Insertion apparatus and insertion method

An apparatus for, and a method of, inserting flat articles, e.g. printed pre-products or additional products, parts of newspapers, goods samples, leaflets, fliers and other inserts, into folded printed products. Use is made of a rotary system with compartments which run along a closed circular rotary path and are oriented as a tangent or secant to the rotary path (U). This makes it possible for the printed products and the articles to be fed in the direction of rotation, as a result of which the forces acting on the products can be reduced. There are also advantages relating to format adaptation, since the opening angle of the product upon adjustment of the compartment base does not change to such a pronounced extent as is the case with radially oriented compartments.

BACKGROUND OF THE INVENTION

1. Field of Invention

The invention lies in the field of the further processing of printed products and relates, in particular, to an apparatus and a method for inserting flat objects into a folded printed product, for example an envelope. Flat objects of this type are, for example, further printed products, printed preproducts or additional products, parts of newspapers, test samples, brochures, flyers and other inserts. The invention serves, for example, to produce a multiple part printed product.

2. Description of Related Art

In order to insert flat objects between the two product parts of a folded printed product, it is known to transfer the printed products coming from the rotary printing press to a separate apparatus, to hold it in the latter and to open it, to insert the flat objects and to remove the end product produced in this way and to convey it further. The apparatuses which have previously been used for this purpose, for example according to EP-A 0 588 764 or EP-A 1 090 867, comprise circulating systems with a plurality of compartments which are moved along a circular circulating track about a rotational axis by being arranged on a rigid rotational body, for example a wheel. The feed stations for the printed products and the objects to be inserted are arranged at the periphery of the circulating system. The printed products are introduced into the compartments with the fold at the front and are opened and held open by an opening device, with the result that the flat objects can be introduced into the opened product. The compartments are defined by dividing walls which extend in the substantially radial direction. The orientation of the compartments, that is to say the direction of an imaginary line or surface between two adjacent dividing walls, is radial. Inter alia, this makes a maximum large opening of the compartments possible, with the result that there are tolerances when the products are pushed in.

However, a disadvantage of the known devices is the great accelerations which the products are subjected to during insertion into the compartments on account of the directional change between the feed direction and the direction of conveying in the circulating system. A further problem arises in the adaptation to different formats: the spacing between the two dividing walls varies to a very pronounced extent with the radius, on which the spacing is measured. Since the products are normally fixed in the compartments at their edges which lie radially on the outside, shorter products are spread open to a greater extent during opening than longer products and are therefore loaded undesirably in some circumstances. Finally, the compartments have to have a certain depth, in order for it to be possible to process products with a predefined maximum format. The radial orientation of the compartments leads here to comparatively large diameters of the system.

BRIEF SUMMARY OF THE INVENTION

The invention is therefore based on the object of specifying an apparatus and a method for inserting flat objects into folded printed products, which avoid the problems of the prior art. In particular, the products are to be treated gently; an adaptation to different formats is to be possible.

The invention proceeds from a prior art, as has been depicted in the introduction. The apparatus comprises a circulating system with a plurality of compartments which can be moved along a closed circular circulating track about a rotational axis, are delimited by dividing walls in the circulating direction and, along the circumference, have openings for inserting the printed products and the objects into the compartments. The circulating system is configured, for example, in the manner of a paddle wheel. There is a controllable opening device for opening and holding open the printed products which are inserted into the compartments at a first feed point with the folded edge at the front. The said controllable opening device is set up in such a way that the folded printed products are opened before a second feed point for the flat objects and are moved past this feed point in the opened state, with the result that the objects can be inserted into the open product. According to the invention, the dividing walls extend at least in regions substantially in the manner of a tangent or secant with respect to the circular circulating track. The compartments are therefore opened in a substantially tangential or secantial direction counter to the circulating direction and are preferably oriented, in particular, at an angle of less than 45° relative to the circulating track. Here, the circulating track is, for example, the track of those ends of the dividing walls which face the rotational axis, or the track of the compartment base. The latter is spaced apart from the rotational axis, in order that the compartments can be arranged in the described way. The direction of an imaginary line or surface between two adjacent dividing walls therefore extends substantially tangentially with respect to the circulating track or intersects the latter at a small angle.

If the circulating track is defined by the track of that point of the compartments, that is to say of the dividing walls or the compartment bases, which is at the smallest distance r from the rotational axis, the dividing walls preferably extend tangentially with respect to the circulating track defined in this way, in the immediate vicinity of the compartment base. The dividing walls are preferably bent toward the rotational axis in the region which faces away from the compartment base. The compartments preferably open counter to the circulating direction.

