Note: Descriptions are shown in the official language in which they were submitted.
CA 02829454 2013-10-07
CONVEYANCE PRINTING SYSTEM AND METHOD FOR PRINTING ON
MULTIPLE DIFFERENT TYPES OF ARTICLES OF MANUFACTURE
Background of the Invention
The present invention relates generally to printing on articles of
manufacture,
and more particularly to a system and method for printing on multiple
different types
of articles of manufacture by the same conveyor printing system.
Performance improvements in computing, networking and communications
has led to enormous advances in the number and types of capabilities that one
can
io achieve using a networked device. For example, in the printing industry,
websites
such as www.vistaprint.com allow a user of a networked device to select and
customize template designs for printed and electronic products, and then to
order
and purchase quantities of such product(s). As the ability to customize
designs for
printed products becomes simpler for the end customer, the demand for
customized
printed designs on different types of products has increased. For example,
consumers desire not only printed paper documents such as business cards,
postcards, brochures, posters, flyers, etc., but also many other types of
items such
as shirts, hats and other garments, promotional items such as rulers, USB
drives,
calculators, toys, tape measures, etc., and other 2- and 3-dimensional items.
In an industrial environment, manufacturers of printed articles of manufacture
typically imprint the same design on a long run of the same type of article of
manufacture. This is due in part to the fact that mass production has
traditionally
been the realm of non-customized unpersonalized products, and further in part
due
to the high setup time for each print run. In general, in the past, higher
efficiencies in
terms of time and cost were achieved by printing the same design on large
quantities
of the same type of article of manufacture. .
Mass customization poses problems to the traditional model for achieving
high efficiencies in printing. For any given type of article of manufacture,
there may
be as many different unique designs to print as there are quantity of the
particular
type of article of manufacture. The problem is compounded when ond adds into
this
mix any number of different types of articles of manufacture.
What is needed is a new printing model which allows any number of unique
print designs to be printed on any number of different types of articles of
manufacture in a highly efficient manner.
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CA 02829454 2013-10-07
Summary Of The Invention
Embodiments include systems and methods for a conveyance printing system
which prints any number of unique print designs on any number of different
types of
articles of manufacture in a continuous flow. Embodiments of the invention may
further be configured to allow multiple different types of articles of
manufacture to be
interspersed in a print manufacturing flow in any order and without regard to
which
type(s) of articles of manufacture are precedingly or succeedingly printed in
the flow.
In an embodiment, a conveyance printing system includes a conveyance
system configured to convey a plurality of trays, each tray comprising an
identifier,
io each tray further configured to hold one or more articles of manufacture
within the
tray. The conveyance printing system further includes a printing system
configured
to receive a print tray from the conveyance system, receive print content
associated
with the tray identifier, and print the received contentonto the respective
print
surfaces of the one or more articles of manufacture held by the tray.
In another embodiment, a printing system is configured for processing
different types of articles of manufacture. The printing system includes a
conveyor
system which receives and conveys one or more articles of manufacture from an
entry port to an exit port of the printing system, an identifier reader which
reads an
identifier associated with the one or more articles of manufacture identifying
a type of
article of manufacture to be printed, a printer configured to receive print-
ready
content and to print the print-ready content on the received articles of
manufacture,
at least one of a pre- and/or post-print-processing treatment unit, and one or
more
controllers configured to selectively turn on or turn off one or more of the
at least one
pre- and/or post-print-processing treatment unit based on a determined type of
article of manufacture to be printed as identified from the read identifier.
In yet another embodiment, a manufacturing tray is configured for multi-
function
processing of different types of articles of manufacture. The tray includes a
tray
base configured to interface with a conveyance system for transport through a
multi-
function processing system, a tray frame connecting to the tray base and
configured
to support each, individually at any one time, a plurality of different
interchangeable
tray inlays for holding different types of articles of manufacture, one of
said plurality
of interchangeable tray inlays supported by in said tray frame, and a tray
identifier
affixed to the tray, the tray identifier programmable to associate processing
information with said tray and with a plurality of articles of manufacture
loaded in said
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tray inlay, the processing information indicating to a processing system which
processes the tray how to process the tray.
In yet another embodiment, a printing system includes height-adjustment
functionality for adjusting the distance between the target print surfaces and
the print
head nozzles. This embodiment includes a printer comprising one or more print
heads configured with a plurality of print nozzles positioned at a
predetermined
height, an engagement mechanism for holding a print tray during printing of
one or
more articles of manufacture held on the tray, a tray height adjustment
mechanism
responsive to a height adjustment signal to adjust the height of the
engagement
mechanism, a sensor which detects a parameter from which a relative distance
between the print nozzles and one or more target print areas of the one or
more
articles of manufacture will be when printed by the print nozzles, and a
controller
responsive to the detected parameter to generate the height adjustment signal
so as
to cause the tray height adjustment mechanism to adjust the engagement
mechanism to hold the print tray at a height such that the target print area
of the one
or more articles of manufacture will be within a distance of the print nozzles
when the
target print area is printed by the print nozzles.
Brief Description Of The Drawings
A more complete appreciation of this invention, and many of the attendant
advantages thereof, will be readily apparent as the same becomes better
understood
by reference to the following detailed description when considered in
conjunction
with the accompanying drawings in which like reference symbols indicate the
same
or similar components, wherein:
FIG. 1A is a top-down view, and FIG.1B is a perspective view of a schematic
representation of an exemplary embodiment of a conveyance printing system;
FIG. 2A is a perspective view of a schematic representation of an exemplary
embodiment of a tray being loaded with articles of manufacture;
FIG. 2B is an exploded view of the tray shown in FIG. 2A;
FIG. 2C is a top down view of a number of different tray inlays configured to
hold different types of articles of manufacture;
FIG. 2D is a top down view of the tray of FIG. 2A shown without a tray inlay
placed therein;
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FIG. 2E is a side view of a tray illustrating a horizontal usage orientation
and a
vertical storage orientation;
FIG. 3 is a perspective exploded view and its corresponding assembled view
of a schematic representation of an alternative exemplary embodiment of a tray
implemented in accordance with the invention;
FIG. 4A is a top perspective view of a schematic representation of an
embodiment of a loading station;
FIG. 4B is a front perspective view of the loading station of FIG. 4A;
FIG. 4B1 is a zoomed-in view of a section of the tray rack shown in FIG. 4B;
.10 FIG. 4C is a rear perspective view of the loading station of FIG. 4A
wherein
the article of manufacture rack and the tray rack are empty of articles of
manufacture
and empty of trays;
FIG. 4D is a block diagram of a schematic representation of an exemplary
pick-to-light system;
FIG. 5 is a block diagram representation of a computer system which may be
used to implement one or more of the conveyance printing system components,
such as but not limited to the system controller;
FIG. 6 is a view of a schematic representation of an unloading station;
FIG. 7A is a top down view and FIG. 7B is a perspective view of a schematic
representation of a section of the conveyance system which implements a
transverse direction of the forward motion of the conveyor;
FIG. 8A is a side perspective view of a schematic representation of an
exemplary embodiment of a pre-treatment system implemented in accordance with
the invention;
FIG. 8B is a perspective view of the pre-treatment system of FIG. 8A
illustrating the entrance of the system;
FIG. 8C is a perspective view of the pre-treatment system of FIG. 8A taken
from the rear and exit of the system with the housing and conveyor removed;
FIG. 8D is a view of a schematic representation of one of the brush units in
the pre-treatment system of FIG. 8A;
FIG. 9A is a top perspective view of a schematic representation of an
exemplary embodiment of a printer system implemented in accordance with the
invention;
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,
FIG. 9B is a top perspective view of the printer system of FIG. 9A with the
upper framing and housing removed;
FIG. 10A is a view of a schematic representation of the linear motion system
within the printing system of FIGS. 9A and 9B with a tray engaged thereon;
FIG. 10B is a view of the linear motion system of FIG. 10B without the tray;
FIG. 11 is a flowchart illustrating an exemplary method for adjusting the
height
of the tray for printing or other processing;
FIG. 12 is a flowchart illustrating the workflow operations of the conveyance
printing system;
FIG. 13 is a block diagram illustrating a retail production system in which
the
conveyance printing system may operate;
FIG. 14A is a schematic representation of an example gang template;
FIG. 14B is a schematic representation illustrating the filling of a gang
template;
FIG. 14C is a schematic representation of a filled gang; and
FIG. 14D is a top down view of a tray filled with printed articles after the
filled
gang file of FIG. 14C is printed on a filled tray.
Detailed Description
Embodiments of the invention, in general, support a new printing paradigm
through methods and systems which alone or together allow any number of unique
print designs to be printed on any number of different types of articles of
manufacture without interrupting the print manufacturing flow or causing
downtime of
the printing system(s). One or more embodiments of the invention may further
be
configured to allow multiple different types of articles of manufacture to be
interspersed in a print manufacturing flow in any order and without regard to
which
type(s) of articles of manufacture are precedingly or succeedingly printed in
the flow.
One or more embodiments of the invention may further be configured to allow
insertion of high-priority print jobs into the queue of a currently running
print
manufacturing flow without interrupting the flow or requiring any downtime of
the
printing system(s).
Turning now to the drawings, FIGS. 1A and 1B show an exemplary
embodiment of a novel continuous-flow conveyance printing system 100 with
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CA 02829454 2013-10-07
capability to print on multiple different types of articles of manufacture
using the
same printer, and to print potentially different image content on every
article of
manufacture, without requiring the printing system to stop or be taken offline
between jobs or between printing of different types of articles of
manufacture.
In an embodiment, the continuous-flow conveyance printing system 100
operates to print customized images on promotional goods or items, typically
characterized by, but not limited to, metallic and/or plastic surfaces. The
continuous-
flow conveyance printing system in the illustrative embodiments described
herein is,
by way of example and not limitation, a production system for direct digital
ink-jet
io printing on promotional items. Other digital printing processes, such as
but not
limited to laserjet, may be alternatively employed. Returning to the
illustrative
embodiment, the system can process a mixture of different promotional items
and
each item may be printed with a different design or image. The printed items
are
sorted and packaged on the system, and in some embodiments, direct shipments
may even be processed and packed on the system.
In the embodiment shown in FIGS. 1A and 1B, the continuous-flow
conveyance printing system 100 comprises two identically constructed
production
loops 110a, 110b, which supply and share a printing system 150 via a
conveyance
system 180. Of course, it is to be understood that other embodiments of the
system
may include only one production loop, or alternatively may include three or
more
such production loops. Each production loop 110a, 110b includes an independent
operations area 120a, 120b comprising a loading station 130a, 130b and an
unloading station 140a, 140b. The printing system 150 includes a pre-treatment
system 160 and a printer system 170.
