EP4212350B1 - Production installation for the production of identity, value or security documents or for the production of a cluster of a plurality of identity, value or security documents - Google Patents

Description

The invention relates to a production plant for producing identification, valuables or security documents or for producing a composite of a plurality of identification, valuables or security documents.

From the EN 10 2016 217 041 B3 A method for producing an individual ID, valuables or security document is known, in which the document has a personalized composite body that includes a document type-specific selection of material sheets in a document type-specific order. The individual material sheets are provided by means of a storage station, whereby the individual material sheets provided are collected and put together in the document type-specific order for the material sheet booklet to be created. The document type-specific composite body is then laminated and cut to a format. The data type-specific composite body is then personalized.

From the EN 10 2018 119 178 A1 A production plant for producing data cards for security elements from a laminate composite is described, which is formed from two processing lines decoupled from each other by an interface, namely a production line and a personalization line, each of which comprises a closed transport path for transporting the blank card cut to the final size in a workpiece carrier. The blank card is in a Savings are placed in the workpiece carrier and are thus guided through all processing stations; this creates a so-called one-piece flow.

It is the object of the present invention to provide a production plant for producing identification, valuable or security documents or for producing a composite of a plurality of identification, valuable or security documents which have a compact structure.

This object is achieved by a production plant having the features of claim 1. Advantageous embodiments with expedient further developments of the invention are specified in the dependent claims.

The production system according to the invention comprises in particular a transport system with at least one workpiece carrier. Preferably, there are a large number of workpiece carriers, which leads to a higher throughput during production. Adjacent to the transport system is a first supply device, which is designed to transfer a cover layer of the ID, valuable or security document to the workpiece carrier. Downstream of the first supply device is a printing device adjacent to the transport system, which comprises a stationary print head in a printing area in order to apply a printed image, in particular a portrait image, to a substrate by moving a printing table together with the substrate fixed to it, and which is designed to transfer the printed substrate back to the workpiece carrier individually. Downstream of the printing device is a further supply device adjacent to the transport system, which is designed to transfer at least one further layer of the ID, valuable or security document to the workpiece carrier. Here too, there can be a plurality of further supply devices, which add individual layers to the stack on the workpiece carrier depending on the structure of the ID, valuable or security document. The at least one further supply device is followed by a device adjacent to the transport system for producing a welded raw card composite with or without a light-transparent window. Furthermore, one of the Device for producing a welded raw card composite with or without a light-transparent window, there is a final supply device downstream of the transport system, adjacent to the transport system, which is set up to transfer a further cover layer of the ID, value or security document to the workpiece carrier to form a foil stack. This final supply device is also followed by a stapling station adjacent to the transport system, which is set up to connect the foil stack to form a foil booklet. The stapling station is followed by a laminating station adjacent to the transport system, in which a heating device is integrated and which is set up to laminate the foil booklet to form a laminate composite. The laminating station is followed by a cutting station, which is set up to subject the laminate composite to multi-sided trimming, the cutting station being assigned a handling device to remove the laminate composite from or out of the workpiece carrier and to feed the laminate composite, in particular cut into strips, back to the workpiece carrier.

This design creates a compact production facility, which also results in a short lead time for the production of identification, valuables or security documents.

It is also possible that a strip of several identification, valuables or security documents is available for further processing, whereby this strip is preferably a combination of four cards in ID1 format or a combination of two cards in ID3 format. This means that the product to be inserted into a magazine is in a strip format which has an area of 104 millimetres by 278 millimetres (if it is a strip in ID3 format) or 104 millimetres by 264 millimetres (if it is a strip in ID1 format). These strips can then be further processed as required and flexibly.

Preferably, the strip contains raw cards in ID 1, ID 2, ID 3 or any other format. These formats are standardized, for example, by ISO 10373, ISO/IEC 7810 and ISO 14443.

In order to ensure that the individual layers are reliably transported to or through the individual stations during production, it is expedient for the workpiece carrier to comprise at least two positioning pins in order to stack and transport the layers of the later identification, valuables or security document with holes in register.

The production plant is preferably equipped with a transport system which is designed as a planar drive system. This planar drive system comprises a permanently excited electromagnetic planar motor which in turn is designed with a plurality of planar stators. In addition, there is at least one runner which can move on the stators in at least two directions and which forms the workpiece carrier of the transport system. Preferably, however, the runner can move in or around four directions.

It has proven advantageous if individual or all of the supply devices are provided with a roller extension for supplying the individual layers that have been separated from a plastic sheet from a roll. This roller extension is preferably provided with a linearly adjustable gripping device for gripping a free end of the plastic sheet.

In order to ensure that the individual layers are positioned as precisely as possible on the workpiece carriers, it has proven advantageous if the supply device also includes a hole punch to punch holes in the layers before they are placed on or in the workpiece carrier. If the workpiece carrier is provided with a positioning pin adapted to the hole, the individual layers can be aligned in the correct position or register on or in the workpiece carrier. It is possible for a plurality of holes to be present or punched in the individual layers, and thus for a corresponding plurality of positioning pins, in particular a number of two positioning pins, to be present on the workpiece carriers. The use of more than one positioning pin on the workpiece carrier serves to prevent the individual plastic layers threaded onto the positioning pins from twisting.

It is also possible for the supply device to be formed with a clamping device and a cutting device. In this way, the unrolled part can be fixed at the end and then reliably severed, i.e. separated.

When punching out individual layers of the subsequent ID, valuables or security document, it is necessary that these maintain their mutual position and do not slip. It is therefore advantageous if the device for producing a welded blank card composite with a light-transparent window is immediately preceded by a pre-fixing station adjacent to the transport system, which is set up to pre-fix the stack of layers provided by the workpiece carrier.

