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WO2002009949A1 - Systeme de reclassement associe a une presse electronique d'impression - Google Patents

Systeme de reclassement associe a une presse electronique d'impression Download PDF

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Publication number
WO2002009949A1
WO2002009949A1 PCT/US2000/020877 US0020877W WO0209949A1 WO 2002009949 A1 WO2002009949 A1 WO 2002009949A1 US 0020877 W US0020877 W US 0020877W WO 0209949 A1 WO0209949 A1 WO 0209949A1
Authority
WO
WIPO (PCT)
Prior art keywords
book
books
errored
processor
printing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2000/020877
Other languages
English (en)
Inventor
James L. Warmus
Mark G. Dreyer
Robert W. Gill
Roger Kitzmiller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
RR Donnelley and Sons Co
Original Assignee
RR Donnelley and Sons Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by RR Donnelley and Sons Co filed Critical RR Donnelley and Sons Co
Priority to AU2000265055A priority Critical patent/AU2000265055A1/en
Priority to PCT/US2000/020877 priority patent/WO2002009949A1/fr
Publication of WO2002009949A1 publication Critical patent/WO2002009949A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42C—BOOKBINDING
    • B42C19/00—Multi-step processes for making books
    • B42C19/02—Multi-step processes for making books starting with single sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B42—BOOKBINDING; ALBUMS; FILES; SPECIAL PRINTED MATTER
    • B42P—INDEXING SCHEME RELATING TO BOOKS, FILING APPLIANCES OR THE LIKE
    • B42P2261/00—Manufacturing; Forming
    • B42P2261/04—Producing books by printing sheets in following order, e.g. for ordering via the Internet