The Conveyance System
As best illustrated in FIGS. 7A and 7B, which show a small portion of the full
conveyance system 180, including a portion of the main loop 188 and a portion
of a
transverse motion section 187 which allows a tray to bypass a section of the
main
loop 188, the conveyance system 180 includes a conveyor 181 such as a conveyor
belt or roller chain(s), conveyor rail(s) 182 for supporting and guiding the
conveyor
181, conveyor drivers 183 for driving the conveyor 181 in at least a forward
(and
potentially a reverse) motion, a plurality of removable print trays 200 for
transporting
articles of manufacture through the system 100 (see FIGS. 1A and 1B),
pneumatic
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stoppers 184 (FIGS. 7A, 7B) for stopping movement of a tray 200 being
transported
on the conveyor 181, sensors 185 for monitoring the position(s) of the tray(s)
200 on
the conveyor 181, controller(s) 186 for controlling the drivers 183 and
stoppers 184
of the conveyance system 180, and transverse conveyance sections 187 for
bypassing the main loop 188 of the conveyor system 180.
The conveyance system 180 transfers the print trays 200 in the two main
loops from the loading stations 130a, 130b to the printing system 150 and then
on to
the unloading stations 140a, 140b, respectively. In an embodiment, the
conveyor
system 180 is implemented using a heavy duty steel belted conveyor, such as a
io modular transfer system manufactured by Bosch Automation Technology and
Robert
Bosch GmbH. Preferably, the conveyance system 180 transfers the trays 200 at a
constant working height. For example, in one embodiment, the working height of
transport relative to the floow on which the conveyance system stands may be
840
mm to provide optimal loading and unloading ergonomics for a standing operator
2a,
2b (referred to generally as 2).
The position of trays 200 along the conveyance path of the main loop 188
and/or one or more of the transverse loops 187 is determinable based on input
from
sensors 185, such as inductive or RFID sensors, positioned at strategic
locations
along the conveyance path (including the main loop 188 and transverse sections
187). Controllable stoppers 184 are positioned at strategic locations along
the
conveyance path to effect stopping (and controllable releasing) of the forward
transport of trays 200 on the conveyor 181 at various predetermined positions
along
the conveyance path.
Trays
All articles of manufacture (also referred to herein as "articles" or "items")
to
be printed are conveyed on trays. Each tray is configured to hold one or more
types
of articles of manufacture (specific embodiments of which are shown in FIG. 2A
as
99a - 99i) in respective fixed positions as the tray 200 is conveyed through
the
system 100.
FIGS. 2A-2E together illustrate an exemplary embodiment of a tray 200 for
use in the system 100. In the exemplary embodiment, each tray 200 comprises a
base plate 201 and a tray inlay 210, example embodiments of which are shown
best
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in FIG. 20 at 210a, 210b, 210c, 210d customized for specific articles of
manufacture
99a, 99b, 99c, 99d, respectively. The inlay 210 of the tray 200 is customized
to carry
a number of articles of manufacture 99 in dedicated slots 211 for each article
99.
Each dedicated slot 211 of the inlay 210 is configured to consistently and
accurately
align one or more specific type(s) of article of manufacture 99 in the tray
inlay 210 of
a tray 200 for correct print alignment, thereby preventing waste and re-print
inefficiencies due to improper article alignment (which can cause printed
images to
be mis-positioned and/or to appear distorted with respect to the article on
which the
printed image(s) is/are printed). Although the illustrative embodiments of the
tray
io inlay 210 shown in FIG. 2C are each shown as configured to hold only a
single type
of article of manufacture 99, the invention is not so limited, and it is to be
understood
that any tray inlay can be configured to hold articles of manufacture 99 of
different
types. The number of articles 99 on a given tray inlay 210 will vary depending
on the
size of the tray inlay 210, the size of the article(s) 99, and other system
parameters
which affect how the articles may be positioned. For example, in an
embodiment,
one system parameter is the width of the printable area. In an example, the
width of
the printable area by the printer system 170 is 72mm. As best illustrated in
FIG. 2C,
in an embodiment all articles 99 are positioned such that the target print
area of each
article is centered down the center line of the inlay 211. The number of
articles 99
carried by one tray 200 can therefore range from one to many.
Preferably, the tray inlay 210 is removable, such that one inlay 210a, 210b,
210c, 210d designed to hold one or more particular type(s) of article(s) of
manufacture 99a, 99b, 99c, 99d, can be switched out of the tray 200 and
replaced by
another inlay 200 designed to hold one or more different type(s) of article(s)
of
manufacture 99. In an embodiment, each type of tray inlay 210a, 210b, 210c,
210d
is designed to fit within a tray frame 220, which is universal to all types of
inlays
210a, 210b, 210c, 210d. The tray frame 220 may literally be a frame which
encases
the outer side surfaces of the inlay 210. (See, for example, frame 250 in FIG.
3,
which illustrates an alternative example embodiment 200b of a tray 200 which
can
be used in system 100). In such embodiment, the frame 220 includes an orifice
that
substantially conforms to the shape and size of the outer edges of the tray
inlay 210
when the tray inlay 210 is placed flat within the frame with the slots 211
facing up
and ready to receive articles of manufacture 99 to be printed.
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Alternatively, the tray frame 220 may include only one or more frame side
members 220a, 220b, 220c which are configured to encase only a portion of the
outer side surfaces/edges of the inlay 210. For example, in an embodiment, the
tray
frame 220 comprises a main frame member 220a positioned along or near one edge
of the base plate 201 and having two sub-members 220b, 220c perpendicularly
arranged along or near the transverse edges of the base plate 201. The
perpendicularly arranged sub-members 220b, 220c may be connected at one end to
respective opposite ends of the main frame member 220a. The inner surfaces of
the
main frame member 220a and perpendicularly arranged sub-members 220b, 220c
io engage three of the outer edges of the inlay 210, providing both support
and
alignment assistance for the inlay 210 with respect to the frame 220. In
addition to,
or instead of the embodiments described herein, the frame 220 may take other
forms. For example, in an exemplary embodiment, the tray includes a handle 280
which allows the operator 2 to manipulate the tray 200, for example when
inserting
or removing the tray 200 into a tray rack lane 135 (discussed hereinafter), or
when
flipping the tray from a vertical position to a horizontal position for use,
or vice versa
for storage (also discussed hereinafter).
In an embodiment, the tray 200 is designed to position the target print
surface
of the article(s) 99 loaded in the tray inlay 210 of the tray 200 at a
constant height as
the tray is conveyed along the conveyor 181 regardless of the specific type of
article
of manufacture 99 that is loaded in the tray 200. For example, in one
embodiment,
each type of inlay 210a, 210b, 210c, 210d, is configured to position the
target print
surface(s) of any articles of manufacture 99a, 99b, 99c, 99d loaded therein to
be
within a known distance of the known height of the print head nozzles when the
tray
is conveyed through the printer system 170. For example, if the known height
of the
print head nozzles in the printer system 170 is 81mm above the conveyor which
passes under the print head(s) in the printer system 107, the inlays 210 may
be
configured such that print surface(s) of the articles of manufacture 99 when
loaded
on the tray 200 have a height of 80 mm when the tray is mounted on the
conveyor
running under the print head(s).
In one embodiment, a constant print surface height across all types of inlays
210a, 210b, 210c, 210d, is achieved by way of one or more vertical positioning
spacers 203a positioned between the base plate 201a and the inlay 210a.
Different
types of inlays 210 may use positioning spacers 203 of different heights, as
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CA 02829454 2013-10-07
controlled by the shape(s) and size(s) of the particular article(s) of
manufacture 99a,
99b, 99c, 99d for which the particular inlay 210a, 210b, 210c, 210d was
designed to
carry.
In one tray design, for example as best illustrated in FIGS. 2A, 2B and 2E,
the
vertical positioning spacers 203 attach at one end to the base plate 201 and
at the
other end to the underside of the inlay 210 by way of screws or bolts. In an
alternative tray design, for example as illustrated in an alternative tray
embodiment
200b in FIG. 3, the tray inlay 240 includes a slotted plate 242 having slots
241 which
conform to an outer shape of a cross-section of the articles of manufacture
for which
it is designed to hold. The slotted plate 242 is mounted over a support plate
243,
which is configured to support the articles of manufacture 99 loaded therein
such
that the printing surface(s) of the loaded articles is maintained at a
predetermined
height relative to one or more points on the tray, while also preventing the
articles
loaded thereon from falling through the respective slots 241. In one
embodiment
where the articles to be loaded thereon are flat and thin, the support plate
243 may
be a flat solid sheet of material with orifices embedded therein whose shapes
correspond to the shapes of the outer edges of the articles of manufacture. In
other
embodiments, where the articles of manufacture to be loaded on the inlay 240
vary
in shape in the 3rd dimension when the print surface of the article is flat
and constant
along a plane parallel to the plane defined by the 1st and second dimensions
defined
by the flat surface of the inlay, the support plate 243 may include molded
cavities
which conform to the shape(s) of the portion(s) of the articles of manufacture
that are
to be engaged and supported by the support plate 243. The height requirement
for
the print surface(s) of the articles of manufacture may be achieved by shaping
the
molded cavities and slots so as to fix the article of manufacture 99 in a
position such
that the target print surface(s) of the article are at the required height
relative to one
or more points on the tray. Alternatively, the required height of the print
surfaces of
the loaded articles may be achieved by affixing vertical positioning spacers
233 to
the bottom of the inlay 240. When vertical positioning spacer(s) 233 are used,
the
height of the spacers 233 are chosen such that the height of the target print
surface(s) of the articles of manufacture 99 mounted thereon meet the height
requirements. This method contemplates that the target print surface(s) of all
articles loaded in the tray inlay lie along the same plane relative to one
another ¨ in
CA 02829454 2013-10-07
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,
other words, the target print surfaces of all articles of manufacture on the
tray are co-
planar when properly seated in the tray.
FIGS. 2A-2E and 3 together illustrate a plurality of exemplary trays, each for
holding a different type of article of manufacture 99. As illustrated, each
tray inlay
210a, 210b, 210c, 210d, 241 is designed specifically to hold one or more
specific
types of articles of manufacture such that the print surface(s) of the held
articles of
manufacture will sit at a specific height relative to the conveyor belt when
the tray is
mounted on the conveyor 181. Since different articles of manufacture have
different
thicknesses and shapes, in general each type of article of manufacture will
have a
io corresponding different tray inlay specifically designed to hold that
particular type of
article of manufacture. In an alternative embodiment (not shown), a tray inlay
may
be configured to hold different types of articles of manufacture. In a
preferred
embodiment, the tray frame is 250mm square, and each inlay is configured to
hold
one or more articles of manufacture positioned such that when a tray 200 is
conveyed through the printing system 150, the target print surfaces are
positioned
down the center line of the available printable width of the print system 170.
In an embodiment, each tray is identified with an identifier 230 from which
information needed to process the tray 200 and/or the articles of manufacture
99
loaded thereon can be read or derived. Various detectable identifiers are
known in
the art and any detectable identifier can be used to implement the tray
identifier. In
one embodiment, the identifier 230 is a Radio Frequency Identification (RFID)
tag,
and is identified by an RFID reader, positioned along the conveyance path, in
combination with a controller. In another embodiment (not shown), the
identifier 230
is a barcode which is detected by a barcode reader. In yet another embodiment
(not
shown), the identifier 230 is a Near Field Communications (NEC) tag which is
detected by an NFC tag reader. The tray identifier 230 may be variously
embodied
using other technologies now known or developed in the future. The tray
identifier
230 is used to extract various items of information needed to process the
articles of
manufacture 99 correctly through the system 100.
