Note: Descriptions are shown in the official language in which they were submitted.
CA 02368036 2002-O1-30
1
IN-LINE ROTARY INSERTER
This is a division of copending Canadian Patent
Application 2,014,543 filed on April 12, 1990.
1. Field of the Invention:
This invention relates to apparatus and method for
handling high volume mail and, in particular, it relates to
in-line rotary inserter devices having a plurality of
hopper-held insert feeding assemblies positioned along
conveyors to dispense inserts onto the conveyors, and having
devices for stuffing envelopes with the inserts.
2. Prior Art and Other Considerations:
Many present devices for stuffing inserts into
envelopes employ conveyors to convey stack-dispensed inserts
to an envelope stuffing device. Multiple inserter devices
rely on a plurality of hoppers disposed along conveyors and
dispensing inserts onto the conveyor in predetermined manner
to achieve collated insert packages that are subsequently
inserted into envelopes.
Such equipment is required to operate at increasingly
higher celerities with high reliability and shortest
possible down-times. Many problems, which either do not
exist or which are inconsequential in low-speed operation
need to be overcome in high-speed operation. For instance,
such problems involve frictional, inertial, and other speed-
related effects of moving apparatus components and of
handled document materials.
Prior art inserter devices include
U.S.Pat.Nos.4,043,551 and 4,079,576 to Morrison et al,
U.S.Pat.No.4,177,979 to Orsinger et al, U.S.Pat.No.4,649,691
to Buckholz, U.S.Pat.No.3,825,247 to Fernandez-Rana et al,
U.S.Pat.No.3,423,900 to Orsinger, U.S.Pat.No.2,621,039 to
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2
Kleineberg'et al, and U.S.Pat.No.3,809,385 to Rana.
It is an important feature of the present invention to
provide apparatus and method for automatically inserting
into envelopes at high celerities a plurality of inserts in
predetermined and preprogrammed continuous manner and to
further automatically process such insert-filled envelopes
through diverting, flap-sealing, turn-over, stacking, and
other operations associated therewith, substantially under
computer control and supervision, while providing higher
production rates than heretofore practically feasible.
SUMMARY OF THE INVENTION
In accordance with principles of the present invention,
envelopes are conveyed from a hopper to an inserting
station, where envelopes are opened and inserts are inserted
therein. The inserts are furnished by the plurality of
modular insert hoppers which are positioned in line above an
endless insert conveyor of the pusher pin type. Envelopes
having inserts inserted therein are transported to a vacuum-
belt transporter/diverter unit and are directed and
transported thereby along at least one path that includes a
turn-over module, a sealing module, and an on-edge stacking
unit.
The inserter apparatus operates under preprogrammable
computer control and supervision. Automatic error handling
and visual display of operational status and program
information are provided.
In accordance with one aspect of the present invention
there is provided in an in-line rotary inserter, said
inserter including an envelope handling system for
processing of insert-filled envelopes, a turnover module
comprised in said envelope handling system, said turnover
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2a
module comprising a belt and pulley system including at
. least first, second, third, and fourth pulleys, at least one
of said pulleys being driven, said pulleys being disposed
substantially in a common vertical plane, wherein said first
and second pulleys define a second pulley pair, said pulleys
of each said pair being disposed proximally to and
substantially above one another, wherein said pairs are
spaced from each other, said pulley system including an
endless flat belt disposed about said pulleys in resiliently
tensioned manner in shape of a flattened figure 'eight'
having a crossover portion, said crossover portion including
two manually contacting length portions of said flat belt
twisted about one another by an angle of substantially one
hundred and eighty degrees, said crossover portion being
operative in nipping between said two length portions of an
envelope delivered to said turnover module and transporting
the envelope therethrough while turning the envelope over by
substantially one hundred and eighty degrees.
In accordance with another aspect of the present
invention there is provided a method of handling and
processing of envelopes including a step of turning over of
envelopes, characterized by steps of: driving an endless
flat belt disposed in a pulley system having at least four
pulleys disposed substantially in a common plane, said
pulleys being arranged in two pairs, said two pairs being
spaced from one another, said pulleys of each pair being
disposed vicinally to one another; carrying said endless
flat belt upon and about said at least four pulleys in
resiliently tensioned manner in the shape of a flattened
figure 'eight' including a belt crossover portion, said belt
crossover portion including two mutually contacting length
portions of said endless flat belt twisted about one another
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2b
_.
by an angle of substantially one hundred and eighty degrees;
_ delivering an envelope to a nip ingress between said two
mutually contacting length portions; nipping the envelope
between said two mutually contacting length portions; and
transporting and turning over the envelope in said belt
crossover portion.