Definitions

  • the present invention relates generally to electronic printing presses, and more particularly to a method of and system for selectively reordering the reprinting of books on one or more electronic printing presses .
  • a printing system which has the ability to produce differing book versions and/or books with customized information is disclosed in Riley U.S. Patent No. 4,121,818, assigned to the assignee of the instant application.
  • the printing system includes a number of packer boxes disposed adjacent a binding chain wherein each packer box stores a plurality of signatures.
  • a control is included for controlling the packer boxes to selectively feed signatures onto chain spaces of the binding chain so that books of varying content can be produced.
  • Customized information can be printed on the signatures by means of an ink jet printer which is selectively operated by the control. ⁇
  • Other types of customization can be effectuated, such as by inserting or onserting cards or the like.
  • Image manipulating systems have been developed which permit gathering of images in an office or home environment.
  • conventional word processing programs such as MICROSOFT ® WORD ® , WORDPERFECT ® and the like, permit a user to import images into a page and also allow a user to command which pages of a document to print.
  • macros i.e., a sequence of commands
  • most word processing programs have merge capability wherein a customized image is merged with other standardized information and printed or displayed.
  • customized information in the form of addressee and address information may be merged with standardized return address information and printed on a series of envelopes .
  • a different image gathering capability provided by CAD (computer aided design) software involves the creation and storage of a base page and one or more layer pages.
  • a user can issue commands to display or print the base page and one or more of the layer pages simultaneously atop one another to achieve an effect similar to the overlay of transparencies so that a composite page appearance results .
  • the demand printer produces high quality color images using a set of fusible toners in an electrophotographic process. More particularly, a web of paper is passed adjacent a series of drums, each of which has been electrostatically charged according to an image pattern for a particular color to be applied to the web. The charge is transferred to the paper and an oppositely charged toner of the proper color is brought into contact with the paper. The oppositely charged web and toner attract so that the toner is held on the paper as other colors are applied thereto. The toners and paper are thereafter heated to fuse the toners to the paper to produce the final image. The web is then cut into sheets (or “forms") and the forms are further processed as needed to produce a final product .
  • demand printers are capable of rapidly printing high quality images of differing content owing to the fact that the images are produced by an electrophotographic process. That is, instead of the need to replate and re- engrave a gravure cylinder when a different image is to be printed therewith, it is only necessary to change the charge applied to the drums of the printer in order to make such change. Thus, different images can be printed by the same printer without significant delays.
  • This advantage makes the demand printer desirable for use in certain production environments. However, applicants are currently unaware of any systems developed by others which utilize this advantage to produce differing book versions in an efficient manner.
  • the demand printer simply reruns the current j ob .
  • a job or production run is processed as a stream of books to be printed. Such streams are often on the order of 1,000 books or more.
  • the stream of books is continually printed from the first book to the last.
  • the press does not necessarily wait for the complete printing of a first book before beginning to print a second book.
  • the press operator was often forced to identify errored books and to manually request the press to reprint the errored books after the corresponding job of printing 1,000 or more books was completed.
  • a first discount level such as an automated carrier route discount is provided for mailings of ten pieces of mail or more sorted by carrier route
  • a second discount level such as an automated five digit discount is provided for mailings of ten pieces or more sorted by five-digit zip codes
  • a third discount level such as an automated three digit discount is provided for mailings of ten pieces or more sorted by the first three digits of the addressees' zip codes
  • a fourth level of discount is provided for mailings of ten pieces or more sorted by state (i.e., the first zip code digit) .
  • the books in the jobs are typically pre-sorted to obtain an optimum level of discount within this discount structure.
  • reordering after completion of the job required manual re-sorting to avoid loss of postal discounts for the errored book(s) or, in a worst-case scenario, loss of discounts for the group (s) of books with which the errored book(s) are associated.
  • manual reordering of errored books and manual re-sorting of reprinted books introduced delay and costs into the printing process.
  • auxiliary finishing devices such as folding devices, trimming devices, weighing devices, binding devices, gluing devices, dot wackers, tip-ons, card feeders, strappers, and/or mechanical co-mailers.
  • Such auxiliary devices can be coupled to the press thereby permitting processing of books as they are printed, or they can be free-standing thereby requiring transportation of books from the press to the auxiliary device for further processing.
  • auxiliary devices can foul a printed book from time to time.
  • a reorder system for use with an auxiliary device adapted to perform a process on a book printed by a first printing press printing a stream of books.
  • the reorder system comprises a first sensor located downstream of the auxiliary device; and a processor in communication with the first sensor.
  • the processor is adapted to recognize an errored book and to cause the errored book to be reprinted after at least one other book has been printed by the first printing press.
  • the processor comprises a global processor and a local processor, the local processor being associated with the auxiliary device.
  • the apparatus is provided with a press processor associated with the first printing press for controlling the operation thereof, and the global processor is in communication with the press processor for causing the first printing press to reprint the errored book in response to signals received by the global processor from the local processor.
  • the apparatus can also be utilized with a second printing press, wherein the global processor is in selective communication with a first press processor associated with the first printing press and with a second press processor associated with the second printing press, and wherein the global processor selectively causes the errored book to be reprinted on one of the first and second printing presses.
  • the global processor can be programmed to select the one of the first and second printing presses to minimize processing time and/or to maximize postal rate discounts.
  • the global processor selects the one of the first and second printing presses by comparing postal information for the errored book to postal information of a book to be printed by the first printing press, and/or by comparing the postal information for the errored book to postal information of a book to be printed by the second printing press.
  • the errored book preferably comprises fixed and variable data
  • the apparatus is provided with a log identifying the fixed and variable data to be used to reprint the fouled book.
  • a reorder system for use with a first and a second printing press.
  • the reorder system comprises a global processor in selective communication with first and second press processors; and a sensor located downstream of the first printing press.
  • the sensor is coupled to the first press processor whereby the first press processor can detect errored books and wherein, the first press processor notifies the global processor of the errored book and the global processor causes one of the first and second presses to reprint the errored book.
  • the global processor selects the corresponding one of the first and second printing presses to minimize processing time. In other embodiments, the global processor selects the corresponding one of the first and second printing presses to maximize a postal rate discount.
  • a reorder system for use in a printing facility having first and second printing presses wherein each of the first and second printing presses are adapted to produce books including both variable and fixed data.
  • the reorder system includes a first sensor located to monitor books output by the first printing press; and a first press processor associated with the first printing press and in communication with the first sensor to recognize errored books.
  • the first press processor is adapted to control a printing order of books in a stream of books to be printed by the first printing press in a given job.
  • the first press processor causes the first printing press to insert the errored book into the stream of books to be printed after at least one other book has been printed.
  • the errored book is only inserted into the stream of books if re-printing the errored book with the stream will entitle the errored book to a predefined postal discount.
  • the reorder system is further provided with a global processor in selective communication with the first press processor, wherein, if the first press processor determines that reprinting the errored book with the stream will not entitle the errored book to the predefined postal discount, the first press processor identifies the errored book to the global processor.
  • the global processor can be programmed to instruct a second press processor associated with the second printing press to cause the second printing press to re-print the errored book if re-printing the book on the second printing press will entitle the errored book to a second predefined postal discount .
  • the first and second postal discounts may be different or identical.
  • the system is provided with a second sensor located to monitor books output by the second printing press, and a second press processor associated with the second printing press and being in communication with the second sensor to recognize errored books .
  • the second press processor is adapted to control a printing order of books in a stream of books to be printed by the second printing press in a given job, wherein, upon recognizing an errored book, the second press processor causes the second printing press to insert the errored book into the stream of books to be printed if re-printing the errored book with the stream will entitle the errored book to a second predefined postal discount.
  • the system can also be provided with a global processor in selective communication with the first and second press processors, wherein if the first' press processor determines that re- printing an errored book with the stream associated with the first printing press will not entitle the errored book to the predefined postal discount, the first press processor identifies the errored book to the global processor. Similarly, if the second press processor determines that re-printing an errored book with the stream associated with the second printing press at this time will not entitle the errored book to the second predefined postal discount, the second press processor identifies the errored book to the global processor.
  • the global processor can be adapted to develop a new job to re-print errored books received from the first and second press processors.
  • a method for reordering an errored book detected at an auxiliary device located downstream of a printing press printing a stream of books containing variable data and fixed data comprises the steps of: creating at least one database identifying the variable and fixed data to be included in each book in the stream of books; recording an identifier of each book exiting the auxiliary device; comparing the identifiers of the books exiting the auxiliary device to the at least one database to recognize an errored book; and, ordering the printing press to reprint an errored book by using the identifier of the errored book to access the at least one database and providing the fixed and variable data needed to reprint the errored book to the printing press.
  • a method for reordering a book printed by a first printing press printing a stream of books comprises the step of: identifying a book in the stream of books to be reordered; and reprinting the book on the first printing press.
  • Such a method can optionally be provided with the further steps of: if reprinting the book on the first printing press without re-sorting the stream of books will not entitle the reprinted book to a predefined postal discount, determining if reprinting the book on a second printing press printing a second stream of books without resorting the second stream will entitle the reprinted book to a second predefined postal discount; and reprinting the book on the second printing press if the reprinted book will be entitled to the second predefined postal discount.
  • a method for reordering a book printed by a first printing press printing a first stream of books comprises the steps of: identifying a book in the first stream of books to be reordered; determining a first postal discount that the reprinted book will be entitled to if reprinted on the first printing press if the first stream of books is not resorted; determining a second postal discount that the reprinted book will be entitled to if reprinted on a second printing press printing a second stream of books if the second stream of books is not re-sorted; comparing the first postal discount to the second postal discount; and, selecting one of the first or second printing presses for reprinting the book based on the comparison between the first and second postal discounts.
  • Fig. 1 is a block diagram illustrating a prior art method of producing books
  • Fig. 2 is a block diagram of a method of producing books
  • Fig. 3 is a block diagram illustrating an exemplary system for implementing the method illustrated in Fig. 2;
  • Fig. 4 is a block diagram illustrating one of the demand printing systems of Fig. 3 in greater detail
  • FIG. 5 is a generalized diagram of the certain steps implemented by the method of FIG. 2;
  • Figs. 6a and 6b are elevational views of a sample book;
  • Figs. 7a, 7b and 8a, 8b are elevational views of other sample books
  • Fig. 9 is a flowchart illustrating programming that may be executed by a user on a personal computer to create the template files 105 of Fig. 5;
  • Figs. lOa-lOf when joined along similarly- lettered lines, together represent programming executed by the control unit 52 of Fig. 3;
  • Figs, lla-llc when joined along the similarly- lettered lines, together represent programming executed by the control unit 52 of Fig. 3 to impose pages to be printed by one of the demand printing systems of Fig. 3;
  • FIG. 12 illustrates programming executed by the control unit of 52 of Fig. 3 to convert page files into bitmap format .
  • FIG. 13 is a schematic illustration of a reorder system constructed in accordance with the teachings of the invention.
  • FIGS. 14a-14d are flow charts illustrating exemplary programmed steps performed by the set-up processors and press processors illustrated in FIG. 13.
  • FIGS. 15a-15f illustrate an exemplary reorder log in various states of completion.
  • FIG. 16 is a flow chart illustrating exemplary programmed steps for preparing a global reorder table.
  • FIGS. 17a- 17d illustrate an exemplary global reorder table in various states of completion.
  • FIGS. 18a-18g are flow charts illustrating exemplary programmed steps performed by the global reorder processor of FIG. 13.
  • FIG. 19 is a flow chart illustrating exemplary programmed steps performed by the press processors shown in FIG. 13 at the completion of a job.
  • FIG. 20 is a flow chart illustrating exemplary programmed steps performed by the local processor associated with an auxiliary finishing device.
  • FIG. 21 is a flow chart illustrating exemplary programmed steps performed by a local processor associated with a weight verification device.
  • FIGS. 22A-22B are a flow chart illustrating exemplary steps performed by the global reorder processor at the end of a job.
  • FIG. 23 is a schematic illustration of an exemplary human interface display generated by the global reorder processor.
  • Fig. 1 illustrates a prior art method of producing books, for example as shown in the above- identified Riley et al . '818 patent identified above.
  • a publishing step 20 the contents of one or more book versions are determined. Each version may comprise, for example, a set of standard or common pages. In addition, some of the versions may include one or more additional pages or other customized information.
  • color correction of color images is undertaken together with undercolor removal and screening for halftone images.
  • page imposition is effected and printing cylinders or plates are prepared. The plates or cylinders are then used during a printing step 26 to prepare signatures which are loaded into packer boxes (not shown) .
