Automated Postage Meter Work-Ahead Job Control
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Solution Overview
Problem
Current digital printing technologies in postage meters result in significant time wastage due to the need to change parameters between successive job runs, leading to delays and inefficiencies, especially in processing multiple batches of mail from different departments.
Innovation Solution
Implementing a work-ahead method where the postage meter operates continuously without stopping between jobs, allowing for simultaneous initialization of the next job while processing the current batch, reducing the need for repeated initialization and minimizing idle time for operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the postage meter stops between jobs to change parameters, then parameter accuracy is maintained, but productivity decreases due to idle time
Solution Approach 1:
The system performs preliminary actions by pre-loading the next job's parameters and preparing the print head during the current job's execution. The operator can enter next job parameters while mail is being processed, and the system validates and stores these parameters in advance, so that when the current job completes, the next job is already configured and ready to proceed immediately without idle time.
Solution Approach 2:
The system maintains continuous operation by eliminating idle periods between jobs. The motor runs continuously through all jobs without stopping, and parameter changes are performed during mail processing rather than during idle time. This ensures the system is always performing useful work - either processing mail or preparing for the next job - with no wasted idle time.
2Productivity
If the motor stops between jobs, then energy consumption is reduced, but productivity decreases due to repeated start-stop cycles
Solution Approach 1:
The motor operates continuously throughout multiple jobs without stopping, eliminating the energy losses associated with repeated start-stop cycles. The system maintains motor运转 while processing batches of mail and preparing parameters for subsequent jobs, ensuring the motor is always performing useful work rather than idling or restarting. This continuous operation significantly reduces overall energy consumption while maintaining high productivity.
3Manufacturing precision
If parameters are changed before each job, then job accuracy is ensured, but device complexity increases due to repeated initialization
Solution Approach 1:
The system performs parameter validation and preparation in advance during the current job execution. The operator enters next job parameters while mail is being processed, and the system validates these parameters against predefined criteria before the job actually begins. This preliminary validation ensures parameter accuracy is maintained while reducing the complexity of the initialization process at job start.
Solution Approach 2:
The system automatically validates and processes parameter changes without requiring complex manual initialization procedures. The parameter validation logic is built into the system, automatically checking entered parameters against predefined rules and rejecting invalid inputs. This self-validating approach ensures accuracy while simplifying the operator's task and reducing the overall complexity of the parameter change process.
Data Source
AI summary
Disclosed is an improved work-ahead method for efficiently operating a software-controlled, automated postage meter of the type used to print postage and other digital data on batches of mail that are run through the meter during successive jobs which originate from different accounts. The operator enters data relating to the parameters for a first job to be completed. After the meter is initialized and the meter overhead is encountered, the first batch of mail for the first job is run through the postage meter. As the first job is being executed and the first batch of mail is being imprinted with postage, the operator enters the data relating to the parameters for the next job. The operator then loads a second batch of mail for the next job into the postage meter. Provided that the first job has been completed, but without having to once again initialize the postage meter and encounter all of the meter overhead, the second batch of letters for the next job is now run through the meter. The postage meter is continuously readied to receive another batch of mail for a new job at the same time that the preceding job is being completed. Once the final job has been completed, meter information regarding all of the job transactions during the workday is retrieved, analyzed, displayed and saved.