In accordance with yet another aspect of the present
invention there is provided a turnover module for turning
over envelopes, the turnover module having an entry and an
egress, envelopes being received by the turnover module at
said entry in a first orientation and delivered from the
turnover module at said egress in a second orientation, the
turnover module comprising a belt/pulley system including: a
plurality of pulleys, at least one of said pulleys being
driven, said plurality of pulleys including leading pulleys
disposed proximally to said entry; a driven endless belt
disposed about said plurality of pulleys in resiliently
tensioned manner substantially in shape of a flattened FIG.
'8' having a crossover region, said endless belt including
in said crossover region a first reach and a second reach,
said reaches resiliently contacting one another along length
portions thereof while crossing over and twisting about one
another; and means for preventing premature tilting of an
envelope prior to and at the beginning of the envelope being
securely nipped between said reaches, said means for
preventing including a disc parallel to and of the same
diameter as and commonly coaxially revolving with one of
said leading pulleys, said disc having an endless belt
encircling its periphery; wherein envelopes are received in
the region of said entry at one end of said reaches, are
nipped between said reaches, are transported along and
through said crossover region while being turned over, and
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2c
are delivered from the other end of said reaches in the
direction of said egress.
In accordance with still yet another aspect of the
present invention there is provided a method of turning over
envelopes in a turnover module, the method comprising steps
of: receiving envelopes at an entry to said turnover module
in a first orientation; nipping envelopes in a nip between
reaches of a resiliently-tensioned driven endless belt that
is disposed about a plurality of pulleys substantially in
the shape of a flattened FIG. ''8' and that has a crossover
region, said reaches contacting one another along length
portions thereof while crossing over and twisting about one
another in the region of said crossover region, said
plurality of pulleys including a leading pulley disposed
proximally to said entry; preventing premature tilting of
envelopes prior to and at the beginning of envelopes being
securely nipped during the step of nipping, said turnover
module including a disc parallel to and of the same diameter
as and commonly coaxially revolving with said leading
pulley, wherein the step of preventing includes a step of
supporting envelopes upon said disc; transporting envelopes
nipped between said two reaches therealong from the region
of said entry toward an egress of said turnover module;
turning envelopes during the step of transporting by virtue
of mutual crossover and twist of said reaches; delivering
envelopes from said nip toward said egress in a second
orientation.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and
advantages of the invention will be apparent from the
following more particular description of preferred
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2d
embodiments of the invention, as illustrated in the
accompanying drawings in which like reference numerals refer
to like parts throughout different views. The drawings are
schematic and not necessarily to scale, emphasis instead
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3
being placed upon illustrating principles of the invention.
FIG.1 is a schematic diagrammatic plan view of a
preferred embodiment of an in-line rotary inserter apparatus
according to the present invention;
FIG.1A is a schematic diagrammatic plan view of another
preferred embodiment of an apparatus of the present
invention;
FIG.2 is a schematic fragmental side elevational view
of a main portion of the apparatus shown in FIG.1;
FIG.2A is a schematic fragmental side elevational view
of a main portion of the apparatus shown in FIG.1A;
FIG.3 is a schematic partial detail view of a vacuum
aripper drum shown in FIGS.2 and 2A;
FIG.3A is a schematic fragmental side elevational
detail view of portions of the inserter mechanism of the
apparatus, for instance as indicated in FIGS.2 and 2A;
FIG.3B is a schematic top view of a partial detail of
an insertion jam detection arrangement according to an
embodiment of the invention;
FIG.3C is a schematic side view of a partial detail of
the insertion jam detection arrangement of FIG.3B;
FIG.4 is a schematic partial side elevation view of a
speed change device of a modular rotary inserter station
indicated in FIGS.1 and 1A;
FIG.5 is a schematic partial detail side view of an
embodiment of an insert thickness sensing arrangement of the
invention;
FIG.5A is a schematic partial detail side view of
another embodiment of an insert thickness sensing
arrangement of the invention;
FIG.6 is a schematic fragmented top view onto a portion
of an insert conveying surface of an in-line rotary inserter
of the invention;
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4
FIG.7 is a schematic fragmented side elevational view
of a diverter of the present invention;
FIG.8 is a schematic top view of a vacuum belt
transporterldiverter unit of the present invention;
FIG.8A is a schematic fragmental vertical section view
of a portion of the unit of FIG.8;
FIG.8B is a schematic side view of an envelope scanner
as indicated in FIG.8;
FIG.9 is a schematic side elevational view of basic
features of an envelope turnover module of the invention;
FIG.9A is an isometric view of basic features of the
turnover module shown in FIG.9;
FIG.10 is a schematic partial side elevational view of
an envelope sealing module of the invention;
FIG.10A is a schematic partial top view of the
embodiment shown in FIG.10;
FIG.11 is a schematic partial fragmented front view and
section of a diverter portion of an on-edge stacking unit of
the invention;
FIG.12 is a schematic partial fragmented top view of
the unit shown in FIG.11;
FIG.13 is a schematic partial fragmented side view and
section of an on-edge stacking unit of the invention;
FIG.14 is a schematic partial fragmented top view of
the unit shown in FIG.13; and
FIG.15 is a schematic partial enlar_qement of a middle
portion of the view in FIG.13, showing additional details.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the in-line rotary inserter apparatus
is shown in FIG.1 and comprises basically the following
subsystems: One or more rotary insert feeder modules 20, 22,
24, 26 for furnishing inserts from insert hoppers, each
including an insert thickness detector; an envelope feed
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station 30 for furnishing envelopes from an envelope hopper;
an inserting station 32 in which envelopes are inserted with
inserts that are collated and conveyed thereto upon a pin
conveyor 34 (from insert feeder modules); and, a vacuum belt
transporter/diverter unit 36 for transport and selective
diversion of inserted envelopes.