  • packer boxes not shown
  • the signatures are then selectively collected on a gathering chain (not shown) during a book assembly step 28 and the gathered signatures are bound and trimmed to create the books.
  • the books are thereafter distributed during a step 30 to users via one or more distribution systems, for example, the U.S. Postal Service.
  • customization occurs during the book assembly step 28, inasmuch as the choice of particular signatures to be included in a book is made at that time.
  • customized information can be printed onto selected signatures using an ink jet printer disposed adjacent the gathering chain.
  • addressee information can be printed by the ink jet printer on assembled books so that preprinted addressee labels need not be used.
  • Other types of customization can be effected at this time, for example, by inserting or onserting cards into or onto a stack of collected signatures, affixing a specialized or customized cover on a gathered stack of signatures, or the like. Customization at this point in the production process is simpler and less expensive than, for example, separately printing each book version with customized information.
  • Fig. 2 illustrates a block diagram of a method 40 which may be used in place of the method of Fig. 1 to produce books.
  • the method 40 includes a step 42 which utilizes the output of publishing and preliminary steps 36, 38 and produces books for distribution according to the step 30 of Fig. 1.
  • the step 42 creates one or more master and variable page files in, for example, a page description language (PDL) such as POSTCRIPT ® (POSTCRIPT ® is a trademark of Adobe Systems, Inc. for its page description language) representing pages to be produced.
  • PDL page description language
  • POSTCRIPT ® is a trademark of Adobe Systems, Inc. for its page description language
  • a press command file is developed which specifies the manner in which data contained within the master and variable page files are to be merged to produce printed pages.
  • the format of the press command file is specified by Barco Graphics of Gent, Belgium and is particularly suited for control of a DCP-1 digital color press manufactured by Xeikon of Mortsel, Belgium. It should be noted that the apparatus and method of the present invention are not limited to use with a particular type of demand printer or a particular system for controlling such a printer, inasmuch as the invention can be adapted for use with any type of printer or control whether located locally or remotely.
  • the master and variable page files and the press command file are converted by a collator and raster image processor (RIP) into bitmaps which may be stored in a memory.
  • the stored bitmaps are used to control one or more demand printers and/or any other type of display device, such as a laser printer, a CRT, an LCD display or the like so that the device displays pages having fixed and variable information thereon.
  • the master and variable page files may be premerged to create a plurality of combined files each representing a page to be reproduced with master and variable information.
  • the combined files can be then sent to any type of printer or other display device, whether local or remote.
  • the combined files can be converted to a suitable format (e.g., ACROBAT ® PDF format) and transmitted to a remote location using a facsimile machine, e-mail or other transmission medium if desired.
  • the assembled books are bound and trimmed and, if desired, further customization can be effected.
  • Fig. 3 illustrates a system 50 which implements the steps 36, 38 and 42 in the method 40 of Fig. 2.
  • a control unit 52 which may be implemented by a personal computer or another type of computer, includes a memory 53 and stores therein data representing images to be printed.
  • the data may be specified by a publisher using a personal computer 54 or any other type of computer and may comprise one or more template files specifying pages to be produced with master or fixed printed information (i.e., printed information which does not vary from book to book of the same version) and variable printed information (which typically varies from book to book) .
  • variable information may be stored in a database created by the publisher and the template file(s) specify the locations on particular pages for variable information stored in the database as noted in greater detail hereinafter.
  • image data may be obtained from any other type of device or devices, such as a scanner which scans input copy, data supplied over a network or any other source .
  • the control unit 52 is further responsive to control and makeready files and causes one or more demand printing systems 62a, 62b, 62c to print desired pages. While three demand printing systems 62a-62c are illustrated in Fig. 3, it should be understood that the control unit 52 may operate a different number of demand printing systems, as desired.
  • control unit 52 may operate a fax machine 64 and/or may communicate with other remote devices to send properly converted combined files, as desired and as noted above.
  • the combined files may be printed or may alternatively be reproducible in a different medium and/or may comprise a non-static image or other information, i.e., movies or audio.
  • the pages printed by the demand printing system 62a, 62b, 62c may be supplied to a finishing apparatus 66 which includes various auxiliary production devices and device interfaces for assembling the pages to produce finished books which are ready for distribution.
  • the finishing apparatus 66 may include one or more gathering devices 70 for gathering printed pages into books, one or more ink jet printers 72 for printing additional customized information, such as addressee information, on each book, one or more label printers 74 for printing address labels and/or other control devices 76.
  • one or more detectors 78 may be provided to sense when a defective book is produced.
  • the control unit 52 may be responsive to the output of the detector 78 to reorder a defective book at an appropriate point in the production sequence thereof so that advantage can be taken of postal discounts, if possible.
  • Fig. 4 illustrates the demand print system 62a of Fig. 3 in greater detail, it being understood that the systems 62b and 62c are identical thereto.
  • the system 62a includes a print system 79 having a press controller 80, a collator 81 and a raster image processor (RIP) 82 which are operable in response to press commands generated by the control unit 52.
  • RIP raster image processor
  • a collator is an electronic device for storing raster image processor files (i.e., bitmap files) and delivering selected files to a digital press in real time, such that the digital press can run at full speed while processing and printing unique page data for each book produced on the press .
  • the RIP 82 converts the page files to bitmap format or any other format, such as a symbolic printer control language.
  • the collator 81 includes memory in the form of mass storage drives and physical memory and collates the bitmap page files. If desired, the collator 81 and/or RIP 82 may comprise a part of the press controller 80. The controller 80 instructs the collator 81 to send page files to the demand printer 84.
  • the print system 79 may comprise the PrintStreamer system, manufactured and marketed by Barco Graphics of Belgium, while the demand printer 82 may comprise the Xeikon DCP-1 digital color press noted above. It should be noted that a different print system and/or demand printer may alternatively be used, such as the Indigo printer manufactured by Indigo NV, of Maastricht, Netherlands if desired.
  • a first sheet of paper 100 is to be printed on a first side 100a with printed pages PI, P4 while a second side 100b of the sheet 100 is to be printed with pages P2, P3.
  • pages P1-P4 are to be imposed such that the page PI is placed on a right-hand portion lOOa-r of the side 100a while the page P4 is placed on a left- hand portion lOOa-1 of the side 100a.
  • the page P2 is to be placed on a left-hand portion lOOb-1 of the side 100b while the page P3 is to be placed on a right- hand portion lOOb-r of the side 100b.
  • the sheet of paper 100 is folded along a fold line 102 with the pages PI and P4 on the outside, the pages P1-P4 will appear in sequence.
  • each book to be produced in this example comprises only a single sheet of folded paper
  • the imposition process need not take into account shingling or bottling effects, although it should be noted that such effects may have to be taken into account when more than one sheet of paper is assembled with other sheets of paper to produce a book and/or when more than two pages are to be printed on a single side of a sheet of paper and thereafter assembled with other pages to create a book.
  • the three books to be produced include variable and fixed information on the first and last pages of each book and fixed information only on the remaining pages.
  • the page PI may include variable information in the form of a personalized message, a variable image, or the like in an area 110 whereas the page P4 may include other variable information in an area 112, for example, postal information for mailing the brochure to an addressee.
  • Corresponding front and back pages of the remaining books may include different variable information.
  • the remaining printed information on pages P1-P4 is identical to the printed information on corresponding pages of the other two books .
  • the present invention is not limited to production of books of the same "version" (i.e., books having the same master information) .
  • the book versions of Figs. 7a, 7b and 8a, 8b may be produced together with the book version of Fig. 6a and 6b in the same production run or job.
  • the book version example of Figs. 7a and 7b includes pages P5-P8 to be reproduced a number of times to produce individual books.
  • the book version of Figs. 7a and 7b is identical to the book version of Figs. 6a and 6b except that an additional area 113 is provided on the page P5 for placement of variable information, in addition to the areas 110 and 112. Because of the addition of the area 113, the remaining master information appearing in an area 114 differs from master information appearing in an area 116 of the page PI of Fig. 6a.
  • the book version example of Figs. 8a and 8b differs from the book version examples of Figs. 6a, 6b and 7a, 7b not only in terms of content of master and variable information, but also number of pages and page size.
  • eight pages P9-P16 are to be printed wherein the pages P9, P12 , P13 and P16 are to be printed in a first side 117a of a sheet of paper 118 and the remaining pages P10, Pll, P14 and P15 are to be printed on a second side 117b of the sheet 118.
  • the pages P11-P14 are printed upside down relative to the remaining pages so that, when the sheet 118 is folded first along a fold line 119a and then along a fold line 119b, the resulting pages P9-P16 appear in order. Thereafter, the folded sheet 118 is trimmed to separate the pages P9-P16.
  • the pages P9-P16 are one-half the size of the pages P1-P8, and further include different master and variable information thereon.
  • books assembled from multiple printed “forms” may alternatively or in addition be produced, if desired.
  • one or more template files 106 are developed by a publisher specifying the content (including appearance) of fixed information and the positioning of all information (i.e., fixed and variable) on the different books or book versions.
  • a database 108 is also developed by the publisher using the personal computer 54 specifying the content of variable information to be placed in variable information areas, for example, the areas 110, 112 on the pages PI, P4 , respectively, of Figs. 6a and 6b.
  • the database 108 further includes control information, as noted in greater detail hereinafter.
  • the template files 106 include data specifying the position and content of fixed information on the pages to be printed.
  • the template files 106 define template pages wherein each template page includes data representing any fixed information to be reproduced on corresponding pages of the books or book versions and area data representing any area(s) on the corresponding pages where variable information is to be reproduced.
  • the template files are duplicated to create working, files .
  • One set of working files is stripped of all area data relating to placement of variable information to create stripped master page files 120 defining template pages having only fixed information thereon.
  • the stripped master page files are then converted into PDL master page files 122 expressed in a page description language, such as POSTSCRIPT ® .
  • An optional imposition process may then convert the PDL master page files 122 into imposed master page files 124 each representing a side of a piece of paper to be printed with at least one, and, likely, two or more template pages having fixed information only thereon.
  • a template page may be identical to that shown in Fig. 6a except that the areas 110 and 112 are removed therefrom.
  • a further set of working files is stripped of all fixed information to create stripped variable page files 126 defining template pages having fixed information removed therefrom and further having the area data defining the areas 110, 112.
  • the data representing template pages having variable information thereon are expanded into a set of intermediate page files.
  • two intermediate page files 130, 132 are thus produced.
  • the file 130 includes a file portion Pl-a defining the position of variable information to be produced on the page PI for the first book.
  • Two other file portions Pl-b and Pl-c define the position of variable information to be produced on the front pages of the remaining two books.
  • file portions P4-a, P4-b and P4-c represent the position of variable information to be reproduced on the last pages of the three books.
  • data are also contained in each of the files 130, 132 identifying the entries in the database 108 to be placed in the areas 110, 112 during printing.
  • the files 130, 132 are then converted into variable page files 134, 136.
  • the files 134, 136 are identical to the files 130, 132, respectively, except that the data in each file identifying entries in the database are replaced by the actual data stored at such entries .
  • the files 134, 136 are converted into files 137, 138 in a PDL format, for example, POSTSCRIPT ® .
  • An optional imposition process may convert the PDL files into imposed final variable page files 139.
  • the print system 79 operates in response to the press commands in a press command file 140 and merges the page files 122, 137 and 138 (if no imposition is to be effected) or merges the page files 124 and 139 (if the pages are imposed) to create the finished books or book versions .
  • Fig. 9 illustrates a flow chart of programming executed by the personal computer 54 for creating the template file(s) 106 of Fig. 5.
  • the programming may be written as an extension of QUARKXPRESS ® , a page make-up program distributed by Quark, Inc. of Denver, Colorado.
  • the QUARKXPRESS ® program may be adapted for operation on the APPLE ® MACINTOSH ® operating system or any other operating system, such as the MICROSOFT WINDOWS ® operating system. Alternatively, a different page makeup program may be used, if desired.
  • a template file is created for each book version to be produced, or, where a book is to include two or more parts (referred to as "sections" hereinafter) a template file may be created for each section.
  • a user may select an area of a page for reproduction of variable information therein, at which point a line object, a text object or an image object may be selected.
  • a block 152 then checks to determine which type of object has been selected.
  • variable text is to be inserted at a point defined by the current cursor position on the computer display
  • the name of the appropriate field in the database 108 is inserted into the template file at the insertion point defined by the current cursor position (block 154) .
  • control returns to the block 150 to await selection by the user.
  • a box is defined by the user to contain an image at a desired location on a selected page.
  • Control from the block 152 thereafter passes to a block 158 which inserts a dummy picture file and an indication of the proper database field name in the template file for the page at the location indicated by the current cursor position.
  • the user will thereafter see the dummy picture file at the insertion point on the display of the computer 54 when the page is viewed.
  • the dummy picture file will display an indication of which database field will be used for insertion on the respective pages.
  • a block 160 prompts the user to enter an indication of whether the image object is to be displayed in one of two display formats. If the image is to be displayed in other than the original size thereof, a block 162 sets a subname defined for the image to "fit,” indicating that the image is to be scaled to fit the box. If the image is to be displayed in the original size thereof, a block 163 prompts a user to select a position for the image at a particular location in the box defined therefor, such as the upper left-hand corner, the lower right-hand corner, or the like. If the user does not select a position, the image is placed in the upper left corner of the image box. Control thereafter proceeds to the block 156.