The Operations Area
Returning to FIGS. 1A and 1B, each independent operations area 120a, 120b
is configured to allow one or more operators 2 (shown as 2a and 2b) to fill
empty
trays 200 with unprinted articles of manufacture 99 (such as, but not limited
to,
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,
promotional items) and to send loaded outgoing trays 200 out onto the
conveyance
system 180 for conveyance to the printing system 150, unload printed articles
from
trays incoming from the printer, and scan, sort and package the printed
articles. In
an embodiment, the operators 2 are human, but in other embodiments, one or
more
tasks performed by the human operators 2 may be automated, for example through
automated machinery and/or use of robotics.
Loading Station
FIGS. 4A, 46 and 4C illustrate an exemplary embodiment of a loading station
130 which may be used in connection with the operations area(s) 120a, 120b of
the
system. The loading station 130 includes a flow rack 131 for storing, and
delivering
to the operator 2, blanks (unprinted) of the various types of articles of
manufacture
99 to be printed by the system 100. In an embodiment, the flow rack 131
comprises
a plurality of lanes, referred to hereinafter as blank article lanes 132a,
132b, ...,
132m, (or simply 132) which are loaded and filled from the back of the rack
131
(shown in FIG. 4C) and pulled out and removed from the front of the rack 131
(shown in FIGS. 4A and 46). The blank article lanes 132 are preferably
configured
to be tilted downward toward the front of the rack 131 at an incline (angle
13) so that
as article blanks 99 are removed at the front of the rack 131 from a blank
article lane
132 for loading into a tray, the remaining article blanks 99 in the lane slide
forward
toward the front of the lane due to the operation of gravity. This allows for
easy
access by the operator 2 loading the trays 200. In an embodiment, articles of
manufacture 99 are packaged in bulk in boxes 98. When a blank article lane 132
is
loaded with a particular type of unprinted article of manufacture 99, one or
more
bulk-pack boxes 98 are opened and placed in a lane 132 which is dedicated to
that
particular type of article of manufacture. The box(es) 98 are preferably
loaded from
the back of the rack. As box(es) 98 are emptied and removed from the lanes
132,
the remaining box(es) slide forward and down the incline of the lane 132 via
gravitational pull.
Every type of article of manufacture 99 (e.g., each different type of
promotional article 99a, 99b, 99c, 99d) has one or several dedicated blank
article
lane(s) 132a, 132b, ..., 132m. The blank article lanes 132 may be organized on
one
or more multiple levels. In the embodiment shown in FIG. 1, the blank article
lanes
132 occupy two levels 131a, 131b, with multiple lanes 132 on each level.
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In an embodiment, the flow rack 131 includes at least one (as shown) or
multiple (not shown) interstage lane 133 configured with a reverse inclination
(at
angle a) towards the back of the flow rack 131. The interstage lane 133 is
used to
gravitationally transport empty raw material boxes 98 from the front of the
flow rack
131 to the back of the flow rack 131 for collection and transport outside of
the
operations area 120.
The loading station 130 also includes one or more tray rack(s) 134 for storing
empty trays 200 ready to be filled with blank articles of manufacture 99. In a
preferred embodiment, the tray rack 134 is stacked below the blank article
rack(s)
131a, 131b. As explained in detail above, each tray 200 includes an inlay 210
configured to hold a particular type of article of manufacture 99 (such as a
promotional item). The inlay 210a, 210b, 210c, 210d for each type of article
99a,
99b, 99c, 99d may be different. Preferably, the tray rack 134 includes a
plurality of
lanes, called tray lanes 135a, 135b, ..., 135n, referred to generally as 135,
located
underneath and in positional correspondence to various ones of the blank
article
lanes 135a, 135b, ..., 135m of the flow rack. In this embodiment, trays 200
having
inlays 210 configured to hold a particular type of article 99 are preferably
stored in a
tray lane 135 directly beneath a corresponding respective blank article lane
132
dedicated to the specific type of article of manufacture 99 that the tray
inlay 210 is
configured to hold.
In an embodiment, the trays 200 are stored in the tray lanes 135 standing on
one side. This allows more trays 135 to be stored in the tray rack 134 per
lane 135.
FIG. 2D best illustrates the desired tray orientation for storage (vertical)
and for
active use (horizontal). The trays 200 are stored in vertical orientation (up
on one
side) in their tray lanes and are flipped horizontal by the operator 2a prior
to being
loaded with blank articles of manufacture 99 of the type for which the inlay
210 of the
tray 200 has been designed to hold. During loading, the conveyance system 180
is
configured to allow the tray 200 to rest on the conveyor rails 182 without
being
conveyed forward. After loading the tray 200 with blanks 99, the operator 2a
releases the tray 200 to be conveyed forward by the conveyance system 180 for
print processing. During unloading, the conveyance system 180 is configured to
allow the tray 200 to rest on the conveyor rails 182 without being conveyed
forward.
After the operator 2b removes the printed articles from the stopped tray 200,
the
operator flips the tray from the horizontal position to the vertical position,
as
13
CA 02829454 2013-10-07
illustrated in FIG. 2D, and returns the empty tray to a tray lane 135 that is
assigned
to hold trays of the corresponding type.
Returning to FIGS. 4A-4D, the blank article rack 131 and tray rack 134 are
preferably positioned adjacent the conveyance system 180 and in particular
such
that the blank article lanes 132 and tray lanes 135 open onto the conveyor
181. This
allows an operator 2a standing in front of the racks 131 and 134, and in
particular,
standing in front of the openings of the lanes 132, 135, with the conveyor 181
passing therebetween, to easily select and ergonomically remove a tray 200
from a
tray lane 135 and place it onto the conveyor 181 in one easy motion, load the
tray
200 with articles 99 removed from the blank article lane 132 above the
selected tray
lane 135, and release the tray 200 for transport by the conveyance system 180.
In
an embodiment, the tray rack 134 is positioned and/or stacked below the flow
rack
131 such that the bottoms of the openings of the tray lanes 135 are the same
height
as the conveyor rails 182. In an exemplary embodiment, the height of the
conveyor
rails off the floor is 840mm, and the width of the conveyor 181 (and including
outside
width of the conveyor rails) is 250mm. The height off the floor of the bottoms
of the
openings of the lower row of tray lanes 131a is 1150mm. The height and width
of
the conveyor, and the heights and setup of the tray and articles racks, are
designed
for optimal loading ergonomics. As best seen in FIG. 4E, the operator can
therefore
stand in an upright position (i.e., with optimal posture), and, without
extending or
raising the upper arm(s) or moving the upper body or shoulders, reach across
the
conveyor to grasp a tray 200 from a tray lane 135, pull it out of the tray
lane 135, and
lay it horizontal into the loading position on the conveyor 181.
In an embodiment, the loading station 130 includes one or more indicators
136 to indicate which type of articles of manufacture 99 are to be loaded onto
corresponding trays 200. In an embodiment, the loading station is configured
with
an indication panel 190 having one or more indicators 136 corresponding to
each
tray lane 135. In this embodiment, trays 200 queued in the tray lane 135 are
dedicated to a particular type of article of manufacture 99. Thus, all trays
200 stored
in the particular tray lane 135 are configured with an inlay 210 which is
designed to
hold the particular article type for which the tray lane is dedicated. When
the
indicator 136 of a particular tray lane 135 indicates that a tray 200 in its
lane should
be loaded, the operator removes a tray 135 from the indicated lane, removes
one or
more articles 99 from the corresponding blank article lane (which are of the
type for
14
CA 02829454 2013-10-07
which the inlay 210 of the selected tray 200 was designed), and loads the tray
200
with the selected article(s) 99.
In an alternative embodiment (not shown), the loading station 130 is
configured with one or more indicators 136 corresponding to each blank article
lane
132. In this embodiment, when an indicator 136 associated with a blank article
lane
132 indicates that a tray 200 should be loaded with articles 99 of the type
contained
in the indicated lane 132, the operator 2a removes a tray 200 from a tray lane
135
corresponding to the indicated blank article lane (which contains trays of the
type
configured to hold the indicated article type), removes one or more articles
99 from
io the indicated blank article lane 132, loads the selected tray 200 with
the selected
article(s) 99, and launches the loaded tray 200 for print processing by
releasing the
tray 200 onto the conveyance system 180. In an embodiment, the conveyance
system 180 includes stoppers 184 which automatically stop a tray in front of
the
loading station 130. The stopper 184 is manually disengaged by the operator 2a
at a
push of a button.
In a specific embodiment, illustrated in FIG. 4D, the indicators 136 are
implemented in what is herein termed a "pick-to-light" system, or light
indicator panel
190. The pick-to-light system 190 supports the operator in picking the correct
trays
200 from the tray rack 134 and/or articles 99 from the blank article rack 131,
and
shortens the reaction time of the operators 2 to increase operations
efficiency. In an
embodiment, each indicator 136 comprises one or more lights, such as LEDs,
that
turn on, turn a specific color, and/or flash in a particular sequence, when
the tray
lane 135 (and/or a blank article lane 132) is to be selected by the operator.
A
controller 195 controls the turning on and off of the indicators. The
controller 195 is
configured with intelligence as to what type of trays 200 are stored in each
tray lane
135 and/or what types of articles of manufacture are in each blank article
lane 132.
The controller 195 is further configured to be in communication with the
system
controller 105 and/or production server 101 to receive information as to what
type of
tray 200 is to be loaded next in the production process. In one embodiment, as
best
illustrated in FIG. 4D, the pick-to-light system 190 includes one yellow 191a,
191b,
..., 191n, and one green 192a, 192b, ..., 192n, light signal for each lane of
the tray
rack. The light signals can have the following states:
Green Light State Yellow Light Signal Meaning
CA 02829454 2013-10-07
State
Current article type to print. Load
Steady On Off
predetermined number of trays.
Current article type to print. Load single
Blinking On Off
tray.
Steady, Blinking or Next article type to be printed will
be on
Steady On
Off this tray.
All lanes All lanes
A warning signal. Check the display
simultaneously simultaneously
screen for details.
blinking blinking
Emergency-Stop button has been
Off Blinking
pressed on the system.
In and embodiment, the loading area 120 includes a tray identifier reader 138,
such as RFID or barcode reader, which scans the tray identifier 230 associated
with
the tray 200 prior to, during, or after loading of the blank articles into the
tray 200.
The scanned tray identifier 230 (or signal or other information from which the
value
of the tray identifier can be derived) is sent to the system controller 105,
which in one
embodiment is in communication with a production server 101 which associates
the
scanned tray identifier 230 with a particular job as will be discussed in
further detail
hereinafter. A "job" is a unit of work to be performed by the printing system
150. A
"job" will generally include information such as the content to be printed in
connection with the job, processing information which may be needed by the
printer
system 150 to determine which pre- and/or post-operations are to be performed
in
addition to the printing, tracking information for identifying which content
and
ultimately which printed articles of manufacture belong to which customer
order, etc.
