Apparatus for feeding a signature collator

Abstract: An apparatus (41, 62) for feeding sets of signatures, supplied by signature stacking machines (10, 11, 12), to a signature collator (5) having a predetermined large number of compartments (6), in such a way that automatic book production can be achieved, comprises, for each compartment (6) of the collator (5), two trains of boxes (24, 25) movable along a forward travel line (26), the boxes (31, 32) of each train of boxes (24, 25) being capable of being positioned initially at a first end of the forward travel line (26), in synchronization with a first manipulator (21), to receive sets of signatures, and being capable of being positioned subsequently at a second end of the forward travel line (26), in synchronization with a second manipulator (23), to transfer the sets of signatures to the compartment (6) of the collator (5).

Description: The present invention relates to an apparatus for feeding sets of signatures to a signature collator which has a predetermined large number of compartments. As is known, for book production, in general, use is initially made of folding machines, which produce, from printed sheets, corresponding signatures, a predetermined large number of which are designed to be stitched together to form a book. In particular, the signatures thus formed and stacked in sets are dropped into a collator, which has a predetermined large number of compartments, each designed to receive the said sets to form stacks of signatures. The collator subsequently supplies the signatures from all the compartments for stitching to form the desired books. At the present time, book production requires a high proportion of manual labour, which is used, with appropriate means of transport, to convey the sets of signatures, each set containing a multiplicity of individual identical signatures, to the collator, placing each set in the corresponding appropriate compartment. This mode of operation is laborious, requires the use of large numbers of personnel and is very time-consuming. Moreover, personnel may make mistakes, for example by loading the signatures into an incorrect compartment, thereby adversely affecting the quality of the books produced and even creating wastage. These problems have been accepted up to the present time as a matter of necessity, since no automatic line for book production, starting from the sheets to be folded into signatures and continuing up to the stitched book, has ever been made or devised. In the prior art are disclosed carrying elements driven in a circulating direction, charging and discharging sheet-like products, see for example documents EP 0 771 754 A and DE 22 37 222 A. In EP 0 218 872 A it is disclosed a plurality of hoppers which are product-loadable and are transported along a path of conveyance. It should be pointed out that this is because a hypothetical book production line would include in a single system, on the one hand, the folding machine, which is a very fast machine designed to carry out a single operation on a single part, and used for successive cycles as required, and, on the other hand, the collator, which is a relatively slow machine, but which acts on a plurality of parts, namely all the signatures required for the production of the desired book. The problem which has given rise to the present invention is that of devising an apparatus to feed a signature collator of the specified type, to enable such a desirable automatic line to be developed. This problem is solved by an apparatus of the specified type, according to claim 1. Advantageously, in the said apparatus there are two trains of boxes, movable independently of each other along the forward travel line. Also advantageously, the apparatus comprises a return travel line, forming together with the forward travel line a closed loop around which the said trains of boxes travel. According to a variant embodiment of the said invention, there are advantageously two trains of boxes, forming two substantially overlapping independent closed-chain box conveyors. Further characteristics and the advantages of the apparatus according to the present invention will be made clear by the following description of a preferred embodiment of the invention, provided for information and without restriction, with reference to the attached figures: Figure 1 is a schematic plan view of an automatic book production line incorporating an apparatus according to the invention; Figure 2 is a schematic plan view, on an enlarged scale, of a detail of the apparatus shown in Figure 1; Figure 3 is a schematic perspective view of a detail of the apparatus shown in Figure 1; Figure 4 is a schematic plan view of an automatic book production line incorporating an apparatus according to the invention, according to a variant embodiment; and Figure 5 is a side view, on an enlarged scale, of a detail of the apparatus shown in Figure 4. With reference to the attached figures, the number 1 is a general reference for an automatic book production line. In the line 1 there is a group consisting of a predetermined small number of folding machines, three in the example, indicated by the numbers 2, 3 and 4. The line 1 also comprises a single collator, which is indicated by the number 5, and comprises a predetermined large number of identical compartments, fifteen in the example, all indicated by the number 6, each designed to house corresponding sets of signatures of the book to be produced. It should be noted that the compartments 6 are disposed in an alignment extending in a longitudinal direction X-X and are distributed regularly at intervals according to a predetermined step P. The line 1 is completed by a group of stitching machines, in particular three machines, indicated by the numbers 7, 8 and 9, which are fed by the collator 5 with identical sets of signatures, fifteen in the example, all different within each set of signatures, the signatures being disposed in the order required for the production of the book, as supplied by the collator. Clearly, in the case of books which are paperbound rather than stitched, a paper-binding apparatus would be provided in place of the stitching machines. In line 1, according to the present invention, corresponding stacking machines 10, 11 and 12 are provided after the folding machines, to make up sets of identical signatures supplied by the folding machines. Three conveyor belts 13, 14 and 15, which run parallel to each other in a direction Y-Y perpendicular to the direction X-X, run from the stacking machines 10, 11 and 12, respectively. The conveyor belts 13, 14 and 15 are disposed at intervals according to the said predetermined step P. Each of the conveyor belts 13, 14 and 15 runs from a corresponding stacking machine 10, 11 and 12, and terminates at a collecting conveyor belt 16, which extends parallel to the direction X-X, and therefore extends parallel to the alignment of the compartments 6 of the collator. The collecting conveyor belt 16 is movable through intervals according to the said step P, over a distance which comprises a first portion 17 in front of the belts 13, 14 and 15, and a second portion 18 in front of the alignment of the compartments 6. Between the second portion 18 of the collecting conveyor belt and the alignment of compartments 6 there extends, in the direction Y-Y perpendicular to the direction X-X, a plurality of linear conveyors, all indicated by the number 19, one for each compartment 6 and each positioned level with a corresponding compartment 6. At a first end 20 of each linear conveyor 19 there is a manipulator 21, at a position between the collecting conveyor belt 16 and the said first end 20. Similarly, at the second end 22 of each linear conveyor 19, there is a manipulator 23, at a position between the second end 22 and the corresponding compartment 6 of the collator. These manipulators 21 and 23 are of a conventional type, are also known as robots, and are normally used in the automatic manipulation of components. Each linear conveyor 19 comprises two identical trains of boxes, indicated by the numbers 24 and 25, movable along a forward travel line, indicated in a general way by the number 26, extending from the first end 20 to the second end 22, and along a return travel line 27 extending in the opposite direction, the forward travel line and the return travel line forming a closed loop 28. The two trains 24, 25 move in substantial alignment and independently of each other under the action of corresponding motor means which are conventional and are not shown. Each train 24, 25 comprises corresponding metal plates 29 and 30, rectangular in shape and bent into an L-shape at the bottom. Between every two plates of each train 24, 25 a corresponding box 31, 32 for housing a set of signatures is formed. Each of the plates 29, 30 has two fixing points, indicated by 33, 34 and 35, 36 respectively, which are disposed along one side of the rectangle, for fixing to corresponding closed chains. In particular, the fixing points 33 and 34 of the plates 29 of the train 24 are fixed to two closed chains 37 and 38, and the fixing points 35 and 36 of the plates 30 of the other train 25 are fixed to two closed chains 39 and 40. The closed chains 37 and 38 and the closed chains 39 and 40 have the same gauge S, and there is a small distance Δ between them. It should be noted that the assembly consisting of the conveyor belts (13,14,15), the collecting conveyor belt, the conveyors and the manipulators (21,23) forms an apparatus 41 capable of feeding the signature collator which has a predetermined large number of compartments, with groups of sets of signatures supplied by groups of signature stacking machines. In operation, the folding machines are fed with sheets to be folded into signatures. In the present example, each of the folding machines carries out five cycles, folding in succession. three of the fifteen signatures required to form the desired book. After the folding machines, the signatures are stacked by suitable stacking machines and transferred, in sets, along the conveyor belts 13, 14 and 15. The sets are dropped from the conveyor belts on to the portion 17 of the collecting conveyor belt 16 which is movable by steps. The collecting conveyor belt 16 which is movable by steps positions itself in such a way as to supply the manipulators with three sets of signatures, exactly level with the position of the compartments 6 of the collator, for which the three sets are intended. The three sets are dropped by the corresponding manipulators 20 into the boxes 31 of the first train 24, which, being also movable by steps, halts next to the first end 20, alongside the manipulator 21. With successive stepping movements of the collecting conveyor belt 16, numbering five in total, all fifteen of the signatures required for the formation of the book are dropped into the boxes of the first train 24 of each linear conveyor 19. When the trains 24 are full, they move along the forward travel line 26 and are carried to the second end 22 of each conveyor, next to the corresponding manipulator 23. The manipulators 23 start to feed the sets of signatures into the compartments 6 of the collator. In the meantime, the second trains 25 travel along the return travel line 27 and are carried to the first end 20 within the range of the manipulators 21. In other words, each of the trains 24 and 25 in succession receives sets of signatures from the corresponding manipulator 21 when it is at the first end 20 of the conveyor 19, and supplies these sets to the manipulator 23 when it is at the second end 22 of the said conveyor. Particularly the boxes 31,32 of the train of boxes 24,25 are positioned initially at a first end of the forward travel line 26, in synchronization with the first manipulator 21 to receive sets of signatures supplied by the group of signature stacking machines 10,11,12, and are positioned subsequently at a second end of the forward travel line 26, in synchronization with the second manipulator 23, to transfer the said sets of signatures from the boxes 31,32 of the train of boxes 24,25 to the compartment 6 of the collator 5. The principal advantage of the apparatus according to the present invention is that it makes it possible to feed, in a fully automatic way, the signatures supplied from folding machines, which act in a very fast cycle on individual components, to a collator, which acts with an operationally slow cycle on a plurality of components. A further advantage of the apparatus according to the present invention is that it has been found to have a simple and reliable structure, which is not the least of the advantages for an apparatus which is required to have a substantially continuous operating cycle. A further advantage of the apparatus according to the present invention lies in the correctness of the completed books, preventing any possible manual error typical of the known art. With reference to Figures 4 and 5, the description of a variant embodiment of the invention is given below; in this embodiment, parts structurally or functionally identical to those shown in Figures 1 to 4 have the same reference numbers. In a line 51 according to Figures 4 and 5 there are linear conveyors 52, each of which comprises two trains of boxes 53 and 54, forming corresponding closed-chain box conveyors 55 and 56, each of which has a forward travel line 26 and a return travel line 27. The closed-chain box conveyor 55 has a greater length and is disposed below, while the closed-chain box conveyor 56 has a smaller length and is disposed above, substantially overlapping the conveyor 55. Owing to its smaller length, the upper conveyor 56 allows the signatures to be loaded into and discharged from the lower conveyor 55 by first manipulators 57 and second manipulators 23 operating at the first ends 58 and at the second ends 59, respectively, of the linear conveyor 52 and facing the stacking machines 10, 11 and 12 and the collator 5 respectively. It should be noted that in the line 51 the number of first manipulators 57 is equal to the number of the stacking machines in the group of stacking machines 10, 11 and 12, the said first manipulators 57 being movable in the longitudinal direction X-X parallel to the alignment of the compartments 6 of the collator. The stacking machines 10, 11 and 12, with the corresponding folding machines 2, 3 and 4, are disposed in alignment in the direction X-X, each in a central position with respect to a corresponding group of five linear conveyors 52 of the fifteen linear conveyors of the line 51. Each of the three first manipulators 57 takes signatures from a corresponding stacking machine and deposits them in the boxes of a linear conveyor 52 of the corresponding group of five linear conveyors; more precisely, it deposits them successively in one of the two trains of boxes 53 and 54, while the other train of boxes is transferring the signatures to the collator by means of a manipulator 23. The first manipulators 57 are of a conventional type. For example, the manipulator 57 may comprise a head 60, which is movable in the three orthogonal directions "a", which is longitudinal and parallel to X-X, "b", which is vertical, and "c", which is transverse and parallel to Y-Y, and is rotatable through 180° as shown by the arrow "d". The head 60 is provided with a gripper 61 which can be orientated as shown by the arrow "e" to take sets of signatures from the stacking machines and to release them into the boxes of the trains of boxes 53 and 54 in succession. The assembly consisting of the linear conveyors 52 and the manipulators 57 and 23 forms an apparatus 62 capable of feeding the collator with sets of signatures supplied by groups of stacking machines. The line 51 according to the variant in Figures 4 and 5 provides the advantage of an unusual compactness, owing to a reduced length of the linear conveyors, for the same output, and is structurally simple, owing to the reduction of the number of first manipulators. Clearly, a person skilled in the art may make numerous modifications and changes to the apparatus described above, in order to meet contingent and specific requirements, all such modifications and changes being contained within the scope of protection of the invention, as defined by the following claims.

Claims: Apparatus (41, 62) for feeding sets of signatures to a signature collator (5) having a predetermined large number of compartments (6), characterized in that it comprises, for each compartment (6) of the collator (5), at least one train of boxes (24,25,53,54) and motor means for moving said at least one train of boxes (24,25,53,54) along a forward travel line (26), a first manipulator (21,57) positioned at a first end (20) of said forward travel line (26), a second manipulator (23) positioned at a second end (22) of said forward travel line (26), said motor means for moving the boxes (31,32) being suitable for positioning the boxes (31,32) initially at the first end (20) of said forward travel line (26), in synchronization with the first manipulator (21,57) to receive sets of signatures supplied by a group of signature stacking machines (10,11,12), and subsequently at the second end (22) of said forward travel line (26), in synchronization with the second manipulator (23), to transfer the said sets of signatures from the boxes (31,32) of the train of boxes (24,25,53,54) to the said compartment (6) of the collator (5). Apparatus (41) according to Claim 1, characterized in that it comprises two trains of boxes (24,25), independent of each other, motor means for moving independently each of the two train of boxes (24,25) along the forward travel line (26), in such a way that when one train of boxes is receiving the sets of signatures at the first end (20) of the forward travel line (26) the other train of boxes is transferring the sets of signatures to the compartment (6) of the collator (5) at the second end (22) of the forward travel line (26). Apparatus (41) according to Claim 2, characterized in that it comprises a return travel line (27), forming together with the forward travel line (26) a closed loop (28) around which the said trains of boxes (24, 25) travel. Apparatus (62) according to Claim 1, characterized in that there are two trains of boxes (53, 54), forming two substantially overlapping independent closed-chain box conveyors (55, 56). Apparatus (62) according to Claim 1, characterized in that the number of first manipulators (57) is equal to the number of stacking machines in the group of stacking machines (10, 11, 12) and the first manipulators are movable transversely with respect to the forward travel line (26) of the said at least one train of boxes (53, 54). Automatic book production line (1,51), characterized in that it comprises a group of folding machines (2,3,4) supplying sets of signatures, a signature collator (5), receiving the signatures and supplying the signatures in the order required for the production of the book to a book making machine, an apparatus (41,62) according to any of the preceding claims, receiving sets of signatures and feeding sets of signatures to said collator (5).

Inventors: MERATTI GIANATTILIO, MERATTI, GIANATTILIO
Applicants: MECCANOTECNICA SPA, MECCANOTECNICA S.P.A.
Application year: 1998
Main classification: B65H39
IPC codes: B65H39, B42C19