Reorder system for a binding line

Claim 2

A collating system, comprising: means for delivering a plurality of different signatures to each of a plurality of points along a conveyor, said delivering means thereby forming a plurality of books at said points in the form of a stream of books carried by said conveyor; accumulator means downstream of said delivering means having an input point for receiving each of said books from said conveyor and an output point for discharging each of said books to said conveyor at substantially the same point therealong; means for rejecting a defective one of said books from said conveyor at a point upstream of said accumulator means to thereafter cause said conveyor to have an opening where said defective one of said books has been rejected; means for reordering said defective one of said books by selectively actuating said feeder means to rebuild the same group of signatures upstream of said point where said defective one of said books has been rejected; and means for causing said reordered one of said books to by-pass said accumulator means in such manner as to rejoin said stream of books at said point opening along said conveyor where said defective one of said books has been rejected.

Claim 3

The collating system of claim 1 wherein said delivering means includes a plurality of feeder means selectively actuable to deliver signatures to said conveyor to progressively build groups of signatures into said stream of books.

Claim 4

The collating system of claim 1 wherein said conveyor has a plurality of discrete signature-receiving spaces for receiving signatures from said delivering means to build one of said books on each of said signature-receiving spaces.

Claim 5

The collating system of claim 3 wherein said accumulator means receives each of said books from one of said signature-receiving spaces and thereafter discharges each of said books to one of said signature-receiving spaces.

Claim 6

The collating system of claim 1 wherein said accumulator means has a fixed number of discrete book-receiving spaces for receiving said stream of books from said conveyor at said input point in seriatim fashion.

Claim 7

The collating system of claim 5 wherein said accumulator means discharges said stream of books from said discrete book-receiving spaces to said conveyor at said output point in a first-in first-out manner.

Claim 8

The collating system of claim 1 wherein said accumulator means causes said stream of books on said conveyor to be transported away from and back to said conveyor for a preselected period of time.

Claim 9

A signature collating system for reordering defective signatures, comprising: a plurality of feeder means selectively actuable to deliver signatures to a conveyor having a plurality of discrete signature-receiving spaces to progressively build groups of signatures on each of said spaces into a stream of books; accumulator means downstream of said feeder means for receiving said each of books from a next available one of said spaces on said conveyor and thereafter discharging each of said books to a next available one of said spaces on said conveyor; means for rejecting a defective one of said books from an original location in said stream of books upstream of said accumulator means to thereafter cause said original location in said stream of books to be an open space; means for reordering said defective one of said books by selectively actuating said feeder means to rebuild the same group of signatures, said feeder means causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said original location of said defective one of said books in said stream of books, said reordering means thereby causing said defective one of said books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said books to by-pass said accumulator means in order to rejoin said stream of books on said conveyor at said original location of said defective one of said books in said stream of books.

Claim 10

A signature collating system for reordering defective signatures, comprising: a plurality of feeder means selectively actuable to deliver signatures to a conveyor having a plurality of discrete signature-receiving spaces to progressively build groups of signatures on each of said spaces into a stream of books; accumulator means downstream of said feeder means for receiving said each of books from a next available one of said spaces on said conveyor and thereafter discharging each of said books to a next available one of said spaces on said conveyor; means for rejecting a defective one of said books from an original location in said stream of books upstream of said accumulator means to thereafter cause said original location in said stream of books to be an open space; means for reordering said defective one of said books by selectively actuating said feeder means to rebuild the same group of signatures, said feeder means causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said original location of said defective one of said books in said stream of books, said reordering means thereby causing said defective one of said books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said books to by-pass said accumulator means in order to rejoin said stream of books on said conveyor at said original location of said defective one of said books in said stream of books.

Claim 11

The signature collating system of claim 8 wherein said conveyor has a plurality of discrete signature-receiving spaces for receiving signatures from said feeder means to build one of said books on each of said signature-receiving spaces.

Claim 12

The signature collating system of claim 8 including means for controlling actuation of said feeder means to build different groups of signatures on said signature-receiving spaces such that said stream of books on said conveyor is personalized.

Claim 13

The signature collating system of claim 8 wherein said accumulator means has a fixed number of discrete book-receiving spaces for receiving said stream of books from said conveyor at an input point in seriatim fashion.

Claim 14

The signature collating system of claim 8 wherein said accumulator means discharges said stream of books from said discrete book-receiving spaces to said conveyor at an output point in a first-in first-out manner.

Claim 15

The signature collating system of claim 8 wherein said accumulator means causes said stream of books on said conveyor to be transported away from and back to said conveyor for a preselected time period.

Claim 16

The signature collating system of claim 13 wherein said preselected time period permits said reordered one of said books to rejoin said stream of books on said conveyor at said open space in said stream of books.