The method according to the invention provides for the printed products, and preferably also the objects, to be inserted to be fed in a direction which corresponds substantially to the orientation of the trailing dividing wall of the associated compartment when the latter is situated in the region of the corresponding feed point. Depending on the position of the second feed point, the object can also be introduced parallel to the leading dividing wall.

The invention makes it possible to feed the printed products in the direction of the compartments and first of all to convey them further without a significant directional change and therefore without great accelerations by rotation of the circulating system. The aerodynamic resistance of the printed product is reduced by the product being moved further with the folded edge at the front more or less in the direction of the product plane instead of perpendicularly with respect to the latter.

The invention has the further advantage that the spacing of the dividing walls does not change so much as a function of the depth of the compartment (from the periphery in the direction of the rotational axis) as in the case of radially oriented compartments. The problems depicted in the introduction with respect to format adaptation are therefore avoided.

A further advantage comprises the fact that the diameter of the circulating system for processing products with a predefined maximum format is reduced as a result of the orientation of the compartments which differs from the radial direction in comparison with those systems, in which the compartments are oriented radially, and the system according to the invention can therefore be of more compact configuration than the prior art.

This design of the circulating system with compartments arranged in an overlapping manner around the rotational center also leads to the products being conveyed within the circulating system in a very compact formation, which makes high conveying rates possible. The formation corresponds substantially to an imbricated formation which runs through a deflection point. The difference from a conventional imbricated formation lies in the fact that dividing walls are arranged between the products within the circulating system. The compartments are wound, as it were, around the rotational axis helically.

In order to feed the products substantially in the circulating direction or in the direction of the instantaneous orientation of the compartment, a feed station for the folded printed products is preferably arranged relative to the circulating system in such a way that the printed products are introduced substantially tangentially or secantially with respect to the circulating track, particularly preferably in the substantially horizontal direction.

It has been shown that dividing walls which are bent counter to the circulating direction and wind, for example, helically around the rotational axis have advantages, since they facilitate opening of the products. This is because, during fixing of one of the product parts against the bent dividing wall, the folded product normally spreads open without additional measures on account of its inherent rigidity. The opening device can therefore be realized in a simple way by a clamping element which presses one of the product parts against the dividing wall. As an alternative, the opening device can be realized by one or more vacuum nozzles in the dividing wall, as a result of which the adjacent product part is sucked against the dividing wall. Opening devices of this type which fix only one of the product parts can also be used in the case of straight compartment walls.

A bent dividing wall has the additional advantage that the space requirement (diameter of the apparatus) is reduced in comparison with the case with straight dividing walls.

The opening process is preferably assisted by further measures. Measures of this type can be the suitable arrangement of the different stations along the circulating track, which make it possible to use the positional change of the product during the transport along the circulating track and therefore to use gravity for opening. Furthermore, opening elements can be provided which can be pushed in between the product parts and raise the latter up from one another. Finally, the product parts can also be raised up from one another by blowing in air.

A control apparatus, by way of which the opening device can be controlled as a function of the position of the compartments along the circulating track, serves for the targeted receiving of a product and for the targeted release at a discharging position. This is realized, for example, by a stationary control track which interacts with driven elements which are arranged on the compartments.

For adaptation to different formats, displaceable stop elements are preferably provided which serve within the compartments as a stop for the folded edge and define the compartment base as a result. The stop elements are displaced, for example, in the radial direction, in order to support products of different format in such a way that the edge which lies opposite the folded edge is situated in the region of the compartment opening independently of the format.

In order to discharge the completed products to a removal device, a stripping device is preferably provided which pushes the products out of the compartments at a discharging position. The stripping device preferably acts on the folded edges. It is, in particular, stationary and moves the product on account of the relative movement between the stripping device and the circulating system. The stripping device can be adjustable for format adaptation.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows an inserting apparatus1with a circulating system10which comprises a plurality of compartments12. In each case one compartment12is formed by two adjacent dividing walls14. The dividing walls14have a continuous 2-dimensional surface or define a 2-dimensional surface. They are mounted on at least one rotational body (not shown here) so as to rotate about a rotational axis D. The dividing walls14define receiving pockets for products, which receiving pockets taper from the periphery of the circulating system10or the compartment opening16toward the compartment base13.

As a result of the rotation about the rotational axis D which extends horizontally here, the compartments12describe a circular circulating track U with a radius r. In the present case, the circulating track U is denoted by the track of that dividing-wall end15which lies at the smallest distance r from the rotational axis D (r>0). If the track of another point on the dividing wall14is considered, for example that of the dividing-wall end15′ which lies on the outside, the corresponding circulating track U′ lies concentrically with respect to the innermost circulating track U, but has a greater radius r′.