The vacuum belt transporter/diverter unit 36 can
provide selective diversion and transport to one of two
paths. At least one path comprises an envelope turnover
module and an envelope sealing module. The other path can be
used for alternate delivery of incompletely inserted
(faulty) envelopes, buckled envelopes, and the like; or it
can be used for selective alternate delivery of unsealed
envelopes for further handling. Turnover module and sealing
module can be arranged in either order, provided that each
is structured accordingly.
For instance, the embodiment shown in FIG.1 provides
first for sealing of envelopes delivered from vacuum belt
transport/diverter unit 36 to sealing module 38. Sealed
envelopes are thereafter delivered to turnover module 40,
are turned over therein to flap-down orientation, and are
farther conveyed to on-edge stacking/diverter unit 42. The
embodiment shown in FIG.1A provides first for turnover of
unsealed envelopes in a turnover module 40A which delivers
turned over envelopes to a sealing module 38A.
The embodiment of the inline rotary inserter apparatus
shown in FIG.1 further comprises an on-edge
stacking/diverter unit 42 that receives envelopes and stacks
them on edge in an accumulator 44 or passes envelopes on to
additional handling equipment 46.
The inserter apparatus shown in FIG.1 further comprises
a main computer 50 for operational control, supervision, and
coordination of individual units and modules interconnected
therewith, a display/control console 52 to display
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6
operational information and receive operator input commands,
a skew detector arrangement 54 for sensing of misalignments
of collated inserts being conveyed to inserting station 32,
and an insert diverter 56 for diversion of inserts (for
instance in case of errors in, damage to, or misalignments of
inserts). Not specifically shown in FIG. 1 is an envelope
diverter 33 (FIG. 2) which is provided in a location between
envelope feed station 30 and inserting station 32. Envelope
diverter 33 is disposed in a lower equipment region (below
pin conveyor 34) along the envelope feed path for selective
interception of envelopes that have been stigmatized as being
faulty. As specific inserts are intended to be inserted into
specific envelopes (and are associated therewith), selective
diversion of inserts by insert diverter 56 in case of the
occurrence of insert fault conditions is associated with
interception and diversion of corresponding envelopes in
envelope diverter 33 and vice versa. Thusly, if either
inserts or associated envelopes are stigmatized as faulty or
otherwise desired to be diverted, the corresponding
associated envelopes or inserts, respectively, are also
diverted in order to avoid empty envelopes or inserts without
envelopes being processed and conveyed farther. Therefore,
envelope diverter 33 also serves to selectively divert (under
preprogrammed computer control of computer 50) those
envelopes for whom intended associated inserts are being
diverted by insert diverter 56.
Referring now also to FIG. 2, a main track bed 60 is
horizontally disposed in the upper portion of a main base 62.
Main track bed 60 carries, in its upper portion, pin
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7
conveyor 34 for receiving in collated manner inserts from
- insert feeder modules 20, 22, 24, and 26, and for
transporting (from left to right) such inserts past skew
detector arrangement 54 and insert diverter 56 to inserting
station 32. Display/control console 52 is shown adjustably
mounted above main track bed 60. Insert feeder modules
(20,22,24,26), skew detector 54, insert diverter 56, and
inserting station 32 are generally disposed above main track
bed 60 in cantilevered bridging manner.