The device for producing a welded raw card composite with or without a light-transparent window comprises in particular a punching device which has a die holder fixed to a punching stand, on which there is a first die, to which a first punching die is assigned for punching the card substrate. The die holder also has a second die, to which there is assigned a second punching die which can be moved coaxially to the first punching die and has the same contour as the latter for punching a window substrate, wherein the first die is arranged at a distance from the second die in an adjustment direction of the punching dies. In the punching position, the first punch and the first die are positioned relative to the card substrate in such a way that they create an opening in the card substrate during the adjustment movement of the first punch, wherein the second punch and the second die are positioned relative to the window substrate in such a way that they punch out a window part adapted to the dimensions of the opening from the window substrate during the adjustment movement of the second punch, wherein the window part can be inserted into the opening by the simultaneous movement of the first punch together with the second punch.

The special thing about the punching device is the production of the double punch. This is originally formed from a single piece, which is only was then separated into the two punches. For this reason, both punches have exactly the same contour. The same applies to the two dies. These were also divided from a single die piece into the two individual dies. For this reason, the two dies have exactly the same contour.

The device for producing a welded raw card composite with a light-transparent window can additionally be provided with a film welding device for welding a carrier film to a single-layer or multi-layer card substrate. The punching device can be adjusted, for example, vertically with respect to the adjustment direction of the punching dies at least between one punching position and one welding position. In a welding position, an area on the first die is preferably present as an abutment for a pressure plate of the film welding device. In this way, the punching device can fulfill a dual function, namely, on the one hand, punching the window substrate and the card substrate and inserting the window part into the opening by means of the simultaneous movement of the punching dies. And, on the other hand, forming an abutment when welding the carrier film. In this way, a particularly compact device for producing a welded card with a light-transparent window and thus a particularly compact production system is available.

In order to increase the forgery protection of ID, valuables or security documents, it is known to incorporate threads, in particular security threads, into the individual layers or to integrate them into the composite body. It has therefore proven to be useful if a thread insertion station is placed between the final supply device for providing the cover layer and the device for producing a welded raw card composite with a light-transparent window, which is set up to provide the workpiece carrier with at least one security thread or a layer with at least one security thread. This ensures that the security thread is integrated into the later card body and cannot be easily released again.

If the ID, valuables or security document is one in ID1 format, it has proven advantageous to increase throughput if there are at least four thread application devices in the transport direction / production direction, each of which can apply a security thread. This is the case, for example, with the German identity card (as of 2021). If the ID, valuables or security document is one in ID3 format, the at least four thread application devices are used to apply a security thread transversely to the transport direction / production direction, which is the case, for example, with the German passport (as of 2021). The thread insertion station can be mounted stationary in the housing of the production system, with the workpiece carrier being rotatable to specify the appropriate direction for the application of the security thread. Alternatively, the thread insertion station itself can also be rotatable, for example by 90 degrees, so that the direction of the thread application can be changed or adjusted.

In order to compensate for the lamination time, it is advantageous if the laminating station comprises at least two independently operable individual presses that can work in parallel. The laminating station is preferably designed in such a way that the tools and their lamination sheets remain in the respective individual press.

Preferably, in addition to the heating device, a cooling device is also integrated into the laminating station, although there are separate temperature ranges for the heating and cooling processes. The present laminating station has the advantage that only the lamination sheets and the card material are heated and cooled again, which results in lower energy requirements. The workpiece carrier is therefore not heated up, as the pre-fixed film booklet is removed from the first workpiece carrier using the transfer device and fed to one of the two individual presses.

The cutting station is preferably set up to subject the laminate composite produced in the laminating station to a four-sided trimming. The laminate composite is preferably cut to a format which comprises a composite of four ID1 formats. Alternatively or additionally, the laminate composite is cut to a format that comprises a composite of two ID3 formats. The trimming is preferably carried out using print marks that have already been applied in advance.

Many ID, valuables or security documents have an additional print on their outermost cover layer. The outermost print can also be a layer of varnish. For example, a layer of varnish made from a signature varnish is suitable here; the layer is then preferably only partially applied to the cover layer. The production system for this preferably includes an additional printing device downstream of the cutting station and adjacent to the transport system for applying a varnish to the cut lamination composite. The positioning of the varnish field or the several varnish fields is carried out, for example, using printer marks that are optically recognized by a camera.

In particular, the further printing device can be a pad printing device for applying a signature varnish which, in its dried state, can be written on with a document-safe ink.

In order to shorten the throughput time during production, it is also advantageous if a drying station for drying the applied varnish is also installed downstream of the printing device.

For some ID, valuables or security documents, it is necessary to apply a hologram foil with a hologram printed on it. It is therefore advantageous if the production plant also includes a hologram application device with a workpiece transport device downstream of the cutting station. This is then set up to lift the workpiece carrier together with the laminate composite from the transport system, to apply a foil with a hologram to the cut laminate composite and then to return the laminate composite with the hologram to the transport system together with the workpiece carrier. The removal of the laminate composite from the workpiece carrier of the transport system of the The production system is designed to allow greater pressure forces to be applied to the laminate composite when applying the hologram foil. These pressure forces could not be exerted in a case where the laminate composite remains on the workpiece carrier.

In order to be able to carry out various further processing steps, such as applying a hologram foil or printing with a varnish field, on both sides of the laminate composite, it has proven to be useful to have a turning device downstream of the cutting station, which is set up to turn the cut laminate composite over in order to subsequently process it on its other side.