  • control returns directly to the block 150, inasmuch as variable information cannot be entered into a line object.
  • other functional aspects of the QUARKXPRESS ® program may be invoked as necessary to produce finished pages.
  • the resulting page template files (s) are stored on a storage medium, such as an optical disc or other storage device, and/or the file(s) are downloaded together with the database to the control unit 52.
  • the database 108 is assembled by creating an
  • ASCII file having a plurality of records wherein each record includes one or more fields entered into the database in tab-delimited format (i.e, the fields are separated from one another in each record by tab keystrokes and the records are separated from one another by line returns) and wherein the fields are arranged under field names of a header.
  • Each field may include text to be reproduced on a page or a name of an image file stored in the memory 53 and defining an image to be reproduced on a page.
  • the database 108 may include an optional field designating the number of copies of each book to be produced, an optional townsort image field, a version identification field indicating book version number if multiple book versions are to be produced, an optional distribution list field, control data and the like.
  • a sample database is set out below having a header consisting of twelve fields (i.e., "version,” “addresslinel, “ “addressline2 , “ etc.) and a number of records, nine of which are shown, each having twelve fields :
  • the field names ADDRESSLINE1 through ADDRESSLINE5, BARCODE and TOWNSORT may appear in the area 112 and one or more of the field names PRICE1, IMAGE1 AND PRICE2 may appear in the area 110.
  • the VERSION field would not be used.
  • the COPIES field may be used as a control code to select the number of book copies to be produced .
  • a block 170 prompts a user to select a template file 106 and a block 172 opens the database 108.
  • a block 174 then reads and stores in a list the database field names for later reference and a block 176 prompts a user to enter information indicating a section number and whether pages are to be printed in simplex (i.e., single- sided) or duplex (i.e., double-sided) format.
  • the section number identifies the order in which multiple sections are to be processed for a particular book.
  • the user may also be prompted to enter a selective processing code identifying a particular book version to process if multiple versions are to be produced during a single press run.
  • a block 177 begins the process of stripping variable information from the template file opened by the block 170 to obtain the stripped master file 120 of Fig. 5.
  • the block 177 selects a first page for processing and a block 178 checks to determine whether there are any images in the template file and, if images are located, a block 180 selects a first image.
  • a block 182 identifies the file name for the image and a block 184 checks the field list to determine whether the file name is included therein. If the file name for the image is included in the field list, then the image comprises variable information and a block 186 deletes the image block. Otherwise, the block 186 is skipped and a block 188 checks to determine whether all images have been processed.
  • a block 190 selects a next image and control returns to the blocks 182-188. Control remains with such blocks until the block 188 determines that all images have been processed and control then passes to a block 192. Control also passes to the block 192 from the block 178 should the latter determine that there are no images in the template file.
  • the block 192 determines whether any text boxes are present in the open template file. If at least one text box is present, a block 194 selects and parses a first text box and a block 196 checks to determine whether the text box includes at least one of the field names of the database 108. If so, then it has been determined that the text box includes variable information and a block 198 deletes the text box.
  • a block 200 checks to determine whether all text boxes in the template file have been processed. If not, a block 202 selects and parses the next text box in the template file and control returns to the blocks 196-200. Control remains with such blocks until all text boxes have been processed, whereupon a block 203 determines whether all pages have been processed. If not, a block 204 selects a next page and control returns to the block 178. Otherwise, a block 205 saves the resulting file as the stripped master file. Control also bypasses the blocks 194-202 and proceeds directly from the block 192 to the block 203 if there are no text boxes in the open template file.
  • a block 206, Fig. 10b converts the stripped master file into the PDL master page file 122 of Fig. 5.
  • an initialization (or INI ) file is created in ASCII code according to the following format :
  • one copy of the file MYJOB.PS is to be printed in duplex and portrait formats at an offset of 0.15 x 0.15 inches from a corner of a finished sheet of paper 8 x 11 inches cut from a sheet originally having dimensions of 9 x 11.5 inches.
  • a block 208 then reopens the same template file originally opened by the block 170 to begin the process of creating the stripped variable page files 126 of Fig. 5.
  • a block 209 selects a first page and a block 210 checks to determine whether there are any images in the file and, if so, a block 212 selects a first image for consideration.
  • a block 214 identifies the file name for the image and if a block 216 determines that the file name is not in the field list, then the image comprises fixed information (i.e., image will be the same in all of the books of a given version) and hence the image box is deleted by a block 218.
  • the image is of the variable type (i.e., the image changes with the books of a given book version) , and hence a block 220 identifies and saves the image box location on the page, the characteristics of the image box, such as the size, skew, background color and subname and the like and further saves the field name of the image from the database 108. Also, a counter in the memory 53 which tracks the number of variable image boxes on the page is incremented.
  • Control from the blocks 218 and 220 passes to a block 222 which checks to determine whether all images have been processed. If not, a block 224 selects a next image and control returns to the blocks 214-222. Otherwise, control proceeds to a block 226 which begins the process of selecting and identifying text boxes . Control will also pass to block 226 from block 210 if, at block 210, it is determined that there are no images in the file. If there are text boxes present in the template file, a block 228 selects and parses a first text box and a block 230 checks the parsed text box to determine whether it includes one or more field names from the database. If not, then it has been determined that the text box includes only fixed information, and hence a block 232 deletes the text box.
  • a block 234 stores the text box location, the insertion points in the text box at which variable information is to be printed and the characteristics of the text box and the field names of the database 108 identified in such text box in the memory 53.
  • a variable text box counter is incremented representing the number of text boxes appearing on each page. Control from the blocks 232 and 234 proceeds to a block 236 which checks to determine whether all text boxes have been processed. If not, a block 238 selects and parses the next text box and control returns to the blocks 230-236.
  • a block 239 determines whether all pages have been processed and, if not, a block 240 selects the next page and control returns to the block 210. Otherwise, control passes to a block 241, Fig. 10c, which saves the resulting file as the stripped variable file 126 of Fig. 5.
  • Control also passes to the block 239 from the block 226 if there are no text boxes found.
  • a block 242 then creates a working copy of the stripped variable file 126 and a first page having variable data thereon is selected and data representing the remaining pages in the file are deleted by a block 244.
  • the block 244 creates a file defining the front page of a book with all fixed information deleted therefrom and an area reserved for variable information.
  • a block 246 selects a first record in the database 108 and a -block 248 reads the record.
  • An optional block 250 checks to determine whether a selective processing code has been entered by the user indicating that the page is to undergo selective page processing.
  • the subject apparatus and method may be utilized to produce not only books of a single version (i.e., where corresponding pages differ only in terms of the variable information stored in the database) but also books of different versions. In the latter case, the books of different versions have different fixed and variable information.
  • the fixed and/or variable information may vary in terms of content or appearance (i.e., style, location, rotation, position, etc.) or both in different versions.
  • a block 252 checks to determine whether the database record read by the block 248 is utilized on the page currently under consideration. If this is not the case, a block 253 checks to determine whether the record currently under consideration is the last in the database. If so, control passes to a block 294 of Fig. lOe. Otherwise, a block 254 selects a next record in the database 108 and control returns to the block 248 where the next database record is read.
  • a block 256 duplicates the data representing the page remaining after execution by the block 244 to initiate development of one of the files 130 or 132.
  • the block 256 creates the file 130 and develops page data representing a first version of the page PI-a and adds further variable information to such page data during immediately succeeding passes through the program.
  • a block 258 checks to determine whether there are any image boxes on the page and, if so, a block 260 selects a first image box.
  • a block 262 then inserts the image identified by the database field into the image box.
  • a block 264, Fig. lOd checks the subname to determine whether the block 162 of Fig. 9 has indicated that the image should be sized to fit the image box. If this is true, a block 266 performs the scaling. Otherwise, a block 268 positions the image in the image box at the position specified by the user and a block 270 checks to determine whether all image boxes have been processed.
  • Control also passes from the block 266 directly to the block 270, thereby skipping the block 268. If not all image boxes have been processed, a block 272 selects a next image box on the page and control returns to the blocks 262-270 so that remaining image boxes are serially processed.
  • a block 274 checks to determine whether there are any text boxes on the page and, if so, a pair of blocks 276, 278 select a first text box and a first insertion point in such box. (If no text boxes are on the page, control proceeds from block 274 to block 292 (FIG. lOe) ) .
  • Blocks 280, 282 and 284 serially insert text data stored in the database 108 at the appropriate insertion points in the text box. The appropriate insertion points are selected by block 284.
  • a block 286 recomposes all text in the text box so that the text obtains a neat finished appearance.
  • the recomposition process is automatically undertaken by the QUARKXPRESS ® program once the variable information is inserted into each text box.
  • the recomposition process is responsive to the user commands as applied to the template file page, such as left, right, center, or full justification, hyphenation and the like.
  • a block 288, Fig. lOe checks to determine whether there are remaining text boxes to be processed on the page and, if so, a block 290 selects the next text box on the page and control returns to the blocks 278-288 to insert text information into such text boxes.
  • a block 292 determines whether all records in the database have been considered for inclusion in additional variable pages of the file 134 to be produced. If not all records have been considered, control returns to the block 254, Fig. 10c, where the next database record is identified and read. On the other hand, if all pages of the file 134 have been produced by considering all records in the database 108, a block 294 converts the file data into POSTSCRIPT ® or another PDL format to create the variable page file 137 of Fig. 5.
  • an INI file is created as before, except that the "duplex" parameter is set to command simplex printing only. If necessary or desirable, should the press run length exceed a certain limit, the programming may be modified to create more than one variable page file for each variable page of the template file.
  • a block 296 checks to determine whether there are other variable pages in the stripped variable page file to be processed. If there are other pages to process (i.e., the answer to the inquiry is "yes"), a block 298 produces a new copy of the stripped variable file, selects the next variable page therein and deletes remaining pages therefrom. Control then returns to the block 246 of Fig. 10c. In the example of Figs. 6a and 6b, the back page P4 and the corresponding pages of the remaining books are now selected for processing. In the fashion noted above, a file representing the variable portions of such pages is produced by developing the file representing the pages P4-a through P4-c and inserting the database information into such file to obtain the variable page file 136 and the PDL version 138. Following generation of the variable page files
  • the press command file may also include data from one or more fields of the database 108 identifying an intended recipient of each book to be produced to assist in reproducing books found to be defective or to produce sample books.
  • the press command file for the example of Figs. 6a and 6b may be as follows (using data' from the sample database set out above) :
  • a block 304 selects the first database record and a corresponding first record in the press command file.
  • A. block 306 then checks to determine whether the template file currently being processed includes the selected database record. If not, a block 308 determines whether all pages have been processed, and if this is not the case, the next record in the database 108 and a corresponding record in the press command file are selected. Control then returns to the block 306. If the block 306 ascertains that the template file includes the selected record, a block 312 inserts an indication of the section number in the press command file at an appropriate point if the section number is not already present. If the section number is present already, the press command identified by the section number entered by the user at the block 176 is identified to be overwritten at a later point.
  • the press command file now appears as follows for the example of Figs. 6a and 6b:
  • a block 314, Fig. lOf selects a first page of the section and a block 316 checks the state of a flag stored in the memory 53 to determine whether a simplex or duplex job has been requested. If a simplex job has been requested, the file name and page number of the master page file and, if variable information is to appear on the page, the file name and page number of the variable page file for the selected page are stored as a single set pair in the memory 53 by a block 318. The determination of whether variable information is to appear on the selected page is accomplished by summing the contents of the variable image box counter and the variable text box counter as incremented by the blocks 220 and 234 of Fig. 10b.
  • a block 320 checks to determine whether all pages have been processed and, if not, the next page is selected by a block 322 and control returns to the block 316 for processing of such page. If all pages have been processed, control passes to a block 324 which determines whether all database and press command records have been processed. Control also passes to the block 324 if the block 308 determines that all pages have been processed. If not all records have been processed at this point, control returns to the block 310 where the next records in the database and press command file are selected.
  • a block 326 determines whether another section is to be processed and, if so, control returns to the block 170 of Fig. 10a. If there is not another section to be processed, the press command file has been fully assembled, and hence the process terminates. If the block 316 determines that a duplex job is to be effected, control passes to a block 328 which stores in the memory 53 a command identifying the file names and page numbers of the master page file (as well as corresponding information relative to variable page files, if variable information is to appear) as two-set pairs. Control from the block 328 then passes to the block 320 described above.
  • Figs. lOa-lOf The result of the programming of Figs. lOa-lOf is a press command file having a sequence of press commands which cause printing of pages in a desired order.
  • the press command file would read as follows :
  • file.m is a file name identifying the master page file 122