The "job" will therefore generally include a job identifier. The job
identifier may be
associated with the content to be printed (in the form of a print-ready
content file
such as a PostScript file), and with each of the processing information, the
tracking
information, the customer order information, etc., all of which may be stored
in the
same or distributed database(s). The job can be for printing a single print-
ready file
to be printed on one or more articles of manufacture, or for printing an
aggregate
print-ready file containing multiple individual print-ready files
corresponding to
16
CA 02829454 2013-10-07
content to be printed on respective individual articles of manufacture on the
scanned
tray. When the job is an aggregate job containing individual respective
content to be
simultaneously printed on multiple respective articles loaded in the tray 200,
the
production server 101 also associates the position of each article in the tray
with a
corresponding customer order.
In an alternative embodiment (not shown), each slot 211 in the tray inlay 210
is configured with an identifier, such as an RFID tag, a barcode, etc. An
identifier
reader, such as RFID or barcode reader, scans the identifier associated with
each
tray inlay slot prior to, during, and/or after loading of the printed article
in order to
io associate the article of manufacture 99 directly with a customer order.
The loading station 130 may include one or more control screens 139 which
function as a communication interface between the system controller 105 and/or
production server 101 and the load operator 2a. System status, the required
trays,
warnings and other information may be displayed on the screen to convey
information to the operator 2.
Unloading Station
As best illustrated in FIGS. 1A, 18 and 6, the unloading station 140a, 140b,
referred to generally as 140, preferably includes an identifier reader 148, a
display or
control screen 149, an order summary printer 141, a labeler 142, and a
packaging
system 143, and may further include a sorting and packing table or station
144, a
shipping label maker 145, and a postage machine 146. The unloading station 140
is
operated by one (or more) operator(s) 2b. In an embodiment, the load operator
2a
and the unload operator 2b are different people. Furthermore, there may be
more
than one load operator 2a and/or more than one unload operator 2b to perform
the
load and unload functions. In an alternative embodiment, the load operator 2a
and
the unload operator 2b may be the same person. The purpose of the unloading
station 140 is to assist an operator 2b to unload articles 99 from a tray 200
arriving
from the printing system 150, to collect the processed articles 99 associated
with
each customer order, to generate and/or receive an order summary form, to
package
the individual articles associated with the individual customer order(s), and
to bundle
the packaged individual articles of each customer order into one or more
shipment
units. In an embodiment, the unloading station 140 may also include an area
for
17
CA 02829454 2013-10-07
packaging the shipment units into shipping packages, applying shipping labels
and
postage for sending the packages out for shipping.
In an embodiment, the identifier reader 148 scans the tray identifier 230 of
each tray 200 arriving from the printing system 150. The identifier reader 148
may
be mounted along the conveyance system 180 in a position to read the
identifier of
each incoming tray 200, or may be a hand scanner (not shown) operated manually
by the unload operator 2b. The scanned identifier 230 is communicated to the
controller 105 or to the production server 101 or other control system, which
looks up
the job associated with the identifier and determines the one or more customer
io orders associated with the identified job. The control screen 149
displays for the
operator 2b an indication of which printed article(s) 99 should currently be
removed
from the scanned tray 200 for packaging and processing. The control system 105
or
production server 101 then automatically generates an order summary associated
with the customer order and signals the order summary printer 141 at the
unload
station 140 to print the order summary and the labeler 142 to print one or
more
labels associated with and identifying the removed article(s) 99. The label(s)
may be
applied directly to the removed article(s) 99 or alternatively to the
packaging for the
article(s). In an embodiment, the unloading station 140 includes a packaging
system, such as an automated bagger 143. In an embodiment, the order summary
form and one or more of the printed article(s) associated with the particular
customer
order are input to the automated bagging system 143 and the label(s) are
applied to
the bag(s). In an embodiment, the bagging process by the automated bagger is
triggered by a touch switch operated by the unload operator 2b. However, in an
alternative embodiment, the bagging may be performed automatically without
operator assistance or input.
Preferably, the unload operation is guided by a pick-to-screen process. The
control screen 149 at the unloading station 140 indicates the number and the
position of the articles 99 on the trays 200 that belong to the same customer
order
and are to be put together in one bag. In an embodiment, the identifier reader
148 is
a RFID reader and is used to scan the RFID tray identifier 230. In an
alternative
embodiment, the identifier reader 148 is a hand scanner which is used by the
unload
operator 2b to scan the identifier corresponding to a respective slot on the
tray to
identify which of the printed articles on a given tray is being unloaded by
the
operator. The information is used by the production server 101 or system
controller
18
CA 02829454 2013-10-07
105 to command the order summary form printer 141, automatic bagger 143, and
label printer 142.
At the sort/pack table 144 the bags are collected. The bags are scanned,
sorted, and in case of direct shipments the bags are packed in cardboard
boxes.
Automatically printed labels are applied to the boxes.
Operator Operations and Ergonomics
The construction and placement of the loading and unloading stations and
conveyance system are designed with particular attention to operator
ergonomics
and time operating efficiency. Referring to FIG. 4E, the height of the tray
rack lanes
135 and conveyor 181 passing in front of the tray rack 134 are preferably
approximately hip-high for an average human operator. The tray rack lanes 135
preferably open onto the conveyor 181 just opposite where the operator 2a, 2b
stands, with the conveyor 181 passing therebetween. The lower surface (i.e.,
floor)
of the tray rack lanes 135 are preferably flush to, or slightly higher than
the height of
the conveyor 181 so as to allow a tray to be easily pulled by an operator 2a,
2b out
of the tray rack lane 135 and onto the conveyor 181. In an embodiment, the
conveyor height is 840 mm above the floor on which the operator stands. This
allows the human operator 2a to stand upright with good posture with minimal
movement of the upper arms and shoulders when handling the trays incoming form
the printing system 150, flipping the trays 200 from a horizontal position to
a vertical
position, and returning empty trays 200 to the tray rack 134. On the load
side, the
operator 2a can also perform the operations of removing trays 200 from the
tray rack
134, flipping the removed trays from a vertical to a horizontal position,
loading the
trays 200 with articles of manufacture 99, and releasing the loaded trays to
the
conveyance system 180 while standing in an upright position and requiring
little to no
body movement other than lower arm and hand movement.
In addition to the construction and placement of the loading and unloading
stations and conveyance system, in an embodiment, the trays 200 are also
designed
with particular attention to operator ergonomics. As best seen in FIGS. 2A,
2B, 2C
and 2E, in an embodiment, a slide rail 221 is configured along at least the
front edge
of the frame 220. The slide rail 221 is preferably manufactured using a low-
friction
material such as hard plastic which facilitates a sliding movement along the
rails 182
of the conveyance system 180 when in the loading and unloading areas of the
19
CA 02829454 2013-10-07
,
system 180. The front edge of the frame 220 may be identifiable as the side of
the
frame, when the frame is oriented horizontally, that is situated in front
along the
forward direction of transport of the conveyance system, as illustrated in
FIG. 2D. As
also illustrated in FIGS. 2B and 2D, the slide rail 221 may be configured with
a
concave cavity 222 to provide a gripping hold for an operator's fingers. The
front of
the frame 220 may also include a handle 280 to allow the operator to grasp the
edge
of the tray nearest the operator and to flip it from the vertical position to
the
horizontal position, or from the horizontal position to the vertical position
(see FIG.
2D) with one hand and with one simple hand movement.
As best seen in FIGS. 2C, 2E, 4A, 4B and 6), when the trays 200 are stored in
the tray rack 134, they are placed vertically with the slide rail 221 engaging
the floor
of the tray rack lane(s) 135 in which they are inserted. The slide rail 221
protects the
side of the frame 220 when it is stored in the vertical orientation in the
tray rack 134.
In an embodiment, the slide rail 221 is made of a hard plastic with a low
friction
factor that allows the trays to slide easily along the floor of the lanes 135
in the tray
rack 134.
The Printing System
Pre-Treatment Station
For some types of articles of manufacture 99, it may be important to clean
and/or pre-treat the articles before the actual printing. Referring back to
FIGS. IA
and 1B, a preferred embodiment of the system 100 includes a cleaning and pre-
treatment station 160. The conveyance system 180 is configured to transport
trays
200 from the loading station 130 to the pretreatment station 160 prior to
moving on to
the printer system 170.
As best seen in FIGS. 8A and 8B, the pre-treatment station 160 includes a
framed housing 161 which encloses and/or houses the pre-treatment and cleaning
components required for pre-treating and cleaning the print surfaces of the
articles of
manufacture 99 on trays 200 as the trays 200 pass through the system 160. In
the
illustrated embodiment, the two different process fluids (e.g., the wetting
agent and
the cleaning solution) are supplied from respective canisters 309a, 309b
situated
under the station's housing. A third canister 309c may be used to collect
excess
process fluid that accumulates inside the station 160. Electronic detectors
continuously check the level of fluid inside the three canisters. An
electrical control
CA 02829454 2013-10-07
cabinet 162 housing the pre-treatment station electronics, and an exhaust air
pump /
filter 163 may be situated at the top section of the housing.
In an embodiment, the pre-treatment station 160 is situated before the
entrance to the printer system 170. The main conveyor belt 180 of the
conveyance
system 180 passes through the pre-treatment station 160. However, since the
main
conveyor speed may be higher than that needed to ensure effective pre-
treatment of
the print surfaces, the pre-treatment station 160 may be configured with a
secondary
slower-speed slide-belt system which engages the trays 200 as they pass
through
the station 160 to slow down the trays as they pass therethrough for increased
pre-
io treatment and cleaning effectiveness. In such embodiment, the main
conveyor 181
continues to run but slides under the trays 200 instead of carrying them.
In an embodiment, the pre-treatment station 160 applies a two-step treatment
process. The first step is the application of a wetting agent which is used to
prevent
or reduce reticulation of the ink when applied to the surfaces of the articles
of
manufacture. Ink reticulation can occur when the surface tension of the ink is
higher
than the surface tension of the material on which it is deposited, and thus
the ink
droplets retain their surface tension and thus do not fully spread out. Under
a
microscope, reticulated ink may appear as a mosaic of similar size irregular
polygonal shapes, and veins or cracks in the printed image may be visible to
the
naked eye.
A wetting agent may be applied to the print surface of the articles of
manufacture. Wetting agents operate to change the properties of the print
surface to
make it more wettable by increasing the surface energy of the material on
which the
ink is to be applied to a level at or higher than the surface tension of the
ink,
triggering the flattening out of the ink droplets and the tendency of the ink
to more
uniformly spread out and stick to the print surface of the article of
manufacture. The
type of wetting agent that is effective for a given type of material generally
varies
depending on the chemical properties of both the ink and the print surface
material of
the article of manufacture on which the ink is to be deposited. Although the
pre-
treatment station 160 is shown with one wetting agent applicator, the pre-
treatment
station 160 may alternatively be implemented with multiple different wetting
agent
applicators, each for applying a different type of wetting agent on different
types of
articles of manufacture with different surface material composition.
