Control system for pre-setting and operation of a printing press and collator

A process for manufacturing multi-part forms using at least one web press having one or more printing stations and one or more processing stations at which operations are performed on webs in registry with a series of printed images produced at a printing station, and also using a collator having a collating station at which job related webs from said press or presses are assembled in registry and having one or more processing stations at which additional operations are performed on the assembled webs in registry with a series of printed images thereon;

• the steps comprising
• (a) creating a digital job description of a form including the location and content of printed images on the several parts of the form and/or the location of process items such as perforations, holes, cuts or other markings on one or more parts of the form,
• (b) storing said job description in a digital memory with a job identifying number,
• (c) creating a digital description of the images to be printed on the parts of the form,
• (d) storing said image descriptions in the memory associated with the job identifying number,
• (e) using the digital job description from the memory to pre-set the printing sections and processing sections of a press for each part of the form,
• (f) producing the several parts of the form on the press or presses and supplying the parts to the collator,
• (g) using the digital job description to pre-set the processing stations of the collator, and
• (h) assembling and completing the processing of the several parts on the collator into a quantity of multi-part forms sufficient to complete the job.

In a forms plant including

• a first terminal for generating data describing the composition and arrangement of a business form,
• a computer receiving data from said first terminal and having at least one data output line,
• said computer functioning to prepare job instructions from the data,
• a data processor communicating with one of said data output lines and functioning to store makeready data, and
• a microprocessor controller receiving the makeready data from said data processor and transmitting the makeready data to a plurality of power operated adjustors on a web processing machine upon command of the operator.

A printing system comprised of:

• at least one machine having a plurality of stations along a path through which web material is transported, said stations including apparatus for operating on said material to produce printed matter and related physical changes on the web material, adjustment means at certain of said stations for changing the lateral or circumferential position of the apparatus relative to the path of movement of said materials;
• computer means including a memory,
• input means including at least one terminal and a display for inputting information including the identification of certain job parameters concerning operations to be performed on the web material and for storing the parameters in said memory;
• means for storing a job number in said memory in association with the job parameters;
• adjustment control means coupled to said adjustment means for controlling the position of said adjustment means in response to control signals derived from information stored in said memory;
• and
• machine control means coupled to said computer means and said adjustment control means for associating a machine with a job number and for applying the control signals to said adjustment control means for presetting the adjustment means at the machine in accordance with the job parameters in memory associated with the job number.

A forms production system comprising:

• data input means for determining in digital form certain parameters of the layout of a form to be produced including a computer, and a memory for storing information pertaining to the parameters concerning the content of a form and for supplying information to produce the form;
• means for supplying a job number to said computer for storage in said memory in association with form content parameters stored in said memory,
• a machine for receiving at least one portion of said information for producing the form, including a plurality of stations arranged along a path and having apparatus for operating on web form material to be moved through the machine along such path;
• said stations including adjustment means for positioning parts of the apparatus laterally or circumferentially relative to the path the material travels through the machine;
• control means responsive to makeready position signals for controlling the settings of said adjustment means, and
• means for generating makeready position signals from said stored information and supplying such signals to said control means to preset said adjustment means in accordance with the parameters of the form to be produced.

Apparatus for producing forms comprising:

• a machine for producing forms including means for transporting material along a given path and a plurality of stations along the path for consecutively performing repetitive operations on the material, said stations including means for operating repetitively on the material as a step in the production of a form and said stations including adjustment means for laterally and/or circumferentially adjusting the operation of the mechanisms relative to the path of travel of the material;
• forms composing means for identifying certain parameters of a form to be produced relative to said adjustment means and the path of travel of the material and a memory receiving and storing such parameters from said forms composing means;
• said forms composing means including a digital processor communicating with said memory,
• means for supplying a job number to said processor for storage in said memory in association with the parameters stored in said memory,
• control means for positioning the adjustment means;
• and
• computer means, responsive to a command signal, for generating position signals from the parameters stored in said memory and applying the position signals to said control means for automatically positioning the adjustment means in accordance with the specified form to be produced.

A printing system comprising:

• a plurality of printing presses, each having a plurality of stations along a predetermined path through which web material is transported, each of said stations including mechanism for operating repetitively on the material to produce printed matter or related physical changes on the material, certain of said stations including adjustment means for locating the lateral or circumferential position of the mechanism relative to the predetermined path of movement of said material;
• a plurality of adjustment control means, a separate one of each of said adjustment means, each of said adjustment control means being responsive to control signals for controlling the position of its connected adjustment means;
• a plurality of processors, a separate one for each of said printing presses, coupled to each of the adjustment control means on its respective press for providing control signals thereto to position the associated adjustment means;
• editing means having a visual display for designing the layout of information to be printed and including means for identification of certain parameters for use in presetting said press adjustment means according to a desired layout, which parameters along with the information to be printed and an associated job identification number are adapted to be stored;
• circuit means coupled to said editing means for supplying said print information in digital form for use in plate making;
• a central computer including a memory, coupled to said editing means for receiving and storing the parameters in the memory with the associated job number;
• terminal means coupled to said central computer for supplying information concerning production, supply and tooling for storage in said central computer memory in association with the corresponding job number;
• and
• circuit means coupling said central computer to each of said plurality of press processors for supplying the parameters from memory to a selected press and to enable said press processor to automatically preset said adjustment means in accordance with said parameters.

In a machine for performing processing operations on a web of material, said machine comprising

• a plurality of stations arranged to define a path along which the web is transported,
• rotary mechanisms at said stations functioning to perform repetitive operations on the passing web,
• a drive for operating said rotary mechanisms in synchronism, including means defining a rotary zero position of the drive,
• means for connecting said rotary mechanism to said drive and providing for limited rotary displacement of selected ones of said rotary mechansims relative to the rotary zero position,
• means for establishing a lateral zero position relative to said web path,
• adjustable mounting means for supporting at least some of said rotary mechanisms for lateral displacement relative to said lateral zero position;
• the improvement comprising
• first power operated adjustment means incorporated in said means for connecting,
• second power operated adjustment means incorporated in said adjustable mounting means,
• control means for receiving makeready adjustment information and connected to both said adjustment means to cause predetermined displacements of the rotary mechanisms relative to the rotary and lateral zero positions;
• a layout device coordinated to said adjustment means and including means for locating the layout of a form or forms to the available operating area of the rotary mechanisms,
• means in said layout device operable to generate parameters of a form layout as digital displacment instruction signals compatible to said control means, and
• means for transmitting such instruction signals to said control means during makeready operation of said machine.

In a forms plant including departments for production supervision, sales/estimating, composition, accounting, a manufacturing department having at least one forms press and one collator, a supply department tor storing ink, paper, and other supplies and including a receiving area, and a shipping department;

• the improvement comprising
• a computer including a CPU, a memory providing means for storing an integrated data base for jobs, and a plurality of terminals for use by the departments to enter order and design information, job instructions, and the like under a job identification code;
• an interactive control for the press and the collator including an operator console, a mcroprocessor controller, power operated adjustors on the press and the collator and drivable by said controller, and means on the press and the collator providing feedback data to said controller;
• and
• means providing data communication between said computer and said controller, whereby a unique data base may be created in said memory for each form manufacturing job and may be utilized and/or added to by each department as the job progresses through the plant.