This turning device is in particular provided with two suction grippers. A first suction gripper is designed to grip the laminate composite by means of a negative pressure and to be adjusted vertically with respect to the plane spanned by the workpiece carrier. The first suction gripper is also designed to be adjusted parallel to the plane spanned by the workpiece carrier. In addition, the first suction gripper is designed to be rotated about an axis oriented parallel to the plane spanned by the workpiece carrier. In addition, there is a second suction gripper which is designed to receive the laminate composite turned by the first suction gripper and to grip it by means of a negative pressure and to be adjusted vertically with respect to the plane spanned by the workpiece carrier. In this way, the second suction gripper can place the turned laminate composite back on the workpiece carrier.

In order to be able to detect production errors, it is advantageous if an inspection device is available adjacent to the transport system, which is set up to subject the cut laminate composite to a quality check and to mark defective laminate composites as scrap.

In this context, it has proven useful if the inspection device is set up to check the register of the individual layers of the laminate composite and to make a correction for the assembly of the individual layers if the register accuracy falls below a specified threshold. In this case, the data is transferred to the production plant's control system.

In order to facilitate further processing or removal of the end products, there is preferably a storage device with at least two magazines adjacent to the transport system, which is designed to store the finished identification, valuables or security document in the magazines sorted by format.

It is possible for the magazine device to comprise a punching device which is designed to separate a laminated composite with a plurality of identification, valuable or security documents into individual identification, valuable or security documents of a predetermined format before storing them in one of the magazines.

Figur 1

eine perspektivische Ansicht einer Produktionsanlage zum Herstellen von Ausweis-, Wert- oder Sicherheitsdokumenten oder zum Herstellen eines Verbunds aus einer Mehrzahl von Ausweis-, Wert- oder Sicherheitsdokumenten,

Figur 2

eine Draufsicht auf die Produktionsanlage nach Figur 1 ohne Gehäuse,

Figur 3

eine vereinfachte perspektivische Ansicht auf das Transportsystem und einen der Werkstückträger der Produktionsanlage aus Figur 1,

Figur 4

eine vereinfachte perspektivische Ansicht auf den Rollenauszug einer der Bereitstellungseinrichtungen der Produktionsanlage aus Figur 1,

Figur 5

eine vereinfachte perspektivische Seitenansicht auf die Druckeinrichtung zur Bereitstellung der Lage mit einem Portraitbild der Produktionsanlage aus Figur 1,

Figur 6

eine vereinfachte perspektivische Ansicht auf den Bogenauszug / Bogenanleger einer der Bereitstellungseinrichtungen der Produktionsanlage aus Figur 1,

Figur 7

eine vereinfachte perspektivische Ansicht auf die Einrichtung zum Herstellen eines verschweißten Rohkartenverbunds mit einem lichttransparenten Fenster (Fensterstanze) der Produktionsanlage aus Figur 1,

Figur 8

eine vereinfachte perspektivische Ansicht auf die Fadeneinlegstation der Produktionsanlage aus Figur 1,

Figur 9

eine vereinfachte perspektivische Ansicht auf die Laminierstation der Produktionsanlage aus Figur 1,

Figur 10

eine vereinfachte perspektivische Ansicht auf die Zuschnittstation der Produktionsanlage aus Figur 1,

Figur 11

eine vereinfachte perspektivische Ansicht auf die weitere Druckeinrichtung zur Applizierung eines Unterschriftenfelds der Produktionsanlage aus Figur 1 zusammen mit einem Lackfeldtrockner,

Figur 12

eine vereinfachte perspektivische Ansicht auf die Wendeeinrichtung der Produktionsanlage aus Figur 1,

Figur 13

eine vereinfachte perspektivische Ansicht auf die Hologrammappliziereinrichtung der Produktionsanlage aus Figur 1,

Figur 14

eine vereinfachte perspektivische Ansicht auf die Überprüfungseinrichtung der Produktionsanlage aus Figur 1, und

Figur 15

eine vereinfachte perspektivische Ansicht auf die Magaziniereinrichtung der Produktionsanlage aus Figur 1.

Further features, properties and advantages of the present invention are described in more detail below using embodiment variants with reference to the attached figures. The embodiment variants described below are merely examples which do not, however, limit the subject matter of the invention. They show:

Figure 1

a perspective view of a production plant for producing identification, valuable or security documents or for producing a composite of a plurality of identification, valuable or security documents,

Figure 2

a top view of the production plant after Figure 1 without housing,

Figure 3

a simplified perspective view of the transport system and one of the workpiece carriers of the production plant Figure 1 ,

Figure 4

a simplified perspective view of the roll extension of one of the supply devices of the production plant Figure 1 ,

Figure 5

a simplified perspective side view of the printing device for preparing the position with a portrait image of the production plant from Figure 1 ,

Figure 6

a simplified perspective view of the sheet feeder / sheet feeder of one of the supply devices of the production plant Figure 1 ,

Figure 7

a simplified perspective view of the device for producing a welded raw card composite with a light-transparent window (window punch) of the production plant from Figure 1 ,

Figure 8

a simplified perspective view of the thread insertion station of the production plant Figure 1 ,

Figure 9

a simplified perspective view of the laminating station of the production plant Figure 1 ,

Figure 10

a simplified perspective view of the cutting station of the production plant Figure 1 ,

Figure 11

a simplified perspective view of the further printing device for applying a signature field of the production plant from Figure 1 together with a paint field dryer,

Figure 12

a simplified perspective view of the turning device of the production plant Figure 1 ,

Figure 13

a simplified perspective view of the hologram application device of the production plant Figure 1 ,

Figure 14

a simplified perspective view of the inspection facility of the production plant Figure 1 , and

Figure 15

a simplified perspective view of the magazine storage device of the production plant Figure 1 .