21
CA 02829454 2013-10-07
The second step of the pre-treatment process is the cleaning process for
smoothing out the wetted print surface and to reduce the surface complexity of
the
print surface for achieving improved print quality. In one embodiment, the
cleaning
agent is a diluted isopropyl alcohol (IPA) solution.
In an embodiment, the pre-treatment station 160 includes an identical pair of
motorized sword brushes applying two different treatment fluids. The first
brush unit
is the pre-treatment brush which is used to apply the surface pre-treatment
fluid or
wetting agent. The second brush unit is the cleaning brush which may apply a
cleaning solution and brush off or remove excess pre-treatment fluid to
perform a
io final cleaning/de-greasing of the surface. A fluid regulator and filter
unit 308a, 308b
for each brush is situated outside the station's housing.
In the embodiment shown herein, and as best seen in FIG. 8C, the pre-
treatment fluid and the cleaning fluid are applied in successive stages by two
respective identical brush units 300a, 300b contained within the pre-treatment
station
160, one of which is diagrammed in FIG. 80 at 300. In an exemplary embodiment,
and as best viewed in FIGS. 8C and 80, the brush units are implemented using,
for
example, a Model KSB111 combination sword brush unit, manufactured by
Wandres. A continuously rotating brush belt 301 is height adjusted on a pair
of
adjustment frames 307a, 307b to touch the target print surfaces of the
articles of
manufacture 99 with the correct contact pressure as they pass under the belt
301.
The rotating brush 301 may be backed by an inflated cushion 302 (i.e., a
pressure
buffer) which regulates the contact pressure between the brush 301 and the
print
surface of the articles of manufacture 99. An integrated spray unit 304
continuously
moistens the brush 301 with the process fluid. A suction unit 305 is also
attached
downstream from the brush 301 to collect particles and keep the brush itself
clean.
As described earlier, in an embodiment, all trays 200 are designed to align
the
target print surface of the various types of articles of manufacture 99 on the
trays
200 at an equal (and predetermined) height such that the print surfaces of the
articles across all the trays 200 on the conveyor system 180 will be at a
known
distance from the print heads when they pass through the printing system 150.
In an
alternative embodiment, the target print surfaces of the articles of
manufacture 99
may not be predetermined, and may in practice vary depending on the type of
article
of manufacture. In such embodiment, the height of the conveyance may be
adjusted
within the printing system 150, such that the target print surfaces are
positioned at a
22
CA 02829454 2013-10-07
predetermined distance from the various processing components (such as, by way
of
example and not limitation, the pre-treatment system brushes, the print head
nozzles, the curing lamps, etc.). The height adjustment can be determined
using the
principles and system described hereinafter with respect to the height
adjustment
system 400 in the printer system 170, and as described in connection with
FIGS.
10A and 10B.
In an embodiment, the pre-treatment station 160 includes an identifier reader
164 which reads the identifier 230 of the tray to determine the type of
article of
manufacture 99 carried by the tray 200. A programmable logic controller PLC
303a
io controls a 2-level pneumatic height adjuster 303b to selectively apply
or skip the
brush treatment depending on the type of article of manufacture on the tray.
The pre-
treatment station 160 is depicted in the exemplary embodiment as having a
single
wetting agent application system 300a and a single cleaning solution
application
system 300b. In alternative embodiments, the pre-treatment station 160 may
implement any number of different wetting agent application systems and/or
cleaning
agent application systems. The type of wetting agent and/or cleaning agent(s)
to
apply can be programmed and associated to a particular job by including
instructions
or process identifications in the information associated with the tray
identifier. When
the tray 200 enters the pre-treatment station 160, a tray identifier reader
may read
the tray identifier, look up the information associated with the tray
identifier, and
determine whether and which pre-treatment agents and/or cleaning agents to
apply
to the print surfaces of the articles of manufacture on the particular tray
200.
Printer System
In an embodiment, as best shown in FIGS. 9A and 9B, the printer system 170
is designed to physically interface with the conveyance system 180 and to
communicate with the system controller 105 and/or the production server 101
(see
FIGS. 1A and 1B). The printer system 170 is preferably mounted within a frame
171,
preferably enclosed for purposes of safety and cleanliness. In an embodiment,
the
frame 171 includes an inner frame on which the printer itself is mounted, and
a guard
frame which acts as a cover for the entire system 170. The inner frame is
preferably
made from mild steel box section for rigidity which is very important for
maintaining a
crisp printed image. The guard frame is preferably made from aluminium
extrusion
in-filled with clear polycarbonate panels. The guards covering the in-feed and
out-
23
CA 02829454 2013-10-07
feed conveyor sections are also made from the same fabricated polycarbonate
sheet.
The trays 200 enter the printer system 170 immediately after exiting the pre-
treatment station 160. In an embodiment, the trays 200 are engaged with a
precision
linear motion system 400 for printing.
The printer system 170 may include an ionization unit 174 which generates
pressurized ionized air aimed at the print surfaces for removing any static
charge,
both positive and negative, from the print surfaces of the articles of
manufacture on
the tray.
io The printer system 170 may further include a plasma jet treatment
system 175
which operates to roughen the print surfaces of the articles of manufacture 99
on the
tray 200 in order to increase surface tension to achieve better wetting. The
plasma
jet treatment is used to change the surface energy of the articles of
manufacture. In
an embodiment, the ink used is UV ink, which has higher viscosity than water-
based
ink. The surface energy is measured in Dynes and to help the ink adhere to the
product, the surface energy needs to be increased to approximately 20 Dynes
greater than that of the UV ink. In an embodiment, the plasma jet treatment
system
175 includes one or more plasma nozzles set at pre-determined heights above
the
print surface of the articles of manufacture. Depending on the type of article
of
manufacture to be treated, the height of the plasma nozzles may be
automatically
adjusted.
In an embodiment, the printer system 170 includes one or more inkjet printer
head(s) 70 designed to apply ink colors Cyan, Magenta, Yellow and Black
(CMYK).
In a particular embodiment, the print width is up to 72mm. The printheads 70
are
affixed to corresponding printhead assemblies, which include a head mounting
plate
with ink nozzles, ink tanks, head drive control circuits, and an outer
housing.
In an embodiment, the printer system 170 includes a sensor 402 which
senses a parameter from which the height of the printing surface of the
articles of
manufacture 99 on the tray 200 within the printer system 150 can be
determined.
Thus, the relative distance between the nozzles 72 of the print head 70 and
the
printing surface of the articles of manufacture in the tray can be determined.
In an
embodiment, the sensor 402 is a laser sensor that is mounted in a fixed
position on
the printer frame 171 above the conveyor 181 at the location that the tray 200
enters
the printer system 170. The sensor 402 measures the distance between the
sensor
24
CA 02829454 2013-10-07
head and the print surface of the articles of manufacture 99 as they pass by a
fixed
location on the conveyor 181. The laser sensor measurement is used as input to
a
tray height adjustment mechanism 403 which adjusts the vertical position of
the tray
200 from its unadjusted vertical position as delivered by the conveyance
system 180
to a height-adjusted position during the actual printing process by the print
head(s)
70. A controller receives and translates the laser signal from the sensor 402
into
parameter representative of an unadjusted vertical position of the print
surface of the
articles of manufacture 99 on the tray 200, and determines a tray height
adjustment
parameter which may be used to signal a tray lift controller 404 to adjust the
vertical
io position of the tray lift 403 so as to position the print surfaces of
the articles of
manufacture 99 to a vertical height that is within a specified distance (with
a range of
tolerance) of the print head nozzles 72 when the tray 200 passes beneath the
print
head(s) 70. Based on the laser sensor measurement, the height of the printing
surface of the articles of manufacture is used to adjust to the optimal
printing
distance. If an article of manufacture 99 is not correctly placed on the tray
200, the
tray 200 can be rejected without print. Otherwise, the articles of manufacture
99 on
the tray 200 are printed.
FIGS. 10A and 10B illustrate an exemplary linear motion system 400. The
linear motion system includes an engagement plate 410 configured to engage a
tray
200 when the tray enters the printer system 170 by delivery of the main
conveyance
system 180. The engagement plate 410 is slidingly mounted on, or otherwise
slidingly attached to, a linear motion transport rail 460. A driving mechanism
462
(directly or indirectly) engages the engagement plate 410 and is configured to
transport the engagement plate 410 along a horizontal plane 465 between a pick-
up
position 468 at one end A of the rail 460 and a release position 469 at the
opposite
end B of the rail 460. In an embodiment, the driver 462 includes a conveyor
chain
driven by a motor. At the pick-up position 468, the engagement plate is
configured
to engage a tray 200 delivered by the conveyance system 180, and the driver
462 is
configured to transport the tray 200 in a forward direction along a fixed
linear path
465 defined by the rail 460 to the release position 469, where the tray 200 is
released back to the main conveyance system 180. After delivering the tray 200
back to the main conveyance system 180, the engagement plate 410 is driven, by
the driver 462, back along the linear path 465 to the pick-up position 465 to
be ready
CA 02829454 2013-10-07
to pick up another tray 200. The driver 462 thus drives in a forward direction
and a
reverse direction.
The engagement plate 410 includes an engagement mechanism for fixing the
tray 200 in static position with respect to the plate 410. In an embodiment,
the
engagement mechanism comprises one or more positioning pins 412. The tray 200
includes positioning sockets or holes 202 in the base plate 210 of the tray
200.
When the main conveyor 181 delivers the tray 200 to the printer system 170,
the tray
is automatically transported to and stopped at a position over the engagement
plate
410 such that the engagement pins 412 align with the positioning sockets or
holes
202 in the bottom of the base plate 210 of the tray. In an embodiment, a tray
sensor
450 is mounted on the rail 460 (or alternatively a position on the frame 171
or other
mounting substrate within the printing system 150). The tray sensor 450
detects the
presence of a tray 200 at the pick-up position 468. The tray is stopped in the
pick-up
position by a stopper 440, preferably mounted along the rail 460. The stopper
460
stops the tray in a position of alignment such that the positioning pins 412
of the
engagement plate 410 align with the sockets/holes 202 of the base plate 210 of
the
stopped tray 200. A lift controller 430 monitors the sensor signal to perperly
control
the timing of a lift 420. The lift 420 operates to lift the engagement plate
410 to
simultaneously engage the bottom of the base plate 210 of the tray 200 and
center
the engagement pins 412 in the positioning sockets/holes of the base plate 210
of
the tray, thereby fixing the tray in place on the engagement tray 410.
The lift controller 430 further receives information, directly or indirectly
through
one or more additional controllers and transmitters and/or receivers, from the
height
adjustment sensor 402 of the printer system 170. The received sensor
information is
used by the lift controller 430 to control the lift 420 to set the height of
the
engagement plate 410 to a vertical position such that the print surface(s) of
the
article(s) of manufacture on the engaged tray 200 within a predetermined
distance
(plus or minus a predetermined tolerance) of the print head nozzles of the
print
heads 70 of the printer system 150.
FIG. 11 depicts an exemplary embodiment of a method for adjusting the
height of a tray to align the print surfaces of the article of manufacture to
be printed
to with a pre-determined distance of the print head nozzles when the tray 200
on
which the articles are carried is printed. As illustrated, a tray approaches
the height
sensor 402 (step 611), where the height sensor takes a measurement (step 612).