According to the invention, the compartments12and the dividing walls14are not oriented radially, as in the prior art, with respect to the rotational axis D and with respect to the circulating track U, U′. In the region of their end15which lies on the inside, the dividing walls14extend substantially tangentially with respect to the circulating track U with the smallest radius r which at the same time specifies the minimum distance of the compartment bases13from the rotational axis D. The corresponding tangent T is shown diagrammatically in the upper part of the circulating system10for one of the compartments12. If a circulating track U′ with a greater radius r′ is considered, the dividing walls14extend secantially with respect to the circulating track U′. It is also possible that the dividing walls14extend secantially with respect to the inner circulating track U at as small an angle as possible The compartments12open counter to the circulating direction (in the clockwise direction here), that is to say the compartment opening16trails the compartment base13.

Holding elements22which are part of an opening device20are arranged in the region of those ends15′ of the dividing walls14which lie radially on the outside. Said opening device20comprises, moreover, a control device (not shown here in greater detail) in the form of a control track and control elements which interact with the latter and by way of which the holding elements22can be moved between an open position and a clamping position.

Stop elements18which define an overall cylinder shell-shaped stop face for the folded edge5of the products are arranged in the region of the compartment base13. The distance a of the stop elements18from the rotational axis D can preferably be adjusted for adaptation to different product formats, with the result that those edges of the products2which lie on the outside always assume the same position. A stripping device24for pushing the products2out of the compartments is situated in the lower region of the circulating track U. In the present case, the stripping device24is stationary, but could also comprise one or more revolving elements, for example a wheel, a cam belt or a gripper chain.

A feed station30for folded printed products2is arranged in the upper region of the circulating track U, on the left of its vertex here. Downstream of this, in the right hand part of the circulating track U, a feed station40is situated for objects8to be inserted into the products2. Said objects8can be configured and assembled in different ways. A removal conveyor50for transporting away the products2with the inserted objects8is situated below the circulating system10.

The rotation of the circulating system10and the product advancing of the feed stations30,40are controlled by a common control device60, preferably adapted to one another by the exchange of suitable control signals.

In the following text, the function of the insertion apparatus1will be described:

The folded products2are fed into the compartments12at a first feed point S1by the feed station30, in the closed state with the folded edge5at the front. During feeding, the products2are advanced in a substantially horizontal feed direction Z1and are separated from the feed stream. The position of the feed point S1is selected in such a way that the compartments12or the trailing dividing wall14of a compartment12have/has a likewise substantially horizontal orientation there. The products2therefore also, first of all, retain their original movement direction within the circulating system10, with the result that large relative movements and high brake and frictional forces are avoided on the product2.

The products2comprise two product parts4,6which are folded with the formation of a preliminary fold3on the trailing product part6. In the closed state of the product2, the preliminary fold3is clamped against the dividing wall14by the clamping element22. During the rotation of the compartment12in the clockwise direction, the product2is moved in such a way that it is opened by gravity. AsFIG. 7shows, the opening operation can be assisted by blowing air. Here, the unheld product part4is supported by the leading dividing wall14of the compartment12. In this situation, the flat object8is introduced into the opened product2at the second feed point S2. The feed direction Z2of the objects8likewise coincides substantially with that orientation of the compartments12which exists at the feed point S2.

After the object8is pushed in, the clamping element22is released, with the result that the product2can be pushed out of the compartment12by the stripping device24and can be discharged to the removal device50. In the present case, the products2are deposited on a conveyor belt in an imbricated formation, but it is also possible to transfer them to a gripper conveyor, as shown inFIG. 4.

For adaptation to different formats, the stop element18is displaced, for example, in the radial direction (adaptation of the distance a). This makes it possible to always fix the products2at the same point, at the preliminary fold3here. As a result, the transfer to the removal device50can also take place without adaptations. This has advantages, in particular, in the case of transfer to a gripper conveyor, because the control of the gripper movement thus does not have to be adapted to different product positions within the compartment12(seeFIG. 4).

The compartment12changes its depth by displacement of the stop element18. However, the opening angle of the product2does not change to such a pronounced extent as a function of the depth as in the case of systems with radially oriented dividing walls14, with the result that an undesirable pronounced widening of the product2is avoided. The effective opening width d of the compartments12which restricts the widening of the product2is considerably smaller, on account of the tangential orientation of the dividing walls14, than the width of the opening16as measured in the circumferential direction which would be critical in the case of radially oriented products.

The dividing walls14of the circulating system fromFIG. 1are bent counter to the circulating direction, that is to say toward the rotational axis D. Since the products2are fixed on the trailing dividing wall14of a compartment12, opening of the product2is achieved in a simple way by the curvature of the dividing wall14and the inherent rigidity of the product2.