In the Figure 1 a production system 100 for producing ID, valuable or security documents or for producing a composite of a plurality of ID, valuable or security documents is shown, which is characterized by a compact structure. The production system 100 is formed with a housing 108 which encapsulates the individual processing stations. The production system 100 and its housing 108 comprise a longitudinal part 102 in which individual processing stations are accommodated. The production system 100 and its housing 108 are also formed with a first system arm 104 and a second system arm 106 in which further processing stations of the production system 100 are accommodated. The two system arms 104, 106 are connected to the longitudinal part 102 to form a unit. The housing 108 also has a plurality of display and/or operating devices 110 in order to monitor and/or control the individual processing stations. In order to make the processing steps or processing stations of the production system 100 visible to a machine operator, the housing 108 has several windows.

In the Figure 2 is a plan view of the production plant 100 from Figure 1 shown, whereby the housing 108 has not been shown for the sake of clarity. It can be seen that the production plant 100 comprises a transport system 112 with at least one workpiece carrier 114.

The transport system 112 and the workpiece carrier 114 are described in detail in Figure 3 shown. The transport system 112 is formed as a planar drive system. This planar drive system comprises a permanently excited electromagnetic planar motor 148, which in turn is formed with a plurality of planar stators. These stators form a kind of "plate" on which the workpiece carrier 114 is placed. The workpiece carrier 114 is formed as a runner of the planar motor 148 that can move on the stators in at least two directions. In the present case, the workpiece carrier 114 is designed to move along or around four axes. It is possible to move along the X-axis, along the Y-axis and along the Z-axis, as well as to rotate around one of these axes. In order to be able to transport the individual layers reliably and without loss, the workpiece carrier 114 has at least two positioning pins 150 in order to stack and transport layers of the later ID, valuables or security document with holes in register.

Out of Figure 2 It can again be seen that a first provision device 144 is adjacent to the transport system 112, which is configured to transfer a cover layer of the identification, value or security document to the workpiece carrier 114.

This first provisioning device 144 is described in detail in Figure 4 shown and comprises a roll extension 152. However, there are also other supply devices 154 which have a structure identical to the first supply device 144, wherein each of the supply devices 144, 154 provides a layer which is separated from a roll 156 from a plastic web (preferably based on polyamide (PA) or polyurethane (PU), preferably based on polycarbonate (PC)). The roll extension 152 is formed with a clamping device 158 and with a cutting device 160. In this way, the unrolled part can be fixed at the end and then reliably severed, thus separated. For unrolling the film from the roll 156, the roll extension 152 has a linearly adjustable gripping device 162 for gripping a free end of the plastic web. The plastic web is guided by at least one guide roller. The roll pull-out 152 also has a hole punch 164 to punch the threaded film. After punching, the beginning of the film is gripped by the gripping device 162 and the roll 156 is pulled linearly to the strip size, which can be picked up by the first workpiece carrier 144. The pull-off strip is then clamped with the clamping device 158, after which a separating cut of the film strip is made with a cutting device 160 in order to separate it. A roller take-off could also be located in place of the clamping device 158.

Out of Figure 2 It is again apparent that the production plant 100 also has a printing device 116 downstream of the first provision device 144 and adjacent to the transport system 112. It provides the portrait image of the user or the portrait images of the users of the later identification, value or security document.

The printing device 116 is in Figure 5 can be seen in more detail. The printing device 116 comprises a supply unit 168 for supplying a web-shaped substrate 170 from a roll 172. The unwound roll 172, in particular the web-shaped substrate 170, is guided through the printing device 116 by a substrate guide 174 with several deflection rollers 176. A splice unit 178 is arranged directly downstream of the supply unit 168 in order to connect at least one layer of the substrate 170 provided on the roll 172 to the substrate 170 of the previous roll. A cutting unit 180, the supply unit 168 and a buffer unit 182 are arranged in an uppermost level 184 of the printing device 116. The splice unit 178 is arranged downstream of the supply unit 168 along a web transport direction, but upstream of a printing area 166 to be explained in more detail. The buffer unit 182, which is also optional, is used for temporary intermediate storage of the unwound web-shaped substrate 170. The buffer unit 182, which is also located downstream of the provision unit 168 in the web transport direction, but upstream of the printing area 166, is also located downstream of the splice unit 178. The buffer unit 182 comprises, merely as an example, a movable deflection roller 186, wherein the buffer unit 182 is set up, due to its movable deflection roller 186, to compensate for a change in the length of the web-shaped substrate 170 that occurs during the printing process due to the movement of a printing table 188. The movable deflection roller 186 is mounted so as to be adjustable perpendicular to the direction of fall. Starting from the buffer unit 182, an alignment unit 190, which is also optional, is located downstream of the buffer unit. This alignment unit 190 is located directly in front of the printing area 166 and is thus configured to align the edges of the substrate 170 with respect to the printing table 188 The substrate guide 174 guides the web-shaped substrate to the printing table 188 and thus to the printing area 166. In the printing area 166 there is the slidably mounted or adjustable printing table 188, which has a vacuum unit in order to fix the web-shaped substrate 170 in sections using a vacuum. For this purpose, the printing table 188 has, for example, a plate that is provided with several suction holes in order to suck the web-shaped substrate 170 onto the plate. The adjustment of the printing table 188 also takes place vertically with respect to the direction of fall. In the printing area 166 there is also a print head 192 which is held stationary during the printing process and is set up to apply a print image to the substrate 170 by means of a displacement of the printing table 188 together with the substrate 170 fixed thereto. In other words, the printing head 192 or the multiple printing heads 192 with their printing nozzles are thus stationary, with the print image being created by the displacement of the printing table 188 with respect to the printing head 192. In order to keep the web-shaped substrate 170 taut here too, one or more deflection rollers or one or more movable deflection rollers can optionally be present in order to maintain the tension in the web-shaped material during the printing process, with the movable deflection rollers in particular being designed in the manner of a "dancer" which is adjusted vertically with respect to the direction of fall. The said deflection rollers move in particular synchronously with the printing table 188. In this way, it is possible to compensate for the film path so that the printing area 166 on the printing table 188 does not move unintentionally. If the substrate 170 in the printing area 166 has then been printed with the print image, the printed substrate 170 is transported further in the transport direction, in this case downwards in the direction of fall. In this way, the printing area 166 is located in a middle level 194, which is located below the top level 184 of the printing device 116 in the direction of fall. In a lower level 196, there are a plurality of likewise optional testing units 198 in order to test the web-shaped substrate 170, in particular optically. In other words, the testing units 198 are downstream of the printing area 166 in the web transport direction, but upstream of a drying oven 200. This means that rejects can be detected before drying and thus a smaller section of the web-shaped substrate 170 needs to be replaced if defects are detected.