26
CA 02829454 2013-10-07
,
,
The tray is conveyed such that it is stopped in a pre-determined position
ready to be
lifted (step 613). The lift engages the tray (step 614). The lift height is
determined
based on the height sensor measurement (step 615). The lift is then controlled
to
set the height of the lift to the determined lift height (step 616). The tray
is then
conveyed for printing, maintaining the lifted height during the printing
process (step
617), and in particular as the print surface(s) of the articles of manufacture
are
printed by the print head(s) 70.
Returning to FIGS. 9A, 9B, 10A and 10B, when an engaged tray 200 is to be
released from the engagement plate 410, the lift 420 is instructed to lower
sufficiently
to disengage the positioning pins 412 from the sockets/holes of the base plate
210 of
the tray 200. The main conveyance system 180 may therefore engage the released
tray 200 and transport it out of the printing system 170.
Referring again to FIG. 9A, the printer system 170 may also include a curing
unit 176, such as an ultra-violet (UV) curing system. The trays 200 pass into
the UV
curing unit 176 immediately upon passing under the printhead(s) 70, and then
out of
the print system 170. At the exit, the tray 200 is transferred back to the
main
conveyor 181 and routed by the conveyance system 180 to the unloading station
140.
Preferably, the printing system 150 includes one or more tray identifier
reader(s) 177 positioned and configured to read the tray identifier 230 on
each tray
200 as it enters the printing system 150. In an embodiment, the tray
identifier 230 is
an RFID tag and the tray identifier reader 177 is an RFID read head. The
signal
from the RFID reader 177 is sent to the system controller 105 or the
production
server 101, or an alternative remote control system, which translates the
signal into a
corresponding tray identifier from which the print job(s) currently associated
with the
tray can be identified and used to derive information needed to process the
articles
of manufacture at each station. For example, in an embodiment, information
which
can be derived from the tray identifier 230 includes the type of articles of
manufacture 99 present on the tray. The information about the type of article
of
manufacture 99 can be used to selectively turn on or off one or more of the
following
functions: application of the wetting agent in the pre-treatment station 160,
application of the cleaning solution in the pre-treatment station 160,
activation of the
cleaning brush in the pre-treatment station 160, activation of ionization in
the printing
system 170, application of plasma treatment in the printing system 170,
printing or
27
CA 02829454 2013-10-07
not printing by the print heads 70, and curing or not curing by the curing
unit 176. In
alternative embodiments, the system 150 is configured, instead of and/or in
addition
to printing, to engrave, etch, embroider, label, stamping, affix, or otherwise
embed or
imprint content information on an article of manufacture 99 which is conveyed
by a
tray passing therethrough. Each tray passing into the system can therefore be
identified using the tray identifier, and one or more of the printing,
engraving, etching,
embroidering, labeling, stamping, affixing or other content embedding systems
can
be enabled to print, engrave, etch, embroider, label, affix, or otherwise
embed
content onto the articles of manufacture 99.
System Control
The printing system 150 includes system controller 105. In an embodiment,
the system controller comprises a computing environment 500, illustrated in
FIG. 5,
for controlling and managing the operations of the printing system. The
computing
environment 500 includes a general-purpose computing device in the form of a
computer 510, which may comprise any electronic device with computing and/or
processing capabilities. The components of computer 510 may include, but are
not
limited to, one or more processors or processing units 520, a system memory
530,
and a system bus 521 that couples various system components including
processing
unit(s) 520 to system memory 530.
System bus 521 represents one or more of any of several types of bus
structures, including a memory bus or memory controller, a peripheral bus, an
accelerated graphics port, and a processor or local bus using any of a variety
of bus
architectures. By way of example, such architectures may include an Industry
Standard Architecture (ISA) bus, a Micro Channel Architecture (MCA) bus, an
Enhanced ISA (EISA) bus, a Video Electronics Standards Association (VESA)
local
bus, and a Peripheral Component Interconnects (PCI) bus also known as a
Mezzanine bus.
Computer 510 typically includes a variety of electronically-accessible media.
Such media may be any available media that is accessible by computer 510 or
another electronic device, and it includes both volatile and non-volatile
media,
removable and non-removable media, and storage and transmission media.
System memory 530 includes electronically-accessible media in the form of
volatile memory, such as random access memory (RAM) 532, and/or non-volatile
28
CA 02829454 2013-10-07
memory, such as read only memory (ROM) 531. A basic input/output system (BIOS)
533, containing the basic routines that help to transfer information between
elements
within computer 510, such as during start-up, is stored in ROM 531. RAM 532
typically contains data and/or program modules/instructions that are
immediately
accessible to and/or being presently operated on by processing unit(s) 510.
Computer 510 may also include other removable/non-removable and/or
volatile/non-volatile electronic storage media. By way of example, FIG. 5
illustrates a
hard disk drive 541 for reading from and writing to a (typically) non-
removable, non-
volatile magnetic media (not separately shown); a magnetic disk drive 551 for
io reading from and writing to a (typically) removable, non-volatile
magnetic disk 552
(e.g., a "floppy disk"); and an optical disk drive 555 for reading from and/or
writing to
a (typically) removable, non-volatile optical disk 556 such as a CD-ROM, DVD-
ROM,
or other optical media. Hard disk drive 541, magnetic disk drive 551, and
optical disk
drive 555 are each connected to system bus 521 by one or more data media
interfaces 540, 550. Alternatively, hard disk drive 541, magnetic disk drive
551, and
optical disk drive 555 may be connected to system bus 521 by one or more other
separate or combined interfaces (not shown).
The disk drives and their associated electronically-accessible media provide
non-volatile storage of electronically-executable instructions, such as data
structures,
program modules, and other data for computer 510. Although exemplary computer
510 illustrates a hard disk 541, a removable magnetic disk 552, and a
removable
optical disk 556, it is to be appreciated that other types of electronically-
accessible
media may store instructions that are accessible by an electronic device, such
as
magnetic cassettes or other magnetic storage devices, flash memory cards, CD-
ROM, digital versatile disks (DVD) or other optical storage, random access
memories (RAM), read only memories (ROM), electrically erasable programmable
read-only memories (EEPROM), and so forth. In other words, any electronically-
accessible media may be utilized to realize the storage media of the exemplary
cornputing system and environment 500.
Any number of program modules (or other units or sets of instructions) may
be stored on hard disk 541, magnetic disk 552, optical disk 556, ROM 531,
and/or
RAM 532, including by way of example, an operating system 544, one or more
application programs 545, other program modules 546, and program data 547. By
way of example only, operating system 544 may comprise file system
component(s),
29
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application programs 545 may comprise program and/or applications, and program
data 547 may comprise files and/or the content thereof.
A user may enter commands and information into computer 510 via input
devices such as a keyboard 562 and a pointing device 561 (e.g., a "mouse").
Other
input devices (not shown specifically) may include a microphone, joystick,
satellite
dish, serial port, scanner, and/or the like. These and other input devices are
connected to processing unit(s) 520 via input/output interfaces 595 and 560
that are
coupled to system bus 521. However, they may instead be connected by other
interface and bus structures, such as a parallel port, a universal serial bus
(USB)
port, an IEEE 1394 interface, an IEEE 802.11 interface, and so forth.
A monitor 591 or other type of display device may also be connected to
system bus 521 via an interface, such as a video adapter 590. In addition to
monitor
591, other output peripheral devices may include components such as speakers
(not
shown) and a printer 596, which may be connected to computer 510 via network
input/output interfaces 570.
Networked Environment
Computer 510 may operate in a networked environment using logical
connections to one or more remote computers, such as a remote computing device
580. By way of example, remote computing device 580 may be a personal
computer,
a portable computer (e.g., laptop computer, tablet computer, PDA, mobile
station,
etc.), a server, a router, a network computer, a peer device, other common
network
node, or other computer type as listed above, and so forth. In a particular
example,
the remote computing device 580 may be the production server 101 shown in
FIGS.
1A and 1B. Remote computing device 580 is illustrated as a computer that may
include many or all of the elements and features described herein relative to
computer 510. Logical connections between computer 510 and remote computer
580 may be implemented as any one or more of a local area network (LAN) 571, a
general wide area network (WAN) 573, a wireless network, etc. Such networking
environments are commonplace in offices, enterprise-wide computer networks,
intranets, the Internet, fixed and mobile telephone networks, other wireless
networks,
and so forth.
When implemented in a LAN networking environment, computer 510 is
connected to a local area network 571 via a network interface or adapter 570.
When
CA 02829454 2013-10-07
implemented in a WAN networking environment, computer 510 typically includes a
modem 572 or other means for establishing communications over wide area
network
573. Modem 572, which may be internal or external to computer 510, may be
connected to system bus 521 via input/output interfaces 560 or any other
appropriate
mechanism(s). It is to be appreciated that the illustrated network connections
are
exemplary and that other means of establishing communication link(s) between
computers 510 and 580 may be employed.
In a networked environment, such as that illustrated with computing
environment 500, program modules or other instructions that are depicted
relative to
io computer 510, or portions thereof, may be fully or partially stored in a
remote
memory storage device. By way of example, remote application programs 535
reside
on a memory device 581 of remote computer 580. Also, for purposes of
illustration,
application programs 528 and other executable instructions such as operating
system 527 are illustrated herein as discrete blocks, but it is recognized
that such
programs, components, and other instructions reside at various times in
different
storage components of computing device 510 (and/or remote computing device
580)
and are executed by data processor(s) 504 of computer 510 (and/or those of
remote
computing device 580).
Overview of Workflow Operations
As discussed previously, each production loop operations area 120a, 120b
includes at least one workstation which allows operators on each production
loop to
work independently yet share a single printing system 150. Each operations
area
120a, 120b can be operated by one or more operators 2a, 2b, depending on the
workload. In an embodiment, when two operators 2a, 2b are present on a
production
loop 110a, 110b, a first operator 2a handles the loading of trays 200 and the
sort &
pack operations where as a second operator 2b handles the unloading and
bagging
operations. Of course, it will be appreciated that the workload could be
partitioned in
various other ways, including through the use of additional or fewer
operators, and/or
through the automation of one or more of the loading and unloading functions.
The various types of unprinted articles in their original packaging (e.g.
carton
boxes) are stored in racks 132 and are placed by the loading operator 2a into
trays
200 which hold the corresponding type of article of manufacture. Different
types of
trays 200, which are customized to carry a particular type of article of
manufacture
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99, are stored in tray racks 135. The green/yellow light Pick-to-Light system
190
visually guides the operator 2a to pick and place the correct articles 99 into
the
correct type of tray 200 and release it to the conveyor system 180 for further
processing by the printing system 150.