  • file.l and "file.4" are file names identifying the variable page files 137 and 138, respectively.
  • the number following each file name designates a particular page of the file identified by the file name.
  • file.m designates the first page of the master file
  • file.l designates the second page of the variable page file "file.l.”
  • the @ sign means to associate the pages of the files linked by such sign and the vertical line in the commands indicates that the page(s) on the left side of the vertical line are to be printed on the front side of a piece of paper whereas the page (s) on the right side of the vertical line are to be printed on the reverse side of the piece of paper.
  • no file name would appear to the right of the vertical line in each command.
  • Figs, lla-llc illustrate an exemplary imposition system which may be used to impose pages for printing.
  • the imposition system of Figs, lla-llc is invoked to create a new press command file which prints at least one, and likely two or more pages on one or both sides of a form.
  • the programming begins at blocks 340 and 342 which open the press command file and select a first record therein.
  • a block 344 then reads such record and a block 346 determines the number of master pages that are in the press command file record read by the block 344.
  • each book includes four master pages.
  • the block 346 determines the number of master pages in the record to determine page assignments to the various forms.
  • "form” designates a single sheet of paper as printed by the press. Each form has two sides, each of which is referred to as a “flat.” Each flat includes a number of pages thereon, wherein the number is hereinafter referred to as the "PPF" number (for "pages- per-flat” number) .
  • a block 348 determines the book or the book version to be produced during the print job having the greatest number of book pages .
  • This book or book version is hereinafter referred to as the "largest book”.
  • a block 350 then prompts a user to enter various imposition parameters including shingling and bottling amounts, placement and appearance of press marks, head direction of each page (when not all pages have the same head direction, for example, as seen in Figs. 8a and 8b) page position (s) on each flat and any other required imposition parameters.
  • the user is prompted to enter the PPF number for each flat type to be produced. For example, the user may be prompted to enter a PPF number of two for the examples of Figs.
  • the parameters may be specified by a user using any commercially available and suitable imposition system such as PREPS ® , by ScenicSoft, Inc. of Everett, Washington, IMPOSTRIP ® , by Ultimate Technographics of Montreal, Quebec, Canada, Quark IMPOSITION ® by Quark, Inc. of Denver, Colorado, or any other system.
  • imposition system disclosed in Sands et al. U.S. Patent Serial No. 738,217, filed July 30, 1991, now U.S. Patent 5,634,091, issued May 27, 1997, and entitled "Digital Page Imaging System" can be used.
  • a block 352 develops an imposition pattern allowing a block 354 to derive the specified imposition patterns.
  • This step effected by the block 352 is necessary inasmuch as the specified imposition parameters are not directly available to such programming, and hence the parameters must be obtained by selecting the largest book or book version to be produced and imposing same so that the imposition parameters can be deduced therefrom. If the imposition parameters can be provided to the programming of Figs, lib and lie directly, then the blocks 352 and 354 would be unnecessary and may be omitted.
  • a block 356, Fig. lib associates master and variable pages to appear on the same flat with each other according to the PPF number for such flat to obtain a master/variable page group for each flat.
  • the master and variable files for the pages PI and P4 would be associated together.
  • the master and variable files for the pages P9, P12, P13 and P16 would be associated by the block 356.
  • a block 358 selects a first master/variable page group and a block 360 determines the form depth of the master/variable page group.
  • the "form depth" is the position of a printed flat in a stack of forms which are stitched together to produce a book.
  • a block 362 checks to determine whether the form depth and the identity of the master/variable page group are a unique combination. If so, a block 364 creates a list in the memory 53 of group/depth combination (if such list has not already been created) and adds the current group and form depth combination to such list .
  • a block 366 develops and saves a flat pattern defining a template for the master/variable page group, taking into account the form depth of such group.
  • the flat pattern is a file defining the positions of the pages associated as a group by the block 356.
  • a block 368 then creates placeholders for the master data of the master/variable page group in the flat pattern so that a new flat file pattern is obtained.
  • the new flat file pattern is stored in the memory 53 and control passes to a block 370, Fig. lib. Control also passes directly to the block 370 from the block 362, bypassing the blocks 364-368, if the page group identity and form depth combination is not unique.
  • the block 370 identifies and selects the flat pattern from the imposed PDL file pattern developed by the block 352 at the form depth of the selected master/variable page group.
  • a block 374 thereafter develops a new press command file entry to reflect the imposed master/variable page group.
  • a block 376 checks to determine whether all master/variable groups for the record of the press command file currently under consideration have been processed. If not, a block 378 selects the next master/variable page group and control returns to the block 360 of Fig. lib. Otherwise, a block 380 checks to determine whether all records in the press command file have been processed. If not, a block 382 selects the next record and control returns to the block 344 of Fig. 11a. If all records have been processed, a block 384 inserts the file data for the master/variable files into the placeholders in the respective flat patterns to develop the imposed master and variable page files 124 and 139 of Fig. 5. A suitable INI file is also created to reflect the new flat geometry.
  • Fig. 12 illustrates programming which may be executed by the control unit 52 of Fig. 3 to facilitate conversion of the imposed page files 124 and 139 into bitmap format using the RIP 82 of Fig. 4.
  • the programming begins at a block 400 which opens the press command file stored in the memory 53.
  • a block 402 then prompts a user to specify options which are available using the RIP 82. The options include the ability to convert only master page files, only variable page files or both master and variable page files into bitmap format.
  • a block 404 selects the first line in the press command file having at least one file name therein. Thereafter, a block 406 selects a first file name and a block 408 checks a file list stored in the memory 53 to see if the file name has been previously placed in the list.
  • a block 410 adds the file name to the file list and a block 412 checks the user- specified options set by the block 402 to determine whether the file should be converted into bitmap format . If so, a RIP list stored in the memory 53 is updated by adding the file name thereto and control passes to a block 416. Control also passes to the block 416 from the block 412 bypassing the block 414 if the file is not to be converted into bitmap format, and from the block 408 if the file name currently under consideration is already in the file list. The block 416 checks to determine whether the end of the current line in the press command file has been reached. If not, a block 418 selects the next file name in the line and control returns to the block 408.
  • a block 420 checks to determine whether the end of the press command file has been reached. If not, a block 422 selects the next line in the press command file having at least one file name and control returns to the block 406. On the other hand, if the end of the file has been reached, a block 424 causes the RIP 82 to convert the files identified in the RIP list into bitmap format by issuing commands and files as appropriate to the RIP 82.
  • the programming of Fig. 12 facilitates conversion of files to bitmap format as required by the print system 79.
  • FIG. 13 A reorder system constructed in accordance with the teachings of the present invention is illustrated in FIG. 13.
  • the disclosed reorder system is adapted for use with one or more demand printers 500 and one or more auxiliary finishing devices 502, 504, 506.
  • the reorder system is adapted for use with one or more demand printers 500 and one or more auxiliary finishing devices 502, 504, 506.
  • the reorder system is preferably adapted for use with electronic printing presses operating in accordance with the method discussed above in connection with FIGS. 2-12.
  • the disclosed reorder system preferably includes a global reorder processor 510, and sensors 512 (identified by the symbol S * in the drawing) selectively located to sense books that have been fouled or rendered defective by a serviced press 500 or auxiliary device 502, 504, 506.
  • the global processor 510 preferably implemented by a personal computer such as a MICROSOFT ® WINDOWS ® based personal computer or SUN ® Workstation, communicates with press controller (s) 509, 514 associated ith each serviced printing press 500, and with device controllers 516, each of which is preferably associated with a particular one of the serviced auxiliary devices 502, 504, 506, via a ' local area network (LAN) 520.
  • LAN local area network
  • a centralized storage device 524 with an associated server (not shown) for controlling access to the storage device 524 is also preferably coupled to the LAN 520. As illustrated below, in some instances, communication between the various controllers 514, 516 and the global reorder processor 510 is conducted indirectly via changes to data stored in the storage device 524.
  • one or more set-up computers 530 are also shown networked to the central storage device 524 in FIG. 13. As explained above and discussed further below, these set-up computers 530 perform such functions as developing master page files, variable page files, and command files (hereinafter referred to as "book tickets") from a customer provided database. The files developed by these personal computers 530 are stored on the central storage device 524 for use by the press controller (s) 509, 514 and the reorder system.
  • press controller (s) 509, 514 are implemented by SUN ®
  • the device controllers 516 are implemented by MICROSOFT ® WINDOWS ® based personal computers, and the set-up computers 530 are implemented by APPLE ® MACINTOSH ® personal computers, persons of ordinary skill in the art will appreciate that other devices could likewise be utilized in these roles without departing from the scope of the invention.
  • the central storage device 524 is implemented by SUN ® Workstations, other devices could likewise be employed in this role without departing from the scope of the invention.
  • the sensors 512 are implemented as bar code readers such as those commercially available from ACCUSORT ® , under the tradename Model 20, the sensors could likewise be implemented by other devices such as electronic eyes on a positive position device or by optical recognition systems .
  • the above described system operates to identify errored books as they are output by the serviced presses 500 and/or as they are output by the auxiliary devices 502, 504, 506.
  • the reorder system automatically reorders the reprinting of the book.
  • the system can immediately reorder a book fouled by a printing press locally without involving the global processor 510; the book can be locally saved to be printed at the end of a particular segment; or the global reorder processor 510 can be employed to select an optimum printing press 500 and location in a stream of books for re-printing the fouled book.
  • the global reorder processor 510 preferably selects the press and stream location for reprinting to maximize postal rate discounts, but other criteria such as processor time needed to move the book to a new location can also form a basis for selecting the press and stream location for reprinting.
  • errored book encompasses missing books, books missing one or more pages, or books fouled in any manner.
  • book refers to bound books and/or one or more signatures prior to binding .
  • FIG. 13 The operation of the reorder system illustrated in FIG. 13 will now be described in connection with FIGS. 14-23.
  • preferred programmed steps for the various processors 509, 510, 514, 516, and 530 will be described via flowcharts. Persons of ordinary skill in the art will appreciate that, although for clarity of explanation, the steps are described as occurring in a particular time sequence, in use the operation of the disclosed reorder system will vary dynamically depending on the circumstances of the processed job.
  • press controller 514 Although for simplicity of discussion, the following description focuses on press controller 514, it will be appreciated that the functioning of the other press controllers 509 are identical to that of press controller 514.
  • a customer In order to initiate a job (e.g., printing a plurality of books containing variable and fixed data such as sales brochures and/or health insurance booklets) , a customer provides the printer with a QUARKXPRESS ® file describing the page layouts, a database (with the filename "DB.ORG” in the instant example), and a pagination file, if specific page impositions are desired.
  • the provision of this information is represented in FIG. 14a by block 600.
  • the customer has provided a QUARKXPRESS ® file named "CustData.Qxp" and a database file named "DB.ORG" containing 10,000 records and that the noted records are postal sorted to obtain optimal postal discounts. If the records are not sorted, a conventional sorting algorithm can be employed to obtain an appropriately sorted database before proceeding with the process discussed below. It is also assumed that 5 demand printing presses are available for printing the new job.
  • the customer provided information is then processed by one or more set-up processors 530 (depending on the size of the job) .
  • the set-up processor 530 begins processing the job by creating a new directory on the central storage device 524 and placing the files received from the customer in the new directory (block 602) .
  • the set-up processor 530 then creates a new log database 534 associated with the job (block 604) .
  • This log database 534 preferably provides a map of the locations and status of various files associated with the job as explained further below.
  • the log database 534 given the file name DB.ORG.LOG in this example, is saved on the central storage device 524.
  • An exemplary format for the log database 534 is shown in FIG. 15a.
  • the set-up processor 530 After the log database 534 is created on the central storage device 524, the set-up processor 530 begins filling the tables it contains with data as they prepare the job for printing. At block 606, the set-up processor 530 fills in the job parameters in the log database 534. As shown at the bottom of FIG. 15b, these parameters preferably comprise the QUARK ® filename (e.g., CustData.Qxp) and the database name (e.g., DB.ORG) of the customer provided files.
  • these parameters preferably comprise the QUARK ® filename (e.g., CustData.Qxp) and the database name (e.g., DB.ORG) of the customer provided files.
  • the set-up processor 530 then splits the customer provided database DB.ORG into more manageable portions or runable segments (block 608) .
  • the number of segments developed by the set-up processor 530 is dependent upon the number of printing presses 500 available to print the job (in this example, five presses) , the press run lengths, and other production variables. For small jobs, no segmentation is normally required.
  • the set-up processor 534 splits DB.ORG into five segments (e.g., DB.ORG.1, DB.ORG.2, DB.ORG.3, DB.0RG.4, and DB.ORG.5) of equal size.
  • Each of the segments are stored in a separate file on the central storage device 524. As shown in FIG.
  • the set-up processor 530 fills in the log database 534 with a segment identification number, the starting and ending records, and the filename of each segment for the job.
  • the set-up processor 530 calls a routine for preparing a global reorder table 540 to be used by the reorder system to manage certain reordering functions as explained below.
  • the set-up processor 530 initiates the routine by creating a new global reorder table 540 which it stores on the central storage device 524 (block 700) .
  • some of the fields of the global reorder table 540 are filled in dynamically as the job progresses to provide information for reordering errored books and for computing postal manifestations.
  • An exemplary global reorder table 540 is shown in FIG. 17a.
  • the set-up processor 530 enters a nested loop (blocks 702-708) wherein, for every database segment (DB.ORG.1, DB.ORG.2, etc.) of the database
  • the set-up processor 530 develops a sorted list of sub-jobs by postal carrier route. This list is entered into the postal sorts portion 541 of the global reorder table 540.
  • the first database segment DB.ORG.1 has a number of books being sent to the 60610 area code.