The dividing walls14could also be of straight configuration. Moreover, it is also possible that they do not have complete surfaces, but comprise a plurality of elements which define a supporting face. The front and rear sides of a dividing wall14could likewise not be assigned in each case to a compartment12, but rather each compartment12could have separate supporting elements for the leading and the trailing compartment walls. A further variant comprises fastening transport pockets to a conveying means, for example a chain, which is moved along the circulating track, for example guided by rail. In this case, the circulating track could also be a shape other than circular. However, the construction shown inFIG. 1of the circulating system is particularly simple in structural terms.

FIG. 2shows an apparatus1according toFIG. 1with a feed station30which receives products2optionally online from a gripper conveyor32, which is connected, for example, to the output of a printing press, or offline from a product store36. The products2are conveyed on a conveyor belt34to the feed point S1and are accelerated in the process, for example.

The feed station40outlined inFIG. 2for the objects8to be inserted comprises two conveyor belts42,44which are driven in opposite directions and between which greater or more complex objects8can also be received and conveyed. The conveyor belts42,44extend in the region of the feed point S2in such a way that the conveying direction Z2of the objects8corresponds approximately to the instantaneous orientation of the compartments12; here, they are inclined obliquely downward. The feed station40can be configured, for example, as described in EP-A 1 475 329. An apparatus according to EP-B 1 456 106 can be used to combine and introduce relatively complex objects.

As described above, the removal device50comprises a conveyor belt52, the conveying direction of which in the region of the product discharging means corresponds to the instantaneous conveying direction (circulating direction) of the products2. The products2which are deposited in an imbricated formation can subsequently be received by further conveyors or guided over deflection means54, for example as described in EP-A 1 411 011.

FIG. 3shows a variant of the arrangement fromFIG. 2, in which the conveying direction of the products2is reversed in the feed means30. The imbricated formation of the products2is fed above the circulating system10counter to the rotational direction in the upper part and is rotated by 180° by a deflection means38, realized here by two conveyor belts which are deflected in a circular shape and are driven in opposite directions. The products2are then introduced into the compartments12as described above.

In addition to the components shown inFIG. 2, the removal device50which is shown inFIG. 3comprises a gripper conveyor56which accepts the products2in a substantially upright position, into which they have been moved by the deflection means54. The grippers grip the products2at the cord or at the folded edge.

FIG. 4shows a variant, in which the products2are accepted from the circulating system10directly by a gripper conveyor58. Here, the products2are gripped by the grippers59at their open edge which lies opposite the folded edge5. To this end, they are pushed slightly out of the compartments12by a stripping element24, with the result that the edge projects and can be gripped by the grippers59. The transfer point is situated to the side of the circulating system10at a position, in which the compartments12are still oriented upward, with the result that the open product edge is still situated above the folded edge5. The product2is therefore pushed out of the compartment counter to gravity. This makes very precise control of the product movement possible.

For format adaptation, the stripping element24can preferably likewise be adjusted, with the result that the product edge to be gripped is always situated at the same position.

The direct acceptance of products2by grippers from a circulating system10is described in application no. CH 0098/08 which is not a prior publication and to which reference is made here additionally with regard to the design of the circulating system and the control of the grippers.

FIGS. 5-7show different options as to how a product2which is introduced into a compartment12can be held and opened.

In the example ofFIG. 5, a clamping element22is situated at the outer edge15′ of the dividing wall14, which clamping element22can be pivoted in a controlled manner relative to the dividing wall14and can clamp one of the product parts6at its preliminary fold3against the dividing wall14. The products2are opened by the compartment12changing its orientation by movement along the circulating track U. Movable stop elements18, against which the folded edge5bears during the conveying by the circulating system10, are arranged in the region of the pocket base13.

Stop elements18′ are shown using dashed lines, which stop elements18′ are at a greater distance a from the rotational axis D and hold a product2′ of smaller length (folded edge5′) in such a way that its preliminary fold3′ can be gripped by the clamping element22.

In the example ofFIG. 6, nozzles26which are connected to a vacuum source27are arranged in the dividing wall14. The product part6which trails in the direction of revolution is held on the corresponding compartment wall by vacuum. The product2is opened in turn during a change in the orientation of the compartment12. The vacuum supply can preferably be established and interrupted in a controlled manner, in order not to attract the product2by suction until it is introduced completely into the compartment12, and to release it again at the transfer point. A preliminary fold3is not necessary in this variant.

FIG. 7shows an example, in which the opening operation of a product2which is already held at a product part6is assisted by additional means. In the present case, the latter are realized by further nozzles28which are connected to a compressed air source29. The nozzles28preferably blow air between the two product parts4,6, that is to say in the direction of the folded edge5, with the result that they are raised up from one another. The nozzles28are stationary or are moved together with the compartments12; in the latter case, the compressed air supply can preferably be controlled. Instead of compressed air, mechanical means could also be used to open the product2, for example an opening blade.