Identifiers 230, such as RFID tags, embedded on or in the trays 200, are used
to tag each tray with process information (e.g. name of the image file to be
printed,
process parameters, workstation number etc.). This assures that the right
content is
printed onto each article of manufacture. The trays 200 are automatically
routed to
the infeed of the printing system 150 by the main conveyor system 180.
io In
addition to the actual ink-jet printing process, the printing system 150 also
preferably applies several pre-treatment and post-treatment processes to the
articles
of manufacture. The different processes, in preferred order of application,
are as
follows:
1. Pre-Treatment: Selected application of one or more wetting
agents followed by selected cleaning.
2. Ionized Air Wash: Naturalizes the surface electric charge on the
promo items
3. Plasma Jet: Increases the surface energy of the articles of
manufacture to allow better wetting by the ink
4. Ink-jet: Actual
printing with four color (CMYK) digital ink-jetting
print head with adjustable printhead-to-substrate distance.
5. UV-Pinning: An
initial curing (for example using an LED light
source) to fix the ink onto the print surface of the articles of manufacture
immediately after the printing.
6. Final UV-Curing:
Final curing by a strong mercury arc-lamp UV
source.
Depending on the type of article of manufacture 99 on the tray 200, as
determined by the information associated with the identifier 230 on the tray
200,
each available process (pre-treatment, ionization, plasma jet, printing, UV
pinning,
UV-curing) can be automatically level adjusted (e.g., to set the intensity,
amount of
treatment of fluid, processing time, etc.) or altogether skipped, based on the
information associated with the tray identifier 230.
32
CA 02829454 2013-10-07
=
After the articles of manufacture 99 on the tray 200 have been fully processed
(as determined from the information associated with the tray identifier 230),
the tray
200 is routed back to the original operations area 120a, 120b for unloading. A
scanner is used by the unloading operator 2b to identify each article 99
removed
from the tray 200. The unloaded articles are then placed into the bagging
machine
and bagged into individual packages. The packages, or alternatively the
individual
articles themselves, are labeled for identification.
The bagged items are conveyed to the sort & pack table via a secondary
ground conveyor system. They are sorted, packed and forwarded to the platform
io outbound logistics process of the plant.
FIG. 12 is an operational flowchart illustrating an exemplary method 620 of
operation of a printing system implemented in accordance with principles of
the
invention. As illustrated, material to be printed such as blank (as-yet
unprinted)
articles of manufacture are loaded into the materials staging rack (article of
manufacture rack 131) for easy access by a loading operator (step 621). It
will be
appreciated that as used herein, the term "blank" article of manufacture
refers merely
to an article of manufacture which has at least one area intended to be
printed on by
the printing system and which has yet to be printed. An article of manufacture
may,
for example, have no printed material on it. Alternatively, an article of
manufacture
may include pre-printed material and may be submitted to the printing system
for
printing of additional material which is not yet printed thereon. In this
case, the
article of manufacture which still has one or more areas still intended to be
printed
would still, for purposes of this particular pass through the printing system,
be
considered a "blank" article of manufacture.
A print job is selected (step 622). As noted previously, "job" is a unit of
work
to be performed by the printing system 150 and is associated with a job
identifier
from which can be extracted information such as the content to be printed in
connection with the job, processing information which may be needed by the
printer
system 150 to determine which pre- and/or post-operations are to be performed
in
addition to the printing, tracking information for identifying which content
and
ultimately which printed articles of manufacture belong to which customer
order, etc.
In an embodiment, the print job is selected automatically by the production
server
101 and communicated to the system controller 105, which signals the Pick-To-
Light
system 190 to indicate what type of tray to load. In an alternative
embodiment, the
33
CA 02829454 2013-10-07
'
,
operator selects a print job from a queue of pending print jobs. Upon
selection of a
print job, the operator selects one or more articles of manufacture of the
type
associated with the selected print job (step 623) and a tray configured to
hold articles
of manufacture of the type associated with the print job (step 624). The
operator
then loads the selected tray with the selected articles of manufacture (step
625).
The print job is associated to an identifier on the tray (for example, the
tray identifier
230 and/or individual slot identifiers in the tray) from which the production
server
and/or other devices can extract the information necessary to identify and
associate
each printed article with its corresponding order information (such as
customer
information, shipping address, etc.). The tray 200 is then released to the
conveyance system 180 for transport to the printing system 170.
The tray 200 is then conveyed by the conveyance system 180 to the entrance
of the printing system 150. Prior to or upon entry into the printing system
150, a
scanner reads the tray and/or slot identifier(s) from the tray 200 (step 628).
The
scanned identifier is matched to the print job to which the identifier is
associated
(step 629), from which a set of job processing instructions may be determined
(step
630). The tray then passes through one or more of the print processing
functions.
For ease of explanation, the term "selectively applied" means a function
referred to
therewith is applied if the job processing instructions associated with the
identifier of
the tray indicate that the particular function should be applied, and is not
applied if
the job processing instructions indicate that the function should not be
applied.
Likewise, the term "selectively performed" means a function referred to
therewith is
performed if the job processing instructions associated with the identifier of
the tray
indicate that the particular function should be performed, and is not
performed if the
job processing instructions indicate that the function should not be
performed.
In an exemplary embodiment, one or more wetting agent(s) are selectively
applied (step 631), followed by a selectively performed cleaning process (step
632).
An ionization wash may be selectively applied (step 633), as well as selective
application of a plasma jet treatment (step 634). Further, the tray conveyance
height
may be selectively adjusted (step 635) prior to actual printing of the print
job (step
636). Post-printing, the selective operations may include selectively
performing one
or more curing processes (step 637). It will be appreciated that all, fewer,
or
additional pre- and/or post-printing processes may be implemented and
selectively
34
CA 02829454 2013-10-07
applied using the selective indication in the job processing instructions
associated
with the tray identifier.
As described in connection with FIGS. 8A-8D, the system may include a pre-
treatment system 160. For example, the pre-treatment system may include a
wetting
agent application and/or cleaning system. The pre-treatment system 160 may be
integrated into the printing system or may be a separate system along the
conveyance system and to and from or through which the conveyance system
conveys a tray along the conveyance path. The tray enters the pre-treatment
system, conveyed by the conveyance system, where the articles of manufacture
are
pre-treated. In an embodiment, a cleaning fluid is applied to the print
surfaces of the
articles of manufacture held on the tray which enters the pre-treatment
system. The
print surfaces may be brushed with the cleaning fluid and then the cleaning
fluid may
then be brushed, wiped, or otherwise removed from the print surface(s) of the
articles of manufacture. In an embodiment, a wetting agent may be applied to
the
print surface(s) of the articles of manufacture to reduce ink reticulation and
to
encourage sticking of ink to the print surface(s) of the articles of
manufacture.
Whether and what type of cleaning fluid and/or wetting agent to apply will
depend on
the material and surface characteristics of the article of manufacture and is
accordingly represented by way of the processing instructions associated with
the
identifier of the tray on which such articles are loaded.
As further described in connection with FIGS. 9A and 9B, upon exit of the pre-
treatment system 160, if utilized, the tray 200 of pre-treated articles of
manufacture is
advanced to the printer system 170. In an embodiment, an identifier reader
such as
an RFID reader scans/reads the tray identifier, which is matched up by the
system
controller 105 and/or production server 101 to the tray's associated print
job. The
system controller 105 and/or production server 101 then retrieves and sends
the
print-ready file containing the content to be printed onto the print area(s)
of the
articles of manufacture on the tray that is associated with the tray
identifier, along
with any associated set of print processing instructions, to the printer
system 170. In
an embodiment, the print-ready file includes individual print content to be
printed on
each of the respective articles of manufacture loaded on the tray.
Potentially, the
individual print content to be printed onto each of the individual articles of
manufacture may be different for each article of manufacture. In an
embodiment, the
print-ready file associated with the tray is a single aggregate print-ready
file
CA 02829454 2013-10-07
,
comprising the individual print content for each of the individual articles of
manufacture on the tray. The printing system treats the aggregate print file
as a
single print job and prints the content of the aggregate print-ready file as a
single
process, simultaneously printing all articles of manufacture on the tray in
one printing
process.
As further described in connection with FIGS. 9A, 96, 10A and 10B, in an
embodiment, the printer system 170 includes a tray height adjustment system
400,
including a tray height or distance sensor 402 and a tray height adjustment
mechanism 410, 420, 430. In such an embodiment, upon or prior to entering the
io printer system 170, the height or distance sensor 402 detects the height
or distance
to the print surface(s) of the articles of manufacture loaded on the tray. The
distance
adjustment mechanism translates the sensed height/distance into an adjustment
amount and selectively raises or lowers the tray to achieve the adjustment
amount.
Alternatively, the distance adjustment mechanism raises or lowers the
printhead(s)
to achieve the adjustment amount.
To print the file associated with the tray, the printer (optionally adjusting
the
tray height or print head position to achieve optimal print-surface-to-print
head
distance) prints the content from the print-ready file onto the print
surface(s) of the
articles of manufacture. In an embodiment, the printer system 170 includes a
curing
system such as a dryer or ultraviolet light. Referring again to FIG. 12, upon
exit from
the printing system, the tray is conveyed to the unloading area, where the
individual
articles of manufacture are unloaded from the tray (step 639), identified
(step 641),
and packaged (step 642). The tray itself is stored for use for processing
another
print job (step 640).
In an embodiment, at the unloading station the identifier (e.g., RFID tag) on
the tray 200 is read by a scanner as the tray enters the unloading area. The
print job
currently associated with the scanned RFID is retrieved by the server and the
individual orders are identified by position in the tray and sorted by the
operator (step
641). In an embodiment, the individual orders are designated by position and
communicated to an operator via a display screen. Additionally, shipping
and/or
order labels are automatically generated from order information associated
with the
individual order derived from the aggregate print job identifier. The operator
can
positionally and visually identify the printed article of manufacture
associated with
36
CA 02829454 2013-10-07
each individual order and can package and apply the shipping/packaging label
to
each individual order.
FIG. 13 is a more detailed block diagram of an online retail production system
700 implementing multiple aspects of the invention. In particular, the system
700
facilitates and implements the simultaneous mass production of individual
orders of
various different articles of manufacture printed with various individually-
customized
printed content. As shown in FIG. 13, an online retailer offering various
different
types of articles of manufacture individually customizable by individual
customers
with personalized printed content provisions one or more customer order
server(s)
720 with web pages 724 which together implement a website 723. Product
content,
such as templates 709, layouts, designs, font schemes, color schemes, images,
graphics, available for various different types of articles of manufacture are
provisioned into a content database 791 or other computer storage by human or
computer designers.
Any number of customers operating client computers 710 may access the
website 723 hosted by the customer order server(s) 720 to view products
(articles of
manufacture) and product templates and to select, design, and/or customize
various
design components of a selected product prior to ordering. For example,
multiple
templates may be available for customizing or personalizing print content for
printing
on a product (article of manufacture) such as a drink holder ("koozie") 99a, a
tape
measure 99b, a ruler 99c, a USB flash drive ("memory stick") 99d, a magnetic
clip
99e, a keychain tag 99f, a letter opener 99g, a foam cube (e.g., stress toy)
99h, a
calculator 99i, or any other type of article of manufacture of a size suitable
for
printing in the conveyance printing system.
