includes the steps of gathering (566) printed sheets in succession from a stack of sheets being supplied to the combined machine for obtaining groups of sheets, folding (572) the groups of sheets for obtaining corresponding signatures, and sewing (575) groups of signatures through continuous threads for obtaining corresponding book blocks. In the solution according to an embodiment of the invention, there arc further provided the steps of reading (509-521) configuration information from at least part of the sheets, causing (569-572) the folding of a current group of sheets to which a current sheet being just gathered has been added for obtaining a corresponding current signature in response to the reading of an end of signature indicator in the configuration information of the current sheet, and causing (578-581) the cutting of the threads of a current group of signatures to which the current signature has been sewn for obtaining a corresponding current book block in response to the reading of an end of book indicator in the configuration information of the current sheet.