Abstract:
A log of printed products having thereon an identification that is programmable and then readable to access information regarding the printed products that make up the log such as product identification, orientation and destination. The printed products include either bound or non-bound printed products. A method of utilizing a smart log includes creating a log of printed products, programming an identification associated with the log with information relating to the printed products, coupling the identification to the log, transporting the log to a destination for processing, reading the identification while the identification is coupled to the log, and handling the log in response to the information read from the identification.

Description:
FIELD OF THE INVENTION 
     The invention relates to logs of printed products having thereon a programmable identification which is accessible to provide product information such as product identification and orientation, and relates to methods for producing such logs and methods for utilizing such logs. 
     BACKGROUND OF THE INVENTION 
     As used in the printing industry, a log is a stack of typically unbound printed products such as signatures that are contained on each end of the stack with an end board. The signatures and end boards are then strapped to create a unified structure that can be transported with a device such as a forklift or crane. Such a log makes transporting quantities of signatures more efficient. In use, the logs are transported to and loaded onto a log loader of a binding line where the log is unstrapped and end boards removed. The signatures are then feedable to the binding line. 
     When transporting and loading a log onto a log loader of a binding line, errors can occurs such as the log of signature being delivered to the wrong log loader or such as the log of signatures being loaded onto the log loader in an incorrect orientation. Different types and models of log loaders require different signature orientations, i.e., spine leading, lap leading, etc. 
     SUMMARY OF THE INVENTION 
     The invention provides a log of printed products which include thereon a programmable identification that is readable to provide information regarding the printed products that compose the log. The information readable from the log ensures that further processing of the log is conducted without errors or is conducted more efficiently. 
     In one embodiment of the invention, the log is composed of unbound printed products such as signatures. When the log of signatures is created, the programmable identification is programmed to include information such as signature identification and orientation. When needed, the log is transported to a binding line and loaded onto a log loader by a lifting device such as a crane and bundle clamp. One or both of the bundle clamp and log loader have a reader thereon to read the identification on the log. The accessed information eliminates errors by ensuring that the log is loaded onto the correct log loader and loaded in the correct orientation. 
     In another embodiment of the invention, the log is composed of bound printed products such as magazine, catalogs, books, direct mail pieces, or the like. The log has thereon a programmable identification which is readable to provide information regarding the contents of the log such as product type, orientation, postal destination, end of pallet, or the like. The identification is readable during subsequent transporting or processing of the log to reduce handling errors and increase processing efficiency. 
     The invention includes methods for producing logs of printed products having thereon a programmable identification containing readable information relating to the printed products that compose the log as well as methods for utilizing or further processing such logs. In particular, the invention also includes a method for forming a log of bound printed products. 
    
    
     Other features and advantages of the invention will become apparent to those of ordinary skill in the art upon review of the following detailed description, claims, and drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a log of signatures. 
     FIG. 2 is a perspective view of a log of signatures being created. 
     FIG. 3 is a schematic of a typical saddle stitcher binding line. 
     FIG. 4 is a perspective view of a bundle clamp loading a log loader. 
     FIG. 5 is a perspective view of the bundle clamp loading the log loader. 
     FIG. 6 is a perspective view of a log of bound printed products. 
     FIG. 7 is a schematic of a portion of a binding line. 
    
    
     Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings, there is shown in FIG. 1 a printed product assembly or log  10  of printed products. The log  10  includes printed products such as the signatures  12  shown in FIG. 1 stacked one adjacent the other. The logs  10  can be of varying sizes and other orientations such as U or L shaped in correspondingly configured enclosures. For example, log  10  can range from 36-50 inches in length. Optionally, on each end of the stack of signatures is an end board  14 . It should be noted however that the present invention can be implemented without the use of end boards. The end boards  14  are typically dimensioned to be approximately the same size as the signatures  12  but can be of other varying sizes. The end boards  14  can be fabricated of materials such as paper, wood or plastic. A fastener such as strap  16  is wrapped around the signatures  12  and end boards  14  to enable the log  10  to be moved as a unitary piece without falling apart. 