The various product templates may be selectable by the customer using client
computer 710 for further customization such as adding customer-personalized
information such as name, business name, address, phone number, website URL,
taglines, etc. Furthermore, the template may include one or more image
containers
allowing a customer to upload one or more images into a selected design
template
209. The customer may edit a selected template and make design changes using a
design tool 727, and furthermore may preview the design using a preview tool
728.
Once a customer is satisfied with their selections/customizations, they can
place an
order 701 through an order and purchase tool 726 at the customer order
server(s)
37
CA 02829454 2013-10-07
720. Orders 701 are stored in an order database 792 and/or sent directly to a
fulfillment center. Orders 701 include customer information such as a customer
identifier, shipping address, etc. Orders 701 also include commercial
information
such as item/article identifier, quantity of ordered articles associated with
item/article
identifier, desired delivery date, production parameters associated with the
item/article identifier such as type, color, finish, size, etc. Orders also
include
content definition defining the particular content to be printed (or engraved,
embroidered, or otherwise imprinted, affixed or embedded) on an associated
ordered
item/article.
A production server 730 at a fulfillment center may retrieve orders 701 from
the order database 792, extract individual item content definition documents
702
associated with the retrieved orders 792, convert the individual item content
definition documents 702 into a set of related individual print-ready files
703,
aggregate individual ordered print-ready files 703 into a set of gangs 704,
and
schedules the job to effect printing of a set of articles of manufacture
through the
conveyance printing system 740 a "gang" at a time. Printed articles of
manufacture
exiting the printing process are sorted into their individual orders,
packaged, and
shipped or otherwise delivered to the respective individual customers.
System 700 is configured for mass production of customized printed products
or items that may be of differing types, shapes, and construction. In this
system,
mass production includes the simultaneous printing of multiple articles of
manufacture which can be ordered from multiple different customers. The
content to
be printed on the various ordered articles of manufacture can differ from
order to
order; thus, each article of manufacture to be printed can potentially be
printed with
unique content.
In the system shown in FIG. 13, a potentially enormous number (e.g.,
thousands or even hundreds of thousands or millions) of individual and
commercial
customers, wishing to place orders for one or more products of various
different
types, shapes, and construction materials, and which are to be printed with
various
graphical and customized designs printed or otherwise affixed thereon, access
the
system over a network 705. In the illustrative embodiment, customers operating
respective client computers 210 may access the system over the Internet or
other
network 705 via web browsers (or similar interactive communication software)
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,
running on personal computers, mobile devices (e.g., smartphones, tablets, or
pad
computers), or other electronic devices 710.
In general, the orders 701 submitted by customers are short run
manufacturing jobs, i.e., manufacturing jobs of products of a particular type
and print
design of less than 40,000 units, typically 1-5,000 units). Through the
network 705,
each customer can access the website 723 comprising a plurality of related web
pages 724 configured to allow a customer to select and customize a graphical
design or template 709 to be printed, etched, engraved, stamped, affixed, or
otherwise embodied on a product (e.g., koozies 99a, tape measures 99b, rulers
99c,
memory sticks 99d, magnetic clips 99e, keychain tags 99f, letter openers 99g,
stress
toys 99h, calculators 99i, etc.). A product may be available in multiple
different types
and construction materials from which the customer may select. Design tool(s)
727
software may execute directly on the customer order server(s) 720, or may be
downloaded from the customer order server(s) 720 as part of web pages 724
displayed to the user to run in the user's browser on the customer's computer
710.
In an embodiment, the design tool(s) 727 enable the customer to perform simple
design functions by completing a selected template using a Design Wizard, or
more
complex design functions using a Design Studio, locally in the browser. In an
embodiment, the templates are embodied using an XML format or other
appropriate
format.
Once the customer has completed customization of the product template
design, the customer places an order through the website 723 in conjuction
with
operation of an order and purchase tool 726. At this point the customized
product
design template is referred to herein as an individual content definition
document
702. An individual content definition document 702 is a document description
of an
ordered article of manufacture, and in one embodiment is stored in an XML
format.
Placement of an order through the order and purchase tool 726 results in a
collection
of information associated with the order, including, by way of example and not
limitation, the content definition document 701, commercial information such
as
desired delivery date, quantity, etc., customer information such as customer
ID,
address, etc., and product specification information such as type, color,
size, etc.
The collection of information, which may be distributed across one or more
databases (e.g., customer database (not shown), ordered items database 792,
scheduled print job database 794, etc.) is referred to herein as an order 701.
The
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individual content definition document 702 is stored in an Orders database
792. In
an embodiment, the individual content definition document 702 stored in XML
format,
and the XML file is then converted by rendering software 732 at a production
server
730 into a set of associated print-ready files such as an Adobe .pdf or other
such
PostScript file(s).
The production server 730 may include scheduling software 731. The
scheduling software 731 operates to schedule the production of articles of
manufacture based on the commercial information and/or production parameters
associated with the received orders 701, such as shipping time, type of
product, etc.
io Rendering software 732 converts individual content definition documents
702
from the web format (e.g., <XML> or Document Object Model (DOM) descriptions)
used in the web browser for displaying the web view of the design as seen by
the
customer during the design process to an associated print-ready (i.e.,
manufacturable) file 703, such as a Postscript (e.g., .pdf) file ready to
print by
printing system of the conveyance printing system.
A Ganging system 733 fills predefined ganging templates 705 containing
placeholders for actual individual print-ready files 703 according to a
schedule
determined from the Scheduling module 731 in conjunction with the print job
management function 731. As an example, FIG. 2C depicts an example tray inlay
210c for holding a plurality of articles of manufacture 99c. As illustrated,
the articles
of manufacture 99c are aligned along both the x- and y- axes.
Given a tray 200 that aligns in the same position in the printer system 170
every time the tray 200 passes through the printer, and having an inlay 210c
configured with fixed positions for holding articles of manufacture in aligned
position,
a print-ready gang file 704 corresponding to the layout of the articles to be
printed
can be constructed.
In an embodiment, and with reference to FIGS. 14A through 14D, individual
print-ready files 703 from individual customer orders are arranged in a layout
according to a predefined gang template 1000. In an embodiment, the gang
template 1000 is saved as a postscript file 704 such as a .pdf file defining a
plurality
of pre-positioned empty cells 1001. A cell 1001 is a content container of pre-
defined
dimensions corresponding to a position and dimensions of a targeted print area
of an
article mounted on a corresponding tray 200 and positioned in the gang file
layout in
CA 02829454 2013-10-07
a unique pre-defined location in the gang template 1000. Each empty cell 1001
may
be filled with a single PostScript individual print-ready file 703.
In the examples shown in FIGS. 14A-14D, the gang template 1000 includes
four cells 1001 of identical size arranged in a single row with the target
print area
aligned down the center of the available printable area (see FIG. 14D). Each
cell
1001 corresponds to a target print area 1010 on an individual article of
manufacture.
The cell layout shown in FIGS. 14A-14D is representative only and will vary
across
different tray inlay types, different types of articles for which a given tray
inlay is
configured, different target print areas on the articles, different numbers of
articles
io accommodated by different trays, etc. In other words, each different
type of tray
inlay will have a corresponding different gang template layout.
Referring back to FIG. 13, the cells 1001 in a gang template 1000 are filled
according to an automated ganging algorithm, executed within the ganging
system
733. The ganging system 733 selects, from a gang template database 720, a gang
template 705,1000 appropriate to a particular article of manufacture and
instantiates a gang print file 704, 1002 for the particular type of tray inlay
that will
hold the particular ordered type of article of manufacture. The ganging system
733
selects ordered items scheduled for production and begins filling
corresponding cells
1000a ¨ 1000d of the instantiated gang file 704 with the corresponding
individual
print-ready files 703 until the gang is filled (see FIGS. 14B and 14C). If the
ordered
quantity of printed articles associated with an individual customer order is
greater
than one, then additional instances of the individual print-ready file 703 may
be
placed in additional cells of the associated gang template 1000 to cause the
ordered
quantity of the item to be printed.
The filled gang file 704 is sent to the conveyance printing system 740, where
a tray of the type associated with the particular gang file 704 is loaded with
corresponding articles of manufacture. The loaded tray is conveyed to the
printing
system 150, where the gang file is printed as a single print job onto the
articles of
manufacture loaded on the tray 200. The tray with printed articles (see FIG.
140) is
then conveyed to an unloading station 140, wherein the printed articles are
removed
from the tray and sorted into individual orders by a human or a computerized
sorting
system. The sorted orders may then be packaged for shipping by a packaging
system.
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It will be appreciated that while one single print ready file containing
corresponding content may be inserted in multiple cells 1001 in a gang 1000,
alternatively and potentially each gang cell 1001 can contain a different
print ready
file containing different corresponding content. Each individual print-ready
file 703
may correspond to the same and/or different customer order. It will be further
appreciated that while embodiments of the tray inlay shown herein depict tray
inlays
configured to hold multiple instances of a single type article of manufacture,
alternative tray inlays may be configured to hold articles of manufacture of
multiple
different types. By way of example only and not limitation, a tray inlay could
hold
io one each of articles of manufacture types 99a, 99b, 99c and 99d. The
corresponding gang file would then include a cell for containing an individual
article
print file 703 for each type of article of manufacture 99a, 99b, 99c and 99d.
As will be appreciated from the above detailed description, the conveyance
printing system offers multiple advantages to the printing industry. Features
include,
but are not limited to:
= A continuous-flow printing system - no need to take the printer offline
to
change out printing pallets;
= Ability to print multiple different types of article of manufacture
without
taking the system offline to change the pallet configuration;
= Automated detection of article of manufacture to print;
= Automated detection of height of articles of manufacture and adjustment
of
height of tray to bring print nozzles within specified tolerance of print
surface;
= Universal tray frame with removable and switchable article of manufacture
specific tray inlay designed for each specific type of article of manufacture
- the height of each inlay is adjusted to place the print surface of the
loaded article(s) of manufacture at a predetermined height which is
standardized across different types of articles of manufacture;
= Automated system indicating to operator which type of tray to load next;
= ergonomic tray handling;
= Ability to easily insert a high-priority print job into the print
manufacturing
flow without stopping the flow or taking the printing system offline;
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= Ability to selectively program which functions to turn on or off based on
information associated with the tray/slot identifier(s).
Those of skill in the art will appreciate that many of the control functions
utilized in the systems and methods described and illustrated herein may be
implemented in software, firmware or hardware, or any suitable combination
thereof.
For example, many control features may be implemented in software for purposes
of
low cost and flexibility. Thus, those of skill in the art will appreciate that
the method
and apparatus of the invention may be implemented by one or more processing
devices (such as, but not limited to a computer, microprocessor, programmable
logic
devices, etc.) by which instructions are executed, the instructions being
stored for
execution on a computer-readable medium and being executed by any suitable
instruction processor. Alternative embodiments are contemplated, however, and
are
within the spirit and scope of the invention.
Although this preferred embodiment of the present invention has been
disclosed for illustrative purposes, those skilled in the art will appreciate
that various
modifications, additions and substitutions are possible, without departing
from the
scope and spirit of the invention as disclosed in the accompanying claims.
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