Envelope feed station 30 is disposed on and within main
base 62 at the end thereof that is opposite to the end which
carries insert feeder modules 20, 22, 24, 26. The upper
portion of envelope feed station 30 includes an envelope
hopper 66 and a hopper mechanism 68. A transverse pass 64,
including first and second sloping walls 70 and 72, is'
disposed in upper portion of main base 62 between inserting
station 32 and hopper mechanism 68. A fall region 74 is
disposed in transverse pass 64. Another embodiment of the
inserter apparatus is shown in FIG.2A to comprise a
transverse pass 64A having a substantially horizontal
surface 70A with a short fall region 74A thereabove, as will
be described in detail later in conjunction with FIG.2A.
Envelope feed station 30 comprises envelope hopper 66,
hopper mechanism 68 for withdrawing of envelopes from hopper
66 and for feeding of envelopes to a first gripper drum 76,
a second gripper drum 78 for transporting envelopes conveyed
thereto by first gripper drum 76, a flap opener 80 to open
envelope flaps of envelopes transported by second gripper
drum 78, and an envelope conveyor device 82, including an
adjustable upper belt device 83, for conveying of envelopes
from second gripper drum 78 to a vacuum gripper drum 84.
tripper drums 76 and 78 Land their operation) are of
generally conventional kind. Envelope diverter 33 is
disposed proximate to the delivery end of envelope conveyor
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8
device 82 to selectively intercept and divert envelope
- rejects into a reject catch bin. Vacuum gripper drum 84
delivers envelopes onto main track bed 60 in readiness for
inserting with inserts in inserting station 32.
Flap opener 80 comprises a rotating rotor 88, having a
rotary valve arrangement associated therewith for valuing of
vacuum to one or more sucker cups 90. Sucker cup 90 is
disposed upon the periphery of rotor 88 whose rotation (and
valuing of vacuum to sucker cup 90) is synchronized and
properly phased with the rotation of second gripper drum 76.
so that the flap of an envelope transported by second
gripper drum 76 past flap opener 80 is momentarily grabbed
and opened (unfolded) by sucker cup 90. A plow/sensor device
92 is disposed just downstream from flap opener 80 and
intercepts an opened flap and further bends it into the
unfolded position as the envelope is transported by and upon
second gripper drum 78. Plow/sensor device 92 is equipped
with a photo-sensor to check correct flap opening and to
detect if an envelope is missing at the time it should be.
present.
Envelope hopper 66 contains an envelope stack 94.
Envelopes are stacked therein in an orientation as indicated
by a typical stacked envelope 96 having a leading edge 100.
a trailing edge 102, and an envelope flap 98 folded along
trailing edge 102 onto its lower face. Consequently,
withdrawal of an envelope from the bottom of stark 94 onto
first gripper drum 76 is performed in an attitude and a
direction that precludes catching of the flap on the next
envelope. Transport of the withdrawn envelope by first
gripper drum 76 to second gripper drum ?8 results in an
orientation of the envelope (upon second gripper drum 781,
as it passes by flap opener 80, having unopened flap 98
facing toward flap opener 80. At this time, sucker cup 90
grabs envelope flap 98 by vacuum action and hinges it about
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9
trailing edge 102 into an open position during passage of
. the envelope. Opened flap 98 is thereupon intercepted by
plow/sensor device 92 and thereby further unfolded, whilst
sucker cup 90 releases as its vacuum is vented and valued
off in accordance with the operation of the rotary valuing
arrangement of rotor 88.
Subsequently, an envelope is delivered and released
onto envelope conveyor device 82. Envelope conveyor device
82 comprises two driven endless belts that nip therebetween
an envelope delivered thereto and that convey it to vacuum
gripper drum 84. A typical envelope will be continuously
transported from conveyor device 82 to vacuum aripper drum
84.
The two driven belts (comprised in conveyor device 821
are arranged in such a manner as to permit slippage of'an
envelope with respect to the belt motion if an envelope is
stopped by a selectively interposable stop gate 86. Upper
belt device 83 is adjustably mounted fox this purpose and
for accommodation of different thickness envelopes. If an,
envelope is intended to be diverted, it is stopped by stop
gate 86 until it can no longer be gripped by the next
qrippers (of vacuum gripper drum 84) passing by. Stop qatz
86 is moved out of the Way of the envelope path at such time
and the envelope will be driven by the belts into a reject
bin located in envelope diverter 33.
In an alternate embodiment, stop gate 86 is interposed
into the path of each envelope to register the envelope in
position. Stop gate 86 is moved out of the way to release
the envelope at the appropriate instant in time to be
gripped by the grippers of vacuum gripper drum 84. To reject
and divert~an envelope, stop gate 86 is moved out of the way
at a time when the envelope can miss and bypass the grippers
of the vacuum gripper drum 84, so that the envelope is