Claim 17

A signature collating system for reordering signatures in a fixed increment manner, comprising: a plurality of feeder means selectively actuable to deliver signatures to a conveyor to progressively build groups of signatures into a book, said conveyor having a plurality of discrete signature-receiving spaces for receiving signatures from said feeder means to build one of said books on each said of signature-receiving spaces, and means for controlling actuation of said feeder means to build different groups of signatures on said signature-receiving spaces into a stream of personalized books; accumulator means downstream of said feeder means for receiving and discharging said stream of personalized books in a first-in, first-out fashion; means for rejecting a defective one of said personalized books from an original location in said stream of personalized books at a point upstream of said accumulator means; said accumulator means having a fixed number of discrete book-receiving spaces for receiving said stream of personalized books from said conveyor, each of said book-receiving spaces receiving one of said personalized books, if any, from the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an input point of said accumulator means and each of said book-receiving spaces thereafter discharging one of said personalized books, if any, to the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an output point of said accumulator means, said accumulator means causing said stream of personalized books on said conveyor to be transported away from and back to said conveyor for a preselected period of time; means for reordering said defective one of said personalized books by selectively actuating said feeder means to rebuild the same group of signatures, said feeder means causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said space of said defective one of said personalized books, said reordering means thereby causing said defective one of said personalized books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said personalized books to by-pass said accumulator means and rejoin said stream of personalized books, said preselected period of time being a time sufficient for said reordered one of said books to rejoin said stream of personalized books on said conveyor at said original location of said defective one of said books in said stream of personalized books, whereby said books may be mail sorted downstream of said accumulator means to maximize postal discounts for original and reordered books.

Claim 18

A signature collating system for reordering signatures in a fixed increment manner, comprising: a plurality of feeder means selectively actuable to deliver signatures to a conveyor to progressively build groups of signatures into a book, said conveyor having a plurality of discrete signature-receiving spaces for receiving signatures from said feeder means to build one of said books on each said of signature-receiving spaces, and means for controlling actuation of said feeder means to build different groups of signatures on said signature-receiving spaces into a stream of personalized books; accumulator means downstream of said feeder means for receiving and discharging said stream of personalized books in a first-in, first-out fashion; means for rejecting a defective one of said personalized books from an original location in said stream of personalized books at a point upstream of said accumulator means; said accumulator means having a fixed number of discrete book-receiving spaces for receiving said stream of personalized books from said conveyor, each of said book-receiving spaces receiving one of said personalized books, if any, from the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an input point of said accumulator means and each of said book-receiving spaces thereafter discharging one of said personalized books, if any, to the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an output point of said accumulator means, said accumulator means causing said stream of personalized books on said conveyor to be transported away from and back to said conveyor for a preselected period of time; means for reordering said defective one of said personalized books by selectively actuating said feeder means to rebuild the same group of signatures, said feeder means causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said space of said defective one of said personalized books, said reordering means thereby causing said defective one of said personalized books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said personalized books to by-pass said accumulator means and rejoin said stream of personalized books, said preselected period of time being a time sufficient for said reordered one of said books to rejoin said stream of personalized books on said conveyor at said original location of said defective one of said books in said stream of personalized books, whereby said books may be mail sorted downstream of said accumulator means to maximize postal discounts for original and reordered books.

Claim 19

The signature collating system of claim 15 wherein said feeder means include a plurality of signature feeder boxes and said actuation controlling means includes source means establishing different combinations of signature feeder boxes to be actuated.

Claim 20

The signature collating system of claim 16 wherein said source means establishes coded data for controlling actuation of said signature feeder boxes to build different groups of signatures in response to different coded data.

Claim 21

The signature collating system of claim 17 wherein said different groups of signatures each have a predetermined thickness and including caliper means for measuring each of said personalized books for said predetermined thickness.

Claim 22

The signature collating system of claim 18 wherein said caliper means is operatively associated with said rejecting means to cause any of said books deviating from said predetermined thickness by more than a preselected amount to be rejected.

Claim 23

The signature collating system of claim 19 wherein said rejecting means also diverts books to be rejected from said conveyor to thereby create openings along said conveyor where said books to be rejected have been diverted.

Claim 24

The signature collating system of claim 20 wherein said reorder means is disposed intermediate said rejecting means and accumulator means and includes means for detecting an opening along said conveyor in any of said signature-receiving spaces.

