Document Production System and Method With Automated Die Exchange

Abstract

A media cutting system is disclosed comprising a die cutter including a cutting surface and a plurality of dies stored proximate the cutting surface, a die exchange system including a die storage system configured to support the plurality of dies and a die transport system, and a computer system comprising a controller configured to operate the die transport system and the die cutter. A die exchange system and methods of making and using the die exchange system also are disclosed.

What is claimed is: 
     
         1 . A media cutting system comprising:
 a die cutter comprising a cutting surface and a plurality of dies stored proximate the cutting surface,   a die exchange system configured to automatically move a die between a storage position and a cutting position, the die exchange system including a die storage system configured to support the plurality of dies, and a die transport system, and   a computer system comprising a controller configured to operate the die transport system and the die cutter.   
     
     
         2 . The media cutting system of  claim 1 , wherein the die storage system comprises an elevator configured to vertically displace a selected die. 
     
     
         3 . The media cutting system of  claim 1 , wherein the die storage system comprises a plurality of stationary die supports. 
     
     
         4 . The media cutting system of  claim 1 , further including a first optical reader positioned upstream from the cutter to read data on a sheet of media indicative of the die to be used to cut the sheet. 
     
     
         5 . The media cutting system of  claim 4 , wherein the controller receives die selection data from the first optical reader. 
     
     
         6 . The media cutting system of  claim 1 , further comprising a printer positioned in-line with the die cutter. 
     
     
         7 . The media cutting system of  claim 1 , wherein the printer is positioned upstream from the die cutter. 
     
     
         8 . The media cutting system of  claim 7 , wherein the controller is configured to receive die selection data from a processor associated with the printer 
     
     
         9 . The media cutting system of  claim 8 , further comprising a buffer system disposed between the printer and the die cutter. 
     
     
         10 . The media cutting system of  claim 8 , wherein no buffer system is included between the printer and the die cutter. 
     
     
         11 . The media cutting system of  claim 1 , wherein the die cutter is a rotary cutter. 
     
     
         12 . The media cutting system of  claim 1 , wherein the die comprises a plate and is mounted on a drum, and the drum with the plate mounted thereon is moved from the storage position to the cutting position. 
     
     
         13 . The media cutting system of  claim 1 , further comprising a second optical reader configured to associate data on a die with a location on a die storage support. 
     
     
         14 . The media cutting system of  claim 1 , further comprising a vision inspection system positioned downstream from the cutter configured to determine the precision of a cut made on a sheet of media. 
     
     
         15 . A die exchange system comprising:
 a die storage system comprising a plurality of supports configured to support a plurality of cutting dies,   an automatic die transport system configured to automatically transport dies in and out of the die storage system, the automatic die transport system including a die loader configured to move dies horizontally in and out of a storage position in the die storage system,   an elevator assembly associated with at least one of the die storage system and the automatic die transport system, the elevator assembly including a drive configured to vertically displace a die that is moved out of a storage position to be placed in a cutting position, and   a computer comprising a die exchange controller configured to operate the die loader and the elevator assembly.   
     
     
         16 . The system of  claim 15 , wherein the die exchange system is configured to be retrofit to an existing die cutter. 
     
     
         17 . The system of  claim 15 , wherein the elevator assembly is part of the die storage system. 
     
     
         18 . The system of  claim 15 , wherein the elevator assembly is configured to simultaneously transport a first die from the die storage system to a die cutter and a second die from the die cutter to the die storage system. 
     
     
         19 . The system of  claim 15 , further including a die cutter, wherein the automatic die transport system moves a selected die between a storage position in the die storage system and an operating position in the die cutter. 
     
     
         20 . The system of  claim 19 , wherein the die exchange controller receives die selection data from at least one of the die cutter and an indicia reader associated with the die cutter. 
     
     
         21 . A method of making a media cutter, comprising:
 obtaining a die cutter, a die storage system, a die transport system, and a controller,   positioning the die cutter, die storage system and die transport system in proximity to one another to enable dies to be automatically transferred from the die storage system to the die cutter using the die transport system, and   programming the controller to automatically transport dies in and out of the die cutter in response to computerized instructions received by the controller.   
     
     
         22 . The method of  claim 21 , further comprising:
 programming the controller to cut media using a die positioned in the die cutter.   
     
     
         23 . A method of cutting media, comprising:
 obtaining a first set of media sheets,   automatically selecting a first die to be used to cut the first set of media sheets,   automatically positioning the first die in a die cutter in a cutting position,   automatically adjusting cutting parameters for the first die,   cutting the first set of media sheets using the first die,   automatically removing the first die from the die cutter,   obtaining a second set of media sheets,   automatically selecting a second die to be used to cut the second set of media sheets,   automatically positioning the second die in the die cutter in a cutting position,   automatically adjusting cutting parameters for the second die, and   cutting the second set of media sheets using the second die.