In the present case, the web-shaped substrate 198 first passes through the first inspection unit 198, which optically examines the underside of the web-shaped substrate 170. Only then does the web-shaped substrate 170 reach the second inspection unit 198, which then checks the printed image and the printed side. Downstream in the web transport direction is the drying oven 200 in order to completely dry the still wet ink. The substrate guide 174 then guides the printed substrate 170 out of the side of the printing device 116 and delivers it individually to the workpiece carrier 114. The printed substrate 170 is delivered on the side of the printing device 116 on which the supply unit 168 with its roll 172 of the substrate 170 is also located.

Out of Figure 2 It is again apparent that at least one further provision device 146 with a sheet extractor 202 is present downstream of the printing device 116 and adjacent to the transport system 112 and is configured to transfer at least one further layer of the identification, value or security document to the workpiece carrier 114.

These supply devices 146 are provided with a sheet extractor 202 as shown in Figure 6 shown in more detail, and which in turn provides layers of plastic (preferably based on polyamide (PA) or polyurethane (PU), preferably based on polycarbonate (PC)) which have been taken from a stack of sheets 204. In this sheet extraction 202, the sheets are removed from the stack of films, with the films being separated by suction, by bending or by stripping. Mixed forms of separation are also possible. The sheet extraction 202 comprises in particular an alignment plate 206 which moves under a gripper 208 in order to ensure alignment when the film is deposited. In the present case, the sheet extraction 202 has a three-axis adjustment option, with a light sensor being used to monitor the correct alignment. A hole punch 210 is also present at these further provision stations 136 in order to make a hole in the respective sheet. The gripper 208 of the sheet extractor 202 then precisely deposits the layer on the workpiece carrier 104.

It is in Figure 2 It can be seen again that the production system 100 comprises further provision devices 146, 154 and also has a pre-fixing station 128 adjacent to the transport system 112, which is immediately upstream of a device 118 for producing a welded raw card composite with a light-transparent window. This pre-fixing station 128 is set up to pre-fix the stack of layers provided by the workpiece carrier 114 before it is provided to the device 118 for producing a welded raw card composite with a light-transparent window.

The device 118 for producing a welded raw card composite with a light-transparent window is in Figure 7 shown in detail. In the present case, it comprises a film welding device 212 for welding a carrier film 214 to the pre-fixed film stack. In addition, a punching device 216 is present. The film welding device 212 for welding the carrier film 214 comprises in particular a pressure plate 218, which is in particular heatable. The punching device 216 comprises a punching stand 220, to which a die holder 222 is fixed. On this die holder 222 there is a first die 224, to which a first punching stamp 226 is assigned for punching the pre-fixed film stack. The die holder 222 also has a second die 228, which is assigned a second punching die 230 that can be moved coaxially to the first punching die 226 and has the same contour as the latter for punching a window substrate 232, the first die 224 being arranged at a distance from the second die 228 in an adjustment direction of the punching dies 226, 230. A suction gripper 234 of the device 118 is present in order to remove the pre-fixed film stack from the positioning pins 150 of the workpiece carrier 114, for which purpose the suction gripper 234 is also equipped with at least one positioning pin, for example. When the suction gripper 234 has picked up the pre-fixed film stack, it positions it with respect to the punching device 216, which in this case is laterally adjustable between a punching position and a welding position. If the punching device 216 is adjusted to the punching position, an opening can be made in the pre-fixed foil stack with the help of the first punch 226 and the first die 224. The remaining piece is removed from the free space between the two dies 224, 228, in particular blown out or sucked out. The first punch 226 is then adjusted further until it dips into the second die 228 of the same contour. In the opposite direction to the adjustment movement of the first punch 226, the second punch 230 is moved in the direction of the window substrate 232, whereby a window part is punched out by means of the second die 228. This is clamped between the two punches 226, 230. The two punches are then moved simultaneously until the window part clamped between them is inserted into the opening that was made in the pre-fixed foil booklet by the first punch 226. The punches are then retracted to their starting position and the punching device 216 is adjusted laterally until it has reached the welding position. In this welding position, the carrier foil 214 is then brought under the pre-fixed foil stack, which is now equipped with the window part. The pressure plate 218 is heated and then presses the carrier film 214 onto the pre-fixed film stack, thereby securing the window part in the film stack. The carrier film 214 is preferably a mottled fiber film. The first die 224 is formed with a small overhang in the present case, which serves as an abutment for the pressure plate 218 of the film welding device 212, whereby the punching device 216 of the device 118 has a dual function (punching and welding). The carrier film 214 can be separated from the web using a cutting unit 236, with a retaining unit in particular also being present, which ensures that the free end of the web can still be grasped by a linearly adjustable gripper. After the window part has been inserted, the pre-fixed film stack with the window is transferred back to the workpiece carrier 114 of the transport system 112.

