Combined Bookbinding Machine Automatic Overlapped Signature Control
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Solution Overview
Problem
Bookbinding machines face challenges in efficiently forming overlapped signatures, particularly with sewing machines due to complex operations and insufficient suction for multi-layered signatures, while flat sheet machines are slower and less efficient in processing large numbers of sheets.
Innovation Solution
A combined bookbinding machine that automatically controls the formation of overlapped signatures using bar code configuration information to guide the processing of both pre-prepared and flat sheet signatures, simplifying operations and reducing manual programming errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sewing machines are used to process overlapped signatures, then processing speed is improved, but device complexity increases and suction capability becomes insufficient for multi-layered signatures
Solution Approach 1:
The patent divides the signature processing into separate basic signatures that are gathered and folded individually, then assembled into overlapped signatures. This segmentation allows the sewing machine to handle simpler units while achieving complex overlapped configurations through systematic assembly, reducing the complexity of handling multi-layered signatures directly.
Solution Approach 2:
The patent performs preliminary folding and gathering of basic signatures before they are assembled into overlapped signatures. By preparing the signatures in advance through systematic folding operations, the machine avoids complex real-time manipulation of multi-layered structures, maintaining speed while simplifying the actual sewing operation.
2Ease of operation
If flat sheet machines are used to form overlapped signatures, then ease of operation is improved, but productivity decreases due to sequential gathering of sheets
Solution Approach 1:
The patent merges the advantages of both sewing machines (speed) and flat sheet machines (ease of operation with digital printing capability) into a combined system. The gathering device collects flat sheets systematically, the folding device creates signatures efficiently, and the sewing machine processes them at high speed, achieving both operational simplicity and high productivity.
Solution Approach 2:
The patent creates a combined machine that can process both pre-prepared signatures and flat sheet signatures, making it universally applicable to different production needs. This multi-functional system can handle overlapped signatures with inserts when needed while maintaining high-speed processing for standard signatures, thus achieving both ease of operation and high productivity.
3Adaptability or versatility
If manual programming is used to control processing sequences, then adaptability is improved, but loss of time increases due to learning phase and programming errors
Solution Approach 1:
The patent implements automatic control where the system self-regulates the processing sequence based on detected signature types and configurations. The control system automatically adjusts gathering, folding, and sewing operations without manual programming, eliminating the learning phase and programming errors while maintaining adaptability to different signature configurations.
Solution Approach 2:
The patent incorporates detection systems that monitor the processing sequence and provide feedback to the control system. This feedback mechanism allows the machine to automatically adapt to different signature types and adjust operations accordingly, maintaining flexibility while eliminating manual programming requirements and reducing setup time.
Data Source
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AI summary
A solution is proposed for controlling a combined bookbinding machine (100). A corresponding method (600) comprises the steps of reading (648) configuration information associated at least in part with a basic signature being ready in each one of a plurality of feeding stations (110f,110p) of the combined bookbinding machine, the configuration information comprising a progressive number of basic signature indicative of a position of the basic signature within a corresponding overlapped signature comprising a plurality of basic signatures being overlapped one to another, selecting (642,645,660) at least one of the basic signatures in at least a selected one of the feeding stations according to the configuration information, depositing (654) said at least one selected basic signature from said at least one selected feeding station astride a transport saddle (140) of the combined bookbinding machine to contribute to the formation of a corresponding overlapped signature on the transport saddle, and transporting (667) each overlapped signature towards a binding station of the combined bookbinding machine to contribute to the formation of a corresponding book block, comprising a plurality of overlapped signatures being bound one to another, in response to the reading of an indicator of end of overlapped signature in the configuration information.