Overview

IntelliSet™ is a state-of-the-art digital presetter for web and sheetfed offset printing presses. It is designed to provide acurate press presetting to reduce paper waste, ink waste, and makeready time by setting all fountain keys and ink speeds to optimal positions before running a job.

The IntelliSet Preset System is designed to accomplish five main objectives:

• To automatically set color as close as possible to those settings that produce a job-OK before a press-run is begun.
• To provide a single, common system for all presses in a plant regardless of the make and model of ink-control console.
• To provide a full-color image preview and an individual plate preview at the press, enabling the operator to inspect CCR dots, register marks, color bar, and job content.
• To provide information for predicting ink consumption.
• To provide mass job storage and rerun capability.

The IntelliSet Presetting System includes many features that assure high preset accuracy as well as easy-to-learn, intuitive, touch-screen operation. The preset sequence is started by touch- selecting from a list of job numbers. Color rotation, paper type (to compensate for ink absorbency), are easily assigned. IntelliSet also supports special colors. The system features an advanced, automated learning capability, which analyzes information derived from each ink key and paper type, assuring preset accuracy from job to job. If stuck keys are encountered during a preset, they are identified on the system and logged for reporting.

There are no restrictions on the job-naming convention used by prepress. Information is automatically extracted from job names and is assembled into a single job number that matched press operators' job tickets. IntelliSet can accept CIP, PDF, and TIFF files.

System Diagram

An IntelliSet system includes one server, called PreOPS, which is located in the pre-press department. Its main purpose is to automatically retrieve CIP3 or TIFF files as they become available and store them as complete jobs for access by the OPS units at the presses.

Download system diagram PDF

Workflow

Plate coverage information is derived from prepress files (CIP3/4 PPF, TIFF or PDF format) by the PreOPS server, and is then downloaded on demand to the press.

Jobs are downloaded to the OPS by touching the appropriate job number shown on the touchscreen. Form numbers within job numbers drop down for selection when a job number is touched. Run numbers within form numbers are shown when the job is displayed. Key settings are maintained for the print positions not affected by run changes.

If a job is interrupted to run a second job, the original job settings can be saved and recalled. If the original job is redirected to a press other than the original, the OPS on that press recalculates the presets.

At any time jobs can be rescheduled to any compatible-sized press equipped with an OPS.

A multi-color composite view of the image can be shown at the OPS, enabling the press operator to check for proper image orientation and to visually verify that the correct job has been downloaded to the OPS.

The plate images can be viewed individually; each with a bar graph overlay indicating the percentage opening for each ink key.

Compensation for the effect of different papers is accomplished by touching the appropriate paper type shown on a drop-down list. Paper-type compensation can be done automatically if the CIP3 job header contains the appropriate paper information.

A "take-off bar" feature is included, enabling the keys affected by such bands to be automatically preset. The press operator can override these settings prior to actuating the preset command.

Provided that the Ink-fountain roller settings are remotely controlled and can be electronically recorded, the OPS can automatically calculate and execute the settings. Otherwise, the OPS will display values for a manual setting.

High accuracy of the preset system is assured through the product's learning feature, which tracks changes in the press characteristics over time. Paper is also taken into account by the learning algorithm.

Reporting

WebAccess allows you to remotely monitor the effectiveness of the presets, and enables you to:

• Generate and print presetting accuracy reports
• Monitor the performance of all press stations in the plant
• View files that are ready for presetting (including the plate images)
• View files that have been previously used for presetting
• And much more...

On-Press Station (OPS)

The OPS is the standard hardware platform for all Rutherford color control products.

The computer module is based on the Dell Optiplex 960 SFF (Small Form Factor), but modified for use in an industrial environment. Its small form factor allows it to be tucked away inside most color control consoles, making for a tidy installation.

The standard OPS touch-screen monitor is an Elo 2200L 22" widescreen LCD. It utilizes new APR (Acoustic Pulse Recognition) touch screen technology which allows the monitor to have a glass surface.

More details on the OPS platform

Pre-Press Server (PreOPS)

There is typically one PreOPS server computer per installation. It is usually located in the prepress department and is responsible for processing CIP3, TIFF, or PDF data for presetting or soft-proofing. In addition, it also provides a web server for the WebAccess reporting system.

The Rutherford PreOPS server computer is built from a Dell PowerEdge 1U server or Dell Optiplex 960 Mini-Tower, depending on the form factor required for the installation.

More details on the PreOPS server