In Figure 2 It can again be seen that the device 118 for producing a welded raw card composite with a light-transparent window is followed by a thread insertion station 130 which is configured to provide the workpiece carrier 114 with at least one security thread 238 or a layer with at least one security thread 238.

This thread insertion station 130 is in Figure 8 shown in more detail. If the ID, valuables or security document is in ID1 format, it has proven advantageous to increase throughput if in the transport direction / In this case, at least four thread application devices 240 are present in the direction of production in order to apply a security thread 238 each. This is the case, for example, with the German identity card (as of 2021). If the ID, value or security document is one in ID3 format, the application device is used transversely. The at least four thread application devices 240 are then used to apply a security thread 238 each transversely to the transport direction / production direction, which is the case, for example, with the German passport (as of 2021). The thread insertion station can be mounted stationary in the housing 108 of the production system 100, wherein the workpiece carrier 114 can be rotated in order to specify the appropriate direction for the application of the security thread 238. Alternatively, the thread insertion station 130 itself can also be rotated, for example by 90 degrees, so that the direction of the thread application can be changed or adjusted.

Out of Figure 2 It is again apparent that the thread insertion station 130 is followed by another supply device 146 with a sheet extractor 202. This is then followed by a final supply device 120 with a roll extractor 152, which provides a final cover layer to form a finished film stack. The final supply device 120 is followed by a stitching station 122 adjacent to the transport system 112, which is designed to connect the film stack to form a film booklet. In addition, there is a laminating station 124 downstream of the stitching station 122 and adjacent to the transport system 112, in which a heating device is integrated and which is designed to laminate the film booklet to form a laminate composite.

In Figure 9 the laminating station 124 is shown in a perspective detail view. The present laminating station 124 has at least two individual presses 242 that can be operated independently of one another, whereby the lamination time required for lamination of the layers can be compensated. In order to minimize the number of parts to be heated, it is advantageous if the film booklet is heated and pressed without the workpiece carrier 114. For this purpose, the laminating station 124 is assigned a transfer device 246 for removing the film booklet from or from the workpiece carrier 114 before lamination and for positioning it between lamination sheets 244 of the individual presses 242 for lamination and for loading the workpiece carrier 114 with the lamination composite after lamination. The transfer device 246 is designed in the form of a portal and is thus set up in such a way that it can serve or load both individual presses 242. In addition to a heating device, the laminating station 124 also has a cooling device, with separate temperature ranges for the heating and cooling processes. In the present embodiment, all tools and also the lamination sheets 244 remain with the respective individual press 242. Since only the lamination sheets 244 and the card material are heated and cooled, there is a lower energy requirement than in systems in which the workpiece carrier 114 is also inserted into the individual presses 242.

Out of Figure 2 It can again be seen that the production plant 100 also comprises a cutting station 126 downstream of the laminating station 124, which is set up to subject the laminate composite to multi-sided trimming.

According to Figure 10 a handling device 248 is assigned to the cutting station 126 in order to remove the laminate composite from or from the workpiece carrier 114 and to feed the laminate composite, in particular cut into strips, back to the workpiece carrier 114. The handling device 248 is preferably adjustable along three axes. In the cutting station 126, in particular, four-side trimming takes place, with print mark-controlled longitudinal cuts removing the lamination edge of the laminate composite. After the four-side trimming, the lamination composite is transferred from the handling device 248 back to the workpiece carrier 114, optionally also to another workpiece carrier. The trimming residues are collected in a container 250.

Out of Figure 2 It is again apparent that the production plant 100 has a further printing device 132 downstream of the cutting station and adjacent to the transport system for applying a varnish to the cut lamination composite.

This additional printing device 132 is in Figure 11 shown in more detail, whereby it can be seen that the further printing device 132 is a pad printing device. It is set up to apply a signature varnish to the laminate composite, which can be written on with a document-safe ink in its dried state. The pad printing device comprises a multi-axis adjustable printing arm 256 with a pad 252, which receives the varnish held in a cliché 254 and then prints it onto the laminate composite. In this case, the further printing device 132 is also assigned a drying station 258 for drying the applied varnish. This forms a type of drying chamber in which the laminate composite is encapsulated for drying.

Out of Figure 2 It is again apparent that the drying station is followed by a turning device 138 which is designed to turn the cut laminate composite so that it can then be further processed on its other side. It is also possible for the workpiece carrier 114 to travel between the individual processing stations to the turning device 138 in order to turn individual films, a pre-fixed film stack, a film booklet or even a cut or uncut laminate composite.

The turning device 138 is in Figure 12 shown in more detail and in this case has two suction grippers 260, 262. A first suction gripper 260 is set up to grip the laminate composite by means of a negative pressure and to be adjusted vertically with respect to the plane spanned by the workpiece carrier 114. The first suction gripper 260 is also set up to be adjusted parallel to the plane spanned by the workpiece carrier 114. In addition, the first suction gripper 260 is set up to be rotated about an axis oriented parallel to the plane spanned by the workpiece carrier 114. In addition, a second suction gripper 262 is present which is set up to receive the laminate composite turned by the first suction gripper 260 and to grip it by means of a negative pressure and to be adjusted vertically with respect to the plane spanned by the workpiece carrier 114. In this way, the second suction gripper 262 can place the turned laminate composite back on the workpiece carrier 114.

Out of Figure 2 It can again be seen that the production plant 100 comprises a hologram application device 136 for applying a film exposed with a hologram to the laminate composite.

The hologram application device 136 is in Figure 13 shown in more detail. It comprises a workpiece transport device 264 and is set up to apply a film provided with a hologram to the cut laminate composite. The laminate composite remains on the workpiece carrier 114. The workpiece carrier 114 is lifted out or removed together with the lamination composite from the transport system 112 and transported by the workpiece transport device 264 through the units or stations of the application device. The removal of the workpiece carrier 114 from the transport system 112 of the production system 100 serves to ensure that greater pressure forces can act on the laminate composite when the hologram film is applied. With the help of the workpiece transport device 264, the workpiece carrier 114 with the laminate composite is conveyed through several units of the hologram application device 136. First, the first protective liner is removed. An adhesive is rolled onto the lamination composite. The hologram film is then applied, which is still protected and supported by a second liner. The carrier film (liner) is removed after UV drying. After applying a top coat and drying it, the laminate composite supplemented with the hologram film is returned together with the workpiece carrier 114 to the transport system 112 (magnetic transport system) of the production plant 100.

Out of Figure 2 It can again be seen that the production plant 100 also comprises an inspection device 140 adjacent to the transport system 112, which is designed to subject the cut laminate composite to a quality check and to mark defective laminate composites as rejects.

The inspection device 140 of the production plant is in Figure 14 In this process module, the individual strips are A plurality of ID, valuables or security documents combined to form a composite are checked. In addition, the checking device 140 comprises a printing unit (not shown in detail) which is set up to print the laminated composite supplied in strips with document-specific and/or person-specific data, thus to individualize it. The individualization or personalization takes place on two different levels, which allows the checking device 140 and thus the entire production system 100 to be made more compact. The printing unit of the checking device 140 is preferably also used to mark a faulty laminate composite as rejects. The checking device 140 is set up to check the register of the individual layers of the laminate composite and to initiate a correction for the assembly of the individual layers if the register falls below a predetermined threshold. In this case, data is transferred to the control system of the production system 100.

Out of Figure 2 It is again apparent that the production plant 100 is also formed with a magazine device 142 adjacent to the transport system 112. This is present on both sides of the transport system 112, whereby in the present case, purely by way of example, identification, valuable or security documents in ID1 format are stored on one of the two sides of the transport system 112 and identification, valuable or security documents in ID3 format are stored on the other of the two sides.

A part of the magazine device 142 for the ID1 format is in Figure 15 shown in more detail. The part of the magazine device 142 for the ID3 format is constructed analogously. It is formed with at least two magazines 266 and is set up to store the finished ID, valuable or security document sorted by format in the magazines 226. For the separation of the ID, valuable or security documents from the laminate composite, the magazine device 142 has a punching device 268 which is set up to separate individual ID, valuable or security documents into a predetermined format. It is not absolutely necessary for the laminate composite to be separated by the punching device 268 if it is required for further processing in another system. It may be useful to provide the laminate composite as a continuous strip. The magazine device 142 is also designed to eject those laminate composites or individual ID, valuable or security documents that have been marked as rejects by the inspection device 140. A handling device 270 is used here for handling or for placing them in the magazines 266. The empty magazines 266 can be served by means of a conveyor device 272. The filled magazines 266 are then ejected by the conveyor device 272 or made available to another system.

LIST OF REFERENCE SYMBOLS

100

Production plant

102

Longitudinal part (production plant)

104

first plant arm

106

second plant arm

108

Housing

110

Display and/or operating device

112

Transport system

114

Workpiece carrier

116

Printing device

118

Device for producing a welded raw card composite with or without a light-transparent window

120

final deployment setup

122

Stapling station

124

Laminating station

126

Cutting station

128

Pre-fixing station

130

Thread insertion station

132

additional printing device

134

Drying station

136

Hologram application device

138

Turning device

140

Verification facility

142

Magazine storage device

144

first deployment facility

146

additional supply device (sheet extractor / sheet feeder)

148

Planar motor

150

Positioning pin

152

Roll extension

154

additional provisioning facility (roll extract)

156

role

158

Clamping device

160

Cutting device

162

Gripping device

164

Perforator

166

Print range

168

Provisioning unit

170

Substrat

172

role

174

Substrate guidance

176

Deflection pulley

178

Splice unit (splice table)

180

Cutting unit

182

Buffer unit

184

top floor

186

movable pulley

188

Printing table

190

Alignment unit

192

Printhead

194

middle floor

196

lower floor

198

Test unit

200

Drying oven

202

Sheet extract

204

Sheet stack

206

Alignment plate

208

Gripper

210

Perforator

212

Film sealing device

214

Carrier film

216

Punching device

218

Pressure plate

220

Punching stand

222

Die holder

224

first matrix

226

first punch

228

second matrix

230

second punch

232

Window substrate

234

Suction cup

236

Cutting unit

238

Security thread

240

Thread application device

242

Single press

244

Lamination sheet

246

Transfer device

248

Handling device

250

Container

252

Pillow

254

cliche

256

Pressure arm

258

Drying station

260

first suction gripper

262

second suction cup

264

Workpiece transport device

266

magazine

268

Punching device

270

Handling device

272

Conveyor system

Claims (15)

1. A production system (100) for producing identification, value or security documents or for producing a composite of a plurality of identification, value or security documents, comprising:

   - a transport system (112) with at least one workpiece carrier (114),

   - a first provision device (144) adjacent to the transport system (112), the first provision device (144) being adapted to transfer a cover layer of the identification, value or security document to the workpiece carrier (114)

   - a printing device (116) which is located downstream of the first provision device (144) and is adjacent to the transport system (112) and which comprises, in a printing region (), a stationarily held print head () in order to apply a printed image, in particular a portrait image, to a substrate () by displacing a printing table () together with the substrate () fixed thereto, and which is set up to transfer the printed substrate () individually to the workpiece carrier (114),

   - at least one further provision device (146) downstream of the printing device (116) and adjacent to the transport system (112), which is set up to transfer at least one further layer of the identification, value or security document to the workpiece carrier (114),

   - a device (118), downstream of the at least one further provision device (146) and adjacent to the transport system (112), for producing a welded raw card composite,

   - a final provisioning device (120) downstream of the device (118) for producing a welded raw card composite, adjacent to the transport system (112), which is set up to transfer a further cover layer of the identification, value or security document to the workpiece carrier (114) to form a film stack,

   - a stapling station (122) downstream of the final provisioning device (120) and adjacent to the transport system (112), which is arranged to join the stack of foils to form a foil staple,

   - a laminating station (124) downstream of the stapling station (122) and adjacent to the transport system (112), in which a heating device is integrated and which is arranged to laminate the film booklet into a laminate composite, and

   - a cutting station (126) downstream of the laminating station (124), which is arranged to subject the laminate composite to a multi-sided trimming, wherein a handling device is associated with the cutting station (126) in order to remove the laminate composite from or out of the workpiece carrier (114) and to feed the laminate composite, in particular cut into strips, back to the workpiece carrier (114).
2. Production system (100) according to claim 1, characterized in that immediately upstream of the device (118) for producing a welded raw card composite with or without a light-transparent window is a pre-fixing station (128) which is adjacent to the transport system (112) and is set up to pre-fix the stack of layers provided by the workpiece carrier (114).
3. Production plant (100) according to claim 1 or 2, characterized in that a thread insertion station (130), which is arranged to provide the workpiece carrier (114) with at least one security thread or a layer with at least one security thread, is interposed between the final provisioning device (120) for providing the cover layer and the device (118) for producing a welded raw card composite.
4. Production system (100) according to one of claims 1 to 3, characterized in that the device (118) for producing a welded raw card composite with a light-transparent window is provided with a punching device (268) with at least one punch (226, 230) and a die (224, 228) assigned to the punch (226, 230), and with a film welding device (212) for welding a carrier film to a single-layer or multilayer card substrate, in that the punching device (268) can be adjusted perpendicularly with respect to the adjustment direction of the punch (226, 230) at least between a punching position and a welding position, and in that, in the welding position, a region present on the die (224, 228) is present as an abutment for a pressure plate (218) of the film welding device (212).
5. Production system (100) according to any one of claims 1 to 4, characterized in that the cutting station (126) is followed by a further pressure device (132) adjacent to the transport system (112) for applying a varnish to the cut lamination composite.
6. Production system (100) according to claim 5, characterized in that the further printing device (132) is a pad printing device for applying a signature lacquer which, in its dried state, can be inscribed with a document-proof ink.
7. Production system (100) according to claim 5 or 6, characterized in that a drying station (258) for drying the applied varnish is arranged downstream of or associated with the further printing device (132).
8. Production system (100) according to any one of claims 1 to 7, characterized in that downstream of the cutting station (126) is a hologram application device (136) having a workpiece transport device (264) which is arranged to lift the workpiece carrier (114) off the transport system (112), applying a foil provided with a hologram to the cut laminate composite, and then delivering the laminate composite, to which the hologram has been added, together with the workpiece carrier (114) back to the transport system (112).
9. Production system (100) according to any one of claims 1 to 8, characterized in that the cutting station (126) is followed by a turning device (138) which is set up to turn the cut laminate composite in order to subsequently process it on its other side.
10. Production system (100) according to any one of claims 1 to 9, characterized in that an inspection device (140) is present which is adjacent to the transport system (112) and is set up to subject the cut laminate composite to a quality check and to mark defective laminate composites as rejects.
11. Production system (100) according to claim 10, characterized in that the inspection device (140) is arranged to check the register accuracy of the individual layers of the laminate composite, and to initiate a correction for the collation of the individual layers should the register accuracy fall below a predetermined threshold.
12. Production system (100) according to any one of claims 1 to 11, characterized in that the workpiece carrier (114) comprises at least two positioning pins (150) for stacking and transporting the perforated layers of the subsequent identification, value or security document in register.
13. Production system (100) according to any one of claims 1 to 12, characterized in that a magazine device (122) with at least two magazines is provided adjacent to the transport system, which magazine device is set up to store the finished ID, value or security document sorted by format in the magazines.
14. Production system (100) according to claim 13, characterized in that the magazine device (122) comprises a punching device which is arranged to separate a laminate composite with a plurality of ID, value or security documents into individual ID, value or security documents to a predetermined format before storage in one of the magazines.
15. Production system (100) according to any one of claims 1 to 14, characterized in that the transport system is formed as a planar drive system with a permanently excited electromagnetic planar motor comprising a plurality of planar stators and at least one slider movable on the stators in at least two directions forming the workpiece carrier.

Images