  • the set-up processor 530 determines that 10 books are being sent to carrier route 12 in area code 60610.
  • the set-up processor 530 stores that information in the postal sort portion 541 of the global reorder table 540. As shown in FIG.
  • the set-up processor enters the database name (DB.0RG.1), the zip code (60610), the carrier route (12), the job parameters in a bit encoded format identifying job processing factors (such as paper size, paper type, finishing mechanisms required, toner, ink, cover stock, and any other preprinted stock) , the number of books to be sent to the carrier route in question (ten books to CR12 in this example) , and sets a done flag to "False" to indicate that this sub-job has not yet been printed.
  • the set-up processor 530 determines whether the postal sorts portion 541 of the global reorder table 540 has been completed for every segment of the database. If not, control returns to block 702. Otherwise, control proceeds to block 710.
  • nested loop 702-708 can be provided with another loop layer wherein the set-up processor 530 performs steps 702-708 for more than one database.
  • Such an approach would be desirable in co-mailing applications where two or more databases representing two or more different jobs, possibly from different customers, are combined and printed simultaneously to improve postal discounts for all of the processed jobs.
  • a further field could be added to the global reorder table identifying the type of attachments for fulfillment on the fly applications where an attachment or enclosure such as a product sample or preprinted enclosure is added to printed books .
  • the setup processor 530 assigns an identification number GRT_Seg_ID (global jreorder table segment identification) to each sub-job and stores the assigned numbers in the postal sorts portion 541 of the global reorder table as shown in FIG. 17c (block 710) .
  • GRT_Seg_ID global jreorder table segment identification
  • the global reorder processor 510 is notified of the upcoming job by the set-up processor 530.
  • the global reorder processor 510 then starts a messages daemon or background program explained in further detail below. Control then returns to block 612 in FIG. 14a.
  • the set-up processor 530 then enters a loop
  • each segment (DB.ORG.1, DB.ORG.2, etc.) is processed according to the method described above in connection with FIGS. 2-12. These processing steps are compactly illustrated by block 614.
  • the command files also referred to herein as "book tickets”
  • the book tickets are logged in the log database 534 (DB.0RG.LOG) .
  • the master and variable files created at block 614 are also stored in the log database 534.
  • the filenames of one master file (CustData.Qxp.M) and 4 variable files (CustData.Qxp.01.VOl, CustData.Qxp.01.V02, CustData.Qxp.01.V03, and CustData.Qxp .01.V04) are added to the log 534.
  • each of these filenames is assigned a file identification number as shown in FIG. 15d.
  • each book ticket is assigned at least a portion of a segment of a database.
  • ten book tickets have been created and logged, and each book ticket has been assigned 1000 records (one-half of a segment in this example) .
  • each book ticket is assigned an identification number.
  • the records associated with the book ticket and the segment in which those records are contained are also logged in the log database 534.
  • the set-up processor performs any additional processing required by the job in question. For example, the optional imposition processing discussed above in connection with blocks 124 and 139 of FIG. 5 would be performed at this block 618.
  • the set-up processor determines whether all of the segments of the job have been processed. If not, control returns to block 612. When all of the segments have been processed, the set-up processor 530 is finished with the job. All necessary files for printing the job are saved on the central storage device 524 where they can be accessed by any of the presses 500 in the system.
  • the press processor or controller 514 Upon receipt of a command to initiate the printing process from a press operator, the press processor or controller 514 pulls copies of a book ticket, its associated PostScript ® files, and other production files from the central database 524 to its local memory such as a hard drive (block 622) . (See FIG. 14b) .
  • the book ticket pulled is identified by the press operator.
  • the press controller 514 raster image processes (RIPs) the files as explained above.
  • the press processor 514 logs these events in the log database 534. As shown in FIG. 15e at reference numeral 548, the press processor 514 logs the identification number
  • the book tickets and their associated files are transferred to the local storage device of the processing press controller 514 for raster imaging processing
  • the files could also be processed without storing to the local drives without departing from the scope or spirit of the invention.
  • the press controller 514 runs the press 500 such that the press begins printing books which are placed into the mailstream.
  • the local press processor 514 initializes a control flag referred to as the global reorder flag to false. Any other necessary housekeeping tasks are also performed at block 628.
  • the local processor 514 determines whether any unprinted books remain in the book ticket. If there are no remaining books, the press processor 514 determines whether the global reorder flag is set to false. If the global reorder flag is false and there are no remaining books, the job is finished and control passes to block 631.
  • the local reorder table can be stored on a disk drive or in random access memory.
  • the errored book is uniquely identified in the reorder table by record number to enable reprinting.
  • the corresponding record numbers are printed on each book in bar code format to facilitate the identification process.
  • control proceeds to block 646. If the device is equipped with an enabled immediate reorder system, or, if it is determined at block 646 that there are no books in the local reorder table, the local print job is finished and the printed books can be advanced to the auxiliary unit (s) for finishing. If, however, there are books in the local reorder table, control passes to block 648. At block 648, the press operator has two options for proceeding with the job.
  • the operator instructs the press controller 514 to cause the press 500 to reprint the books locally using the record numbers stored in the local reorder table (block 650) .
  • the operator would then position the reprinted books in the appropriate locations in the trays of printed books (block 652) such that a complete stream of books is available for finishing as if no books had been errored.
  • the press operator instructs the press controller 514 to log the record number of the errored books in the log database 534 reorder table 550 (block 654) .
  • the manner in which these errored books are processed is discussed below in connection with FIG. 20.
  • the entry of the book record numbers is shown at reference numeral 550 in FIG. 15f .
  • the reorder system can be optionally disabled by a press operator via the press controller 514.
  • the press operator might wish to disable the system in small jobs where no other presses 500 are used to print books for the job. Nonetheless, in the preferred embodiment, the reorder system is enabled and functions as described below.
  • control passes to block 656. Since in the instant example it is assumed that the first book identified in the book ticket has just been printed without error, the global reorder flag will not be set to true. Accordingly, control passes to block 658 (FIG. 14d) .
  • the press controller 514 determines whether the next book in the book ticket (i.e., the next book to be printed by the press) is to be addressed to a new carrier route or different postal code (e.g., different 5-digit zip code, different 3-digit zip code, or different state) . If not, control returns to block 630 and the press processor 514 continues looping through blocks 630-638 and blocks 656-658 until an errored book is detected at block 636 or a carrier route or postal code change is identified at block 658.
  • a new carrier route or different postal code e.g., different 5-digit zip code, different 3-digit zip code, or different state
  • the local processor 514 sends a request for any global reorders via the LAN 520 to the global reorder processor 510.
  • the request from the press processor 514 identifies the sub-job number (i.e., GRT_Seg_ID) to the global processor 510.
  • the local processor 514 then awaits a reply to its request.
  • the global processor 510 is programmed to run a messages daemon. That program is illustrated by the flow charts shown in FIGS. 18a- 18g.
  • the global processor 510 waits to receive a message via the LAN 520. Upon receiving a message, control proceeds to block 802 where the global processor 510 identifies the type of message received. In this instance, the global processor 510 has received a global reorder request from the local press controller 514 and, thus, at block 804 it calls the "Any Global Reorders" routine.
  • the global processor 510 identifies the current sub-job based on the GRT_Seg_ID value received from the local processor 514.
  • the global processor 510 searches the postal sorts portion 541 of the global reorder table 540 (see FIG. 17b) to determine if any reorder books have been assigned to the current sub-job. Such reorder books could have been errored by one of the other demand printers in the system or been fouled by an auxiliary device 502, 504, 506 in the system.
  • the files necessary to reprint the errored books, already raster image processed, are downloaded to the requesting local processor 514 (block 810) .
  • the local processor 514 was the requesting processor, only press commands would be transferred. If no reorder books are scheduled for the sub-job, the global processor 510 so notifies the requesting local processor 514 (block 810) .
  • the local press controller 514 proceeds from block 662 to block 664 where it sets the global reorder flag to true. Control then returns to blocks 630-636 (FIG. 14c) . Assuming for the moment that the next serviced book is not bad (block 636) , control proceeds to block 656 via block 638. At block 656, the press processor 514 notes that the global reorder flag is set and, therefore, proceeds to block 668 where the global reorder book received from the global processor 510 is put into the datastream. Assuming no errored books are detected at block 636, the loop comprising blocks 630-638, 656 and
  • the press processor 514 sends a "new postal route" message to the global processor 510 via LAN 520.
  • the new postal route message notifies the global processor 510 that the press 500 has completed a sub-job and is moving to the next sub-job.
  • the new postal route message preferably includes the current GRT_Seg_ID (i.e., an identification of the sub-job just completed) , the new zip code, and the new carrier route of the next sub-job.
  • the local press processor 514 advances to block 674 where it waits for a new GRT_Seg_ID from the global processor 510.
  • the new GRT_Seg_ID will be used for identifying the new sub-job in future communications with the global processor 510.
  • the global reorder processor 510 upon identifying the message from the press processor 514 as a new postal route message (block 802) , the global reorder processor 510 calls the new postal connector routine (block 812) .
  • the global reorder processor 510 first identifies the expected parameters in the message received from the press processor 514, namely, the database name (e.g., DB.0RG.1), the current GRT_Seg_ID, the new zip code and the carrier route (block 814) .
  • the global processor 510 accesses the postal sorts portion 541 of the global reorder table 540 and sets the "Done" flag (see FIG.
  • the global reorder processor 510 then scans the postal sorts portion 541 of the global reorder table for a row that matches the database name, the new zip code and the new carrier route (block 818) . Once such a matching row (i.e., sub-job) is found, the GRT_Seg_ID of the matching row is returned to the calling local press processor 514 by the global processor 510 (step 820) .
  • the press processor 514 upon receiving the new GRT_Seg_ID, the press processor 514 advances to block 676 where it sets the global reorder flag to "false" before returning to block 630.
  • the local processor 514 advances to block 678.
  • the local processor 514 compares the errored book to the next book to be printed. If that comparison indicates that reprinting the book immediately will place the errored book into the same postal discount it would have obtained had no error occurred without re-sorting, control advances to block 680. The errored book is then immediately inserted into the datastream for immediate reprinting (block 680) and control returns to block 630.
  • the local controller 514 sends a "new reorder" message to the global reorder processor 510.
  • the new reorder message includes the current GRT_Seg_ID, the record number of the errored book, the current zip code, the current carrier route, and a data pointer, to the global reorder processor 510.
  • the data pointer comprises a path name identifying where the raster image processed files for reprinting the book are stored, thereby enabling movement of the reorder to another press without requiring further raster image processing of the errored book.
  • the local processor 514 continues looping through the flowcharts illustrated in FIGS. 14c and 14d, immediately reordering errored books where appropriate
  • the global reorder processor 510 when it identifies a new reorder message (block 802) , which can be from a press processor 514 or a device controller 516 for an auxiliary finishing device, it calls the new reorder routine (block 822) shown in FIG. 18c.
  • the global reorder processor 510 After receiving the expected parameters (e.g., current GRT_Seg_ID, record number, current zip code, current carrier route, and the data pointer) from the calling local processor 514, 516 (block 824), the global reorder processor 510 creates a new record in the "reorders" portion 555 of the global reorders table 540 (block 826).
  • the expected parameters e.g., current GRT_Seg_ID, record number, current zip code, current carrier route, and the data pointer
  • the global reorder processor 510 enters the parameters received in the new order message into the reorders portion 555. (See FIG. 17d.)
  • the global reorder processor 510 then scans the postal sorts portion 541 of table 540 to find the best place to fit the reordered book (block 830) .
  • a best fit for book placement and queueing routine is described in full in Wong, U.S. Patent No. 4,500,083, and Wong, U.S. Patent No. 4,674,052, both of which are hereby incorporated hereby by reference. Nonetheless, a preferred best fit sorting routine will now be described in connection with FIG. 18d for completeness.
  • the global reorder processor 510 After identifying the zip code and carrier route information (block 832), the global reorder processor 510 scans the postal sorts portion 541 of the global reorder table 540 for any sub-jobs which have the same 5-digit zip code as the reorder record and whose "Done" flag is set to false (block 834) . If one or more such sub-jobs are found, the global reorder processor 510 determines whether any of the sub-job (s) identified at block 834 do not have enough books to qualify for a bundle break discount (block 836) .
  • the postal office additional discounts to books sorted into bundles within a predefined area (e.g., 5-digit zip code, 3-digit zip code, 1-digit zip code) wherein the number of books in a bundle are above a predefined number, such as ten for bundles sorted by 5-digit zip code.
  • Block 836 attempts to locate any bundle having fewer books than the predefined threshold number for the postal category in question. Referring to FIG.
  • the global reorder processor 510 makes this determination by calculating the number of books per bundle originally assigned to the sub-job in question (e.g., the "# Book Bundle" category) , subtracting any books that were reordered outside the sub-job (e.g., errored books sent to the global reorder processor for reprocessing and not reassigned to be printed in the same sub-job) , and adding any global reorder books downloaded by the global reorder processor 510 and processed with the sub-job (e.g., the number of books printed in a sub-job pursuant to a request for global reorders (block 660 in FIG. 14d) ) .
  • the number of books in the bundles of the sub-job(s) identified in block 834 are then compared to the U.S. postal regulation for the class of mail being produced (block 836) . If any of the identified sub-groups do not have enough books to qualify for a bundle book discount, the global reorder processor 510 selects the first such sub-job, and adds one to its "# After" field in the postal sorts portion 541 of the reorder table 540 (block 838). If all of the identified sub-job(s) qualify for a book bundle discount (block 836) , control proceeds to block 840, where the last sub-job is assigned the reorder job by adding one to its "# After" field. Upon completion of blocks 838 or 840, control proceeds to block 852 in FIG. 18c.