Claim 25

A signature collating system for reordering signatures in a fixed increment manner, comprising: a plurality of signature feeder boxes selectively actuable to deliver signatures to a conveyor to progressively build groups of signatures into a book, said conveyor having a plurality of discrete signature-receiving spaces for receiving signatures from said signature feeder boxes to build one of said books on each said of signature-receiving spaces, and means for controlling actuation of said signature feeder boxes to build different groups of signatures on said signature-receiving spaces into a stream of personalized books; accumulator means downstream of said signature feeder boxes for receiving and discharging said stream of personalized books in a first-in, first-out fashion; means for rejecting a defective one of said personalized books from an original location in said stream of personalized books at a point upstream of said accumulator means, said rejecting means also diverting books to be rejected from said conveyor to thereby create openings along said conveyor where said books to be rejected have been diverted; said accumulator means having a fixed number of discrete book-receiving spaces for receiving said stream of personalized books from said conveyor, each of said book-receiving spaces receiving one of said personalized books, if any, from the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an input point of said accumulator means and each of said book-receiving spaces thereafter discharging one of said personalized books, if any, to the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an output point of said accumulator means, said accumulator means causing said stream of personalized books on said conveyor to be transported away from and back to said conveyor for a preselected time period; said output point of said accumulator means being disposed a preselected distance downstream of said input point of said accumulator means; means for reordering said defective one of said personalized books by selectively actuating said signature feeder boxes to rebuild the same group of signatures, said signature feeder boxes causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said space of said defective one of said personalized books, said reordering means thereby causing said defective one of said personalized books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said personalized books to by-pass said accumulator means and rejoin said stream of personalized books, said preselected period of time and said preselected distance being a time and distance sufficient for said reordered one of said books to rejoin said stream of personalized books on said conveyor at said original location of said defective one of said books in said stream of personalized books, whereby said books may be mail sorted downstream of said accumulator means to maximize postal discounts for original and reordered books.

Claim 26

A signature collating system for reordering signatures in a fixed increment manner, comprising: a plurality of signature feeder boxes selectively actuable to deliver signatures to a conveyor to progressively build groups of signatures into a book, said conveyor having a plurality of discrete signature-receiving spaces for receiving signatures from said signature feeder boxes to build one of said books on each said of signature-receiving spaces, and means for controlling actuation of said signature feeder boxes to build different groups of signatures on said signature-receiving spaces into a stream of personalized books; accumulator means downstream of said signature feeder boxes for receiving and discharging said stream of personalized books in a first-in, first-out fashion; means for rejecting a defective one of said personalized books from an original location in said stream of personalized books at a point upstream of said accumulator means, said rejecting means also diverting books to be rejected from said conveyor to thereby create openings along said conveyor where said books to be rejected have been diverted; said accumulator means having a fixed number of discrete book-receiving spaces for receiving said stream of personalized books from said conveyor, each of said book-receiving spaces receiving one of said personalized books, if any, from the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an input point of said accumulator means and each of said book-receiving spaces thereafter discharging one of said personalized books, if any, to the next available of said signature-receiving spaces of said conveyor in seriatim fashion when said signature-receiving spaces are positioned at an output point of said accumulator means, said accumulator means causing said stream of personalized books on said conveyor to be transported away from and back to said conveyor for a preselected time period; said output point of said accumulator means being disposed a preselected distance downstream of said input point of said accumulator means; means for reordering said defective one of said personalized books by selectively actuating said signature feeder boxes to rebuild the same group of signatures, said signature feeder boxes causing the same group of signatures to be rebuilt a fixed number of signature-receiving spaces upstream of said space of said defective one of said personalized books, said reordering means thereby causing said defective one of said personalized books to be reordered in a fixed increment manner relative to said accumulator means; and means for causing said reordered one of said personalized books to by-pass said accumulator means and rejoin said stream of personalized books, said preselected period of time and said preselected distance being a time and distance sufficient for said reordered one of said books to rejoin said stream of personalized books on said conveyor at said original location of said defective one of said books in said stream of personalized books, whereby said books may be mail sorted downstream of said accumulator means to maximize postal discounts for original and reordered books.

Claim 27

The signature collating system of claim 22 wherein said by-pass means comprises a by-pass/direct gate associated with said accumulator means at both of said input and output points to permit said reordered one of said books to remain on said conveyor.

Claim 28

The signature collating system of claim 23 wherein said preselected distance between said input point and said output point of said accumulator means corresponds to a preselected number of signature-receiving spaces on said conveyor.

Claim 29

The signature collating system of claim 24 wherein said fixed number of book-receiving spaces of said accumulator means inclusive of a single space associated with each of said by-pass/direct gates is determined by the formula BRS=SRS/FIR+SRS/IOD where SRS/FIR is the number of signature-receiving spaces associated with said fixed increment reordering, SRS/IOD is the number of signature-receiving spaces associated with said input--output distance, and BRS is the number of book-receiving spaces.