     The invention includes the use of a programmable identification  18  in conjunction with the log  10 . The identification  18  preferably is positioned within one or both of the end boards  14  and can take the form of an embedded microchip, a RF tag or similar programmable technology such as electronic, magnetic, optical or computer related technologies. For example, RF tag technology is available from Motorola. Preferably, the identification  18  is adhered to one of the end boards  14  such as with an adhesive. However, it should be noted that other attachment or securing methods can also be employed to associate the identification  18  to the end board  14 . If end boards are not used, the identification  18  can be placed on the stacked signature(s) such as with a RF tag or magnetic ink printed on one or more signatures such as on the lap of a signature. 
     The identification  18  is intended to make the log  10  a “smart log” and thus eliminate errors when transporting and using the logs in the binding process, errors such as in loading the wrong signature or a signature in the wrong orientation onto a loader of a binding line. 
     With reference to FIG. 2, a log  10  is conventionally created on press with the use of a stacker  20  (a portion of which is shown in FIG.  2 ), also called a bundler or stacker/bundler, to make logs of a given length dimension. On a conventional stacker  20  such as model 3600 available from QTI of Sussex, Wis., an arm  22  having a suction cup  24  puts down the lower most end board  14  before the stack of signatures  12  is created then positions the uppermost end board  14  after the stack is created. At some point before, during or after creation of the stack, the identification  18  is appropriately programmed by programmer  26 , for example. The information programmed or embedded onto the identification  18  preferably includes signature identification (what form has been bundled), log orientation (where the backbone is and the direction of the high/low folio), and log position on a pallet. Any other information could be programmed or embedded as well. After a log  10  is created and the identification  18  programmed, the log  10  is typically piled via crane/hoist onto a pallet and stored until needed at a binding line or other processing destination. 
     Turning now to FIG. 3, a typical saddle stitcher binding line  28  is shown. It should be noted that the invention is capable of being used with other configurations and types of binding lines and capable of being used in other processing in other destination in addition to bindery lines. The binding line  28  includes generally the following conventional components: pallets  30  for the logs  10 , log loaders  32 , pockets  34 , a trimmer  36 , a mail table  38 , a stacker  40  and a controller  42 . It should also be noted that more or less than the nine log loaders  32  shown in FIG. 3 can be utilized depending upon the specifics of a given binding job. 
     Before a binding job is begun, information regarding the job is downloaded into the controller  42 . Pocket assignments for each signature are inputted into the controller  42 ; i.e., which pockets will be feeding which signatures, and inputs the log loader type to be used for each signature. 
     Different types and models of log loaders  32 , also called feeders, require different signature orientations; i.e. spine leading, lap leading, etc. Associated with each log loader  32  is a pallet  30  for the logs  10  that are to be loaded onto a particular log loader  32 . Logs  10  that correspond to a given pocket/log loader  32  are transported such as by a forklift from a storage location onto a pallet  30  and positioned adjacent a respective log loader  32 . A hoist such as a conventional crane system provided with a bundle clamp is preferably utilized to transfer logs  10  from the pallet  30  to the corresponding log loader  32 . 
     Turning now to FIGS. 4 and 5, it is imperative that the correct signatures  12  in the correct orientation are loaded onto a particular log loader  32 . To this end, the identification  18  on each log  10  is utilized to eliminate handling errors. Preferably, the bundle clamp  44  and the log loader  32  each include a reader  46  or scanner to read the data from the identification  18  on each log  10 . The position of the reader  46  on the bundle clamp  44  or log loader  32  can vary. Both the bundle clamp  44  and the log loader  32  are in communication with the controller  42  and can be in communication with each other. It should be noted that the reader  46  could be located only on the bundle clamp  44  or only on the log loader  32  instead of in both locations. 
     Typically, log loaders hold approximately two and one half logs of signatures. When a log  10  needs to be loaded onto a log loader  32 , the bundle clamp  44  picks up the log  10 . The reader  46  on the bundle clamp  44  reads the information from the identification  18 . The information is sent to the controller  42  for verification that the proper signatures  12  are being loaded onto a particular log loader  32  that corresponds to a particular pocket  34 . The information is also used to ensure that the bundle clamp  44  rotates and orients the signatures  12  properly with respect to the log loader  32 ; i.e., lap leading and spine down. It should also be noted that the bundle clamp  44  could read the identification  18  from the log  10  before the bundle clamp  44  picks up the log  10 . 
     A crane (not shown) then moves the bundle clamp  44  with log  10  held therein to a particular log loader  32  and orients the log  10  in response to the information it obtained from the identification  18  on the log  10 . Before the bundle clamp  44  can release the log  10  onto the log loader  32 , the reader  46  on the log loader  32  reads the information from the identification  18 . The information is sent to and analyzed by the controller  42 . From a look-up table, the controller  42  knows the proper orientation and signature identification required for each log loader  32 . If the analyzed information does not match what the controller  42  is programmed to accept, the bundle clamp  44  is not permitted to open or release the log  10 . A technician is alerted as to the problem such as with an audible alarm or on a display. 
     If the analyzed information matches what the controller  42  is programmed to accept, the bundle clamp  44  is permitted to open and the log  10  is released onto the log loader  32 . A technician then removes the strap  16  and removes the end boards  14  and the signatures  12  proceed conventionally into the respective pocket  34 . The end boards  14  can then be reused in the formation of another log  10  and thus reprogrammed when a new log  10  is created. Optionally, the end boards  14  with identification  18  thereon could be discarded. 
     The above described embodiment of the invention involves a log  10  comprised of printed products that were individual conventional signatures  12 . A second embodiment of the invention is illustrated in FIGS. 6 and 7. 
     With reference to FIG. 6, a log  50  is shown that is comprised of already bound printed products  52 , also called books, such as magazines, catalogs, direct mail pieces, or the like stacked one adjacent the other. On each end of the stack of bound printed products is an end board  54 . The end boards  54  are preferably dimensioned to be approximately the same size as the bound printed products  52  and are fabricated of materials such as paper, wood or plastic. Straps  56  are wrapped around the printed products  52  and end boards  54  to enable the log  50  to be moved in one piece without falling apart. 
     To create a log  50  of bound printed products  52 , a stacker (not shown) also called a bundler or stacker/bundler, is employed such as model 3600 available from QTI of Sussex, Wis. After the log  50  is created, an identification  58  is appropriately programmed as explained above with respect to the first embodiment. The information programmed or embedded onto the identification  58  preferably includes product identification and distribution information such as subscriber information, postal destination end of pallet and sequence. Any other information could be programmed or embedded as well. 
     The information associated with each log  50  can then be utilized when moving the log  50  to a pallet to ensure that the log  50  is being transported to the proper location. The transportation device utilized to move the log  50  has thereon a suitable reader  46  to read the information from the identification  58  on the log  50  to ensure that no transportation errors occur. 
     The information associated with the log can also be utilized by a distribution or mailing center. For example, the U.S. Postal Service (USPS) could be provided with a reader  46 . Upon arrival or upon loading into sorting equipment by a crane, the reader  46  would read the identification  58  for a given log  50  and gain information about that log  50  such as the type of product, number of products in the log, products&#39; ultimate destinations, postal fee information, etc. The read information could be used to increase the efficiency of the delivery system by enabling increased automation and less handling errors. 
     Turning now to FIG. 7 in particular, a portion of a binding line  60  is shown and a second method for forming the logs  50  of bound printed product  52  is illustrated. The printed products  52  are bound in the usual bindery fashion in conjunction with a controller  62 . After the products  52  complete the assembly process, they are conveyed on a mail table  64  towards equipment used to prepare the products for shipment to the USPS or any other destination. In the usual fashion, the products  52  are bundled following USPS specifications. That is, bundled packages of products  52  (strapped, shrink wrapped or combinations thereof) are made for carrier route, 5-digit, 3-digit, etc. and piled on a pallet. The height and weight of these bundles are limited by USPS specifications and typical bindery equipment. 
     Lane A of FIG. 7 utilizes equipment and a method of preparing traditional bundles of bound printed product  52 . The conventional equipment includes the following: a directional conveyor  66 , a reject conveyor  68 , a bundle stacker  70 , a bundle strapper  72 , bundle conveyors  74 , a bundle wrapper  76 , a heat tunnel  78  and a bundle pallet  80 . This equipment is typically used in the bindery to prepare bound printed products  52  for shipment. A hand strapper  82  is also shown that is used as a back-up method of securing bundles if any failures occur during the packaging process. Products  52  come off the mail table  64  into Lane A, bundles of products  52  are strapped and wrapped, transported through a heat tunnel  78  then conveyed via the bundle conveyor  74  to a pallet  80 . Bundles sizes vary depending upon the number of pieces for a particular postal sort. 
     Lane B of FIG. 7 utilizes equipment and a method of preparing the bound printed products  52  in logs  50 , which is a more effective way of handling quantities of product  52 . The equipment utilized includes: a directional conveyor  84 , a reject conveyor  86 , a log stacker  88 , a log strapper  90 , a log conveyor  92 , a log crane  94 , and a log pallet  96 . 
     As shown in FIG. 7, workers for performing certain tasks are positioned at locations C, D and E. At location C, a worker piles product onto the pallet  80  if that product was produced in the traditional method of bundling. At location D, a worker operates the log crane  94 . At location E, a worker collects recalled printed products that are required to be loaded into a working pallet. Recalls are magazines that are re-manufactured for rejected products (missing pages, bad trim, missing staples, etc.). Because of the manufacturing process, these products cannot be produced before the log or bundle changes from one sort to the next unless generic books are used. The recalled magazines (if they do not get into the proper log or bundle) are removed from the binding line  60  onto the conveyors  68  and  86 . The worker collects these products  52  and places them into the required log or onto the required pallet. 
     In operation, as the assembled printed products  52  are conveyed on the mail table  64 , a controller  62  decides which Lane, A or B, the printed products  52  will be directed to. Typically, carrier route sort products  52  would be directed to Lane A because the products  52  for carrier routes justify a traditional bundle. 
     Because any mailed pieces (other than a carrier route package) need to be sorted by the USPS or like entity, an effective way to present product to the sorting system is in the form of a log  50 . A log  50  of product  52  presents more pieces to the sorting system in the same amount of time than numerous bundles of product, which are currently lifted one, or a few at a time, by USPS personnel. Further, a log  50  of product  52  typically has less waste material than a series of bundles. A log  50  utilizes fewer straps  56 , whereas the amount of bundles equaling the products  52  held in one log  50  would produce many more straps as well as wrapping material. Consequently, because more pieces are delivered to a sorter in the same amount of time, and less waste material required for the same amount of product, a log  50  of product  52  is more efficient than a traditional bundle. 
     An example of the usage of Lane B is as follows. If 700 pounds of magazines are to be manufactured for a 5-digit postal destination and each magazine weighs ⅕ of a pound, then 3500 magazines will be produced for this 5-digit pallet. If each magazine is ⅕ of an inch thick, then 700 inches of magazines need to be fitted onto a pallet. To optimally fit a typical pallet, which is approximately 47 inches by 40 inches, logs  50  would be created in approximately 46 inch lengths. As the magazines proceed on the directional conveyor  84  into the log stacker  88 , the controller  62  preferably, although not necessarily, monitors the process. When 46 inches of magazines have been stacked, the log  50  is delivered to the log strapper  90  where it is strapped. Without interruption, and while one log  50  is being strapped, another log  50  can be formed in the log stacker  88 . The strapped log  50  is conveyed towards a crane  94  where it is picked up and then placed on the pallet  96 . After fourteen logs  50  have been created at 644 inches, approximately 56 inches of product remain to be produced. The controller  62  or stacker can either create another log of 46 inches and then a 10 inch log, or split the remaining 56 inches of product into equal lengths (28 inch logs) or any combination thereof. Monitoring the process of sorting the bound printed products  52  is well known in the industry, and therefore, knowing where one bundle, log or pallet ends and the next begins, is commonly executed in many binderies. The end of bundle/log/pallet information could be data included in the programmable identification  18 . Such information could be used to help ensure bundle/log/pallet integrity. Sounding a horn or illuminating a light when a pallet is complete could be an aid for any technician working this area. Sorting the printed products  52  either in logs  50  or bundles poses no difficulties for the controller  62 . It should be noted that bundles of any size or length could be made at any time. 
     When the above described 5-digit pallet of magazines is completed, the next pallet is begun. If the next pallet is anything except a carrier route pallet, it is directed into Lane B. If the next sequence of production is a carrier route pallet, it would be directed into Lane A where bundles of magazines would be produced. 
     When creating the logs  50  in Lane B, the end boards  54  are placed on each end of the stack that is to form the log  50  at the log stacker  88 . Optionally, an identification  58  as described above for that log  50  can be programmed. Further, when creating logs  50  of bound printed product  52 , it may be necessary to compensate the products during the stacking process. Because bound printed products are sometimes thicker near the backbone, compensating them will offset this bulkier dimension and create a straighter more manageable log  50 . For example, FIG. 6 shows a log of compensated magazines wherein after every ten magazines, the next ten are turned 180°.