  • the global reorder processor 510 searches the postal sorts portion 541 of the global reorder table 540 for sub-jobs with the same first three zip code digits as the reorder book in question and whose "Done" flag is set to false. If any such sub-job(s) are found, the global reorder processor 510 proceeds to blocks 836, 838 and/or 840 as described above. Otherwise, control proceeds to block 846.
  • the global reorder processor 510 scans the postal sorts portion 541 of the global reorder table 540 for sub- job (s) having the same state zip code (i.e., same first digit) and having a false "Done" flag. If any such sub- job(s) are identified, control advances to blocks 836,
  • the reorder is added to the last sub-job with a false-done flag (block 848) , or, if all sub-jobs are finished (block 847) , the reorder is added to the reorder table 550 in the log database 534 (block 850) (see FIG. 15f) .
  • the global reorder processor 510 Upon returning to block 852 (FIG. 18c) , the global reorder processor 510 sets the GRT_Seg_ID parameter in the reorders portion 555 of the global reorder table 540 to the GRT_Seg_ID value of the matching sub-job identified via the blocks shown in FIG. 18d. The global processor 510 then updates the postal sorts portion 541 of the global reorder table 540 (see FIG. 17d) by adding one to the "# Books After" column of the sub-job assigned the reorder (block 854) . Thus, when the press 500 and controller 514 processing the sub-job assigned the reorder sends a message requesting global reorders to the global reorder processor 510 (block 660 in FIG.
  • the global reorder processor 510 addresses the reorder portion 555 of the global reorder table for reorders with a matching GRT_Seg_ID, and downloads the pointer to data parameter (e.g., a pathname) to the local processor 514 to initiate the reorder (blocks 808 and 810 in FIG. 18b) .
  • data parameter e.g., a pathname
  • the global reorder processor 510 adds one to the "# Reordered" column of the sub-job sending the new reorder message.
  • the global processor 510 has received a new order request message from the local processor 514 processing the sub-job with GRT_Seg_ID 1; has identified the sub-job assigned GRT_Seg_ID 3 as an appropriate fit; has added one to the "# Reordered" column for sub-job GRT_Seg_ID 1; and has added one to the "# After" column of GRT_Seg_ID 3.
  • the global reorder processor 510 in selecting a sub-job for reprinting an errored book, the global reorder processor 510 also considers the bit encoded values in the "Job Params" column of the postal sorts table 541 (see FIG. 17d) . As discussed above, these parameter values specify physical specifications for printing the book such as paper size. The global reorder processor 510 will preferably only assign the errored book to a sub-job having the same parameters for reprinting to ensure the book is properly printed.
  • the setup computer 530 causes a "new database" message to be sent to the global reorder processor 510.
  • the global reorder processor 510 calls a new database routine (block 858) shown in FIG. 18f .
  • the global reorder processor 510 begins the new database routine by clearing the GRT_Seg_ID value for every sub-job in the postal sorts portion 541 of the global reorder table 540 (block 860) .
  • the processor 510 then enters a nested loop (blocks 862-868) wherein all of the sub-jobs from the new database and all of the sub- jobs from the preexisting job are sorted in postal sort order.
  • Blocks 862-868 are substantially identical to blocks 702-710. Accordingly, for brevity, the description of this nested loop will not be repeated here .
  • the global reorder processor 510 After sorting the postal sorts portion 541 of the global reorder table 540 to include all of the sub- jobs from the new database and the preexisting job, the global reorder processor 510 assigns new GRT_Seg_ID values to each of the sub-jobs in the postal sorts table 541 (block 870) . The global reorder processor 510 then re-calculates a new GRT_Seg_ID value for every record in the reorders portion 555 of the global reorders table 540 (blocks 872 and 874) . This re-calculation is performed in accordance with blocks 830-856 shown in FIGS. 18c and 18d to ensure that each pending reorder is processed to maximize postal discounts.
  • a database it may be necessary to delete a database from the global reorder table 540.
  • Such an occasion can arise, for example, when a customer changes its mind concerning a job and decides to not proceed with a mailing that has already been received by the printer.
  • a "delete database" message will be developed by the set-up processor 530.
  • the global reorder processor 510 identifies a delete database message (block 802 of FIG. 18a) , it will call the delete database routine (block 876) shown in FIG. 18g.
  • the global reorder processor 510 begins the delete database routine by entering a nested loop illustrated by blocks 878-884.
  • the global reorder processor 510 identifies the sub-jobs in the postal sorts portion 541 of the global reorder table 540 (block 880) for every database or database segment that is to be deleted (block 878) , and sets the done flag for the sub-jobs to be deleted to true (block 882) . This process is continued until every sub-job in every database or database segment to be deleted has had its corresponding done flag set to true (block 884) .
  • Control then shifts to blocks 886 and 888 where the global reorder processor 510 addresses the reorders portion 555 of the global reorder table 540 to determine if any of the pending reorders were directed to a sub-job whose done flag was changed in the nested loop defined by blocks 878-884.
  • the global reorder processor 510 reassigns any such reorders to a new sub-job pursuant to blocks 830-856 shown in FIGS.
  • the reassignment performed in block 888 ensures that no re-orders that have previously been assigned to a canceled sub-job are inadvertently skipped.
  • the reorder system is preferably constructed to automatically reorder books that have been fouled by auxiliary finishing devices.
  • a preferred embodiment for accomplishing this purpose is shown in FIG. 20.
  • each of the auxiliary finishing devices includes a device controller 516 and two sensors 512.
  • One of the two sensors 512 is located to monitor books as they are inserted into the finishing device 502, 504, 506, and the other sensor 512 is located to monitor books as they are outputted by the device 502, 504, 506.
  • each finishing device including the auxiliary devices 504 and 506 shown in FIG. 13, is provided with its own device controller 516, and each of these device controllers 516 is coupled to the central storage device 524.
  • the input sensor 512 and device controller 516 scan each book as it enters the auxiliary finishing device 502, 504, 506
  • the press controller 516 can instead be adapted to develop and send a new reorder message to the global reorder processor 510.
  • the global reorder processor 510 calls the new reorder routine at block 822 of FIG. 18a and processes the new reorder as explained in connection with blocks 824-856 of FIGS. 18c and 18d.
  • the global reorder processor 510 has the ability to assign reorder jobs resulting from errors by the auxiliary finishing devices to printing presses on the fly. Of course, to enable this approach to proceed without undue processing delays, it will be necessary for the global reorder processor 510 to locate the raster image processed files by referencing the log data base (See FIG. 15f) .
  • each finishing device in each press line includes a device controller 516 and a pair of sensors 512. Each of these press controllers preferably independently perform the steps illustrated by blocks
  • the subject finishing device is a postal weight monitoring device which preferably includes a scale for weighing one or more books and an associated processor for calculating an expected weight of the book(s) .
  • the book can be reordered by either placing it in the job reorder table 550 of the log database 534 (See FIG. 15f) or by sending a new reorder message to the global reorder processor 510 to enable the global reorder processor to reorder the book pursuant to block 822-856 of (FIGS. 18a, 18c and 18d) .
  • the post weight calculating device reads an identifier from each book (blocks 1000 and 1002) via a sensor 512.
  • the identifier is a bar code, which is read via a bar code sensor.
  • the local processor 516 looks up the bar code information in a database that lists page and type counts (block 1004) . Block 1004 may be omitted if the page count, name and address of the addressee, or database identifier is embedded in the bar code.
  • the local processor 516 calculates the expected weight of the identified book based on its expected page count combined with a previously established tolerance range based on the paper weight used in the book.
  • the expected weight of any cover stock and any inserts, together with an additional pre-determined tolerance range for these items, are added to the calculated weight total for the book in question.
  • the local processor 516 adds any applicable expected kit weights (additional fulfillment pieces) (together with any associated predetermined tolerance) to the calculated weight of the expected book.
  • the expected weight of an envelope (together with any associated pre-determined tolerance weight) is added to the calculated weight of the book identified at block 1002.
  • the scale of the device is used to weight the book.
  • the local processor 516 compares the measured weight of the book with the expected weight to determine if the subject book falls within the tolerance range developed by blocks 1004-1012. If the actual weight of the book falls within the calculated tolerances, controller 516 returns to block
  • the disclosed reorder system provides a mechanism for re-ordering books contained in the job reorder table 550 of the log database 534 (See FIG. 15f) when all presses have completed there assigned jobs.
  • the global reorder processor 510 begins this process by determining whether any books remain in the job reorder table 550 (block 1100) . If no books are present in the job reorder table 550, the process terminates (block 1102) . Otherwise, the global reorder processor 510 analyses the book ticket identified in the log database 534 to determine how many of the books in the reorder table are still stored to the local drives of the press processors 514 of the individual presses 500 (block 1104) .
  • the global reorder processor 510 also calculates the percentage of books to be reprinted remaining on each press.
  • the information developed at block 1104 is then displayed on a display device (block 1106) to enable an operator to decide how to process the remaining jobs.
  • An exemplary graphical user interface display is shown in FIG. 23.
  • the global processor 510 determined that 800 books in the reorder table 550 remain in raster image processed format on press A; 830 of the books in the reorder table 550 remain in raster image processed format on press B; 16 of the books in the reorder table 550 are still in raster image processed format on press C; 14 of the books in the reorder table 550 are still in raster image processed format on press D; and 1024 of the books in the reorder table 550 are not currently in raster image processed format on any press. As shown in FIG.
  • the global reorder processor 510 also determines that the 800 books still on press A constitute 30% of the books requiring reprinting; the 820 books on press B constitute 31% of the books requiring reprinting; the 16 books on press C constitute less then 1% of the books to be reprinted; the 14 books n press D constitute less then 1% of the books to be reprinted; and the 1024 books that are not currently on any press constitute 36% of the books still requiring reprinting.
  • the operator can decide whether or not to make the books present on each of the presses a single book ticket; which press to employ for reprinting the books; whether or not to transfer the files to the selected press; and whether or not reprocessing will be required.
  • the operator can initiate the reorder process by selecting the "save/do" button, or the operator can cancel the process and start over by selecting the "cancel" button in a conventional manner.
  • the selection of the reorder parameters in FIG. 23 can be automatically selected based on predefined system guidelines.
  • the global reorder processor 510 enters a loop defined by blocks 1108-1120.
  • the global reorder processor 510 processes one press run per loop through blocks 1108-1120. For example, with respect to the 800 reorder books on press A, the global reorder processor 510 first determines whether the "make single book ticket" option has been selected (block 1110) . If not, the global reorder processor 510 proceeds to the next potential press run via block 1122, in this example, the 820 books on press B.
  • the global reorder processor 510 makes the book ticket at block 1112 and then transfers the book ticket to the press specified in the "press to print on" column of the graphical user interface shown in FIG. 23 (in this instance press A) .
  • the global reorder processor 510 then proceeds to block 1116 where it determines whether the "auto file transfer” option has been selected. Since in this example, the "auto file transfer” option has not been selected (see FIG. 23) , the global reorder processor 510 proceeds to block 1118 where it determines whether there are more runs to process. Since in this example, there are more runs to process, control returns to block 1108.
  • the global reorder processor 510 then independently cycles through block 1108-1118 for the remaining presses (B-D) in the same manner as discussed above in connection with press A. With respect to the 14 books on press D, however, upon reaching block 1116, the global reorder processor 510 determines that the "auto file transfer" option has been selected by the operator and, therefore, proceeds to block 1120. At block 1120, the global reorder processor retrieves the raster image processed files on the press controller associated with press D and delivers those files to the press controller associated with press C. Control then proceeds to blocks 1118 and then back to block 1108.
  • control Upon reaching the 1024 books which are not currently stored on any press in raster image processed format (i.e., the last row in FIG. 23), the processor 510, once again begins the loop defined by blocks 1108- 1120. However, upon reaching block 1110, the global reorder processor 510 determines that the "make single book ticket" option has not been selected. Accordingly, control proceeds to block 1122 where, if there are more runs to process, control returns block 1108. Otherwise, as in this example, control proceeds to block 1123.
  • the global reorder processor 510 selects all of the press runs in which the "make single book ticket" option has not been selected (in this example, the 1024 books that do not remain on any press in raster image processed format) . These books are referred to hereinafter as "the remaining books”.
  • Control then proceeds to block 1124 where the global reorder processor 510 combines all of the remaining books in a new database.
  • the global reorder processor 510 determines whether the re-process option has been selected for any of the books in the new database. If so, the global reorder processor 510 transfers the new database to the set-up processor 530, and the set-up processor 530 begins processing the remaining books as a new job at block 614 of FIG. 14a.
  • the global reorder processor 510 re-calculates the postal manifestation reports for the entire print job.
  • the global reorder processor 510 determines whether any book bundles identified in the postal sorts portion 541 of the global reorder table 540 have fallen below the required number of books by subtracting any reorders and adding any additional book printed in a given bundle. It also determines whether any book bundles were bumped up into a discount category by adding reorders thereto. This final re-calculation ensures that the entire print job is properly accorded a proper postal discount .
  • the re-calculated postal manifestation report is printed out in hard copy or an electronic file is created that can be transmitted to the appropriate postal authority.
  • the reorder system can be adapted such that, if a book bundle or sub-job has fallen out of a postal discount category due to one or more errored books, all of the unprinted books in the sub-job or bundle are transferred to the global reorder processor 510.
  • the global reorder processor then assigns the books in the reordered bundle or sub-job to one or more new sub-jobs in the global reorder table to thereby maximize postal discounts for the reordered books and for the sub- job (s) receiving the reorder books to the extent the additional book(s) push the receiving sub-job (s) into a new postal discount category.
  • the reorder system is capable of immediately locally reordering books errored by a printing press; of transferring errored books from one press to another to maximize postal discounts; and of reordering books fouled by finishing devices.
  • the disclosed system is able to recalculate postal discounts to account for books reordered during a given job.
  • reorders are assigned to sub-jobs to maximize postal discounts, the assignment of reorders could also be based on the amount of processing time required to reprint the job without departing from the scope or spirit of the invention.

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  • Accessory Devices And Overall Control Thereof (AREA)

Abstract

L'invention porte sur un procédé et un système sélectif de réimpression de livres à réimprimer sur une ou plusieurs presses électroniques. Dans une première exécution, on utilise des détecteurs et un processeur pour identifier et faire réimprimer les livres endommagés par une machine auxiliaire. Dans une deuxième exécution, on utilise un détecteur et un processeur global communiquant avec un premier et un deuxième processeur local respectivement associés à une première et à une deuxième presse pour faire réimprimer les livres soit sur la première presse, soit sur la deuxième afin de réduire le temps de traitement et/ou obtenir les meilleurs rabais de distribution postale. Dans une troisième exécution, on utilise un détecteur et un processeur de presse pour faire réimprimer les livres présentant des défauts en réinsérant un tel livre dans un courant de livres en cours d'impression si sa réinsertion dans ledit courant permet d'obtenir un rabais de distribution p ostale prédéfini.
PCT/US2000/020877 2000-07-31 2000-07-31 Systeme de reclassement associe a une presse electronique d'impression Ceased WO2002009949A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
AU2000265055A AU2000265055A1 (en) 2000-07-31 2000-07-31 Reorder system for use with an electronic printing press
PCT/US2000/020877 WO2002009949A1 (fr) 2000-07-31 2000-07-31 Systeme de reclassement associe a une presse electronique d'impression

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2000/020877 WO2002009949A1 (fr) 2000-07-31 2000-07-31 Systeme de reclassement associe a une presse electronique d'impression

Publications (1)

Publication Number Publication Date
WO2002009949A1 true WO2002009949A1 (fr) 2002-02-07

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ID=21741643

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2000/020877 Ceased WO2002009949A1 (fr) 2000-07-31 2000-07-31 Systeme de reclassement associe a une presse electronique d'impression

Country Status (2)

Country Link
AU (1) AU2000265055A1 (fr)
WO (1) WO2002009949A1 (fr)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4500083A (en) * 1983-12-08 1985-02-19 R. R. Donnelley & Sons Company Collating and binding system and method with postage indication
EP0992365A1 (fr) * 1998-09-29 2000-04-12 Hewlett-Packard Company Dispositif de fabrication de brochures

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4500083A (en) * 1983-12-08 1985-02-19 R. R. Donnelley & Sons Company Collating and binding system and method with postage indication
EP0992365A1 (fr) * 1998-09-29 2000-04-12 Hewlett-Packard Company Dispositif de fabrication de brochures

Also Published As

Publication number Publication date
AU2000265055A1 (en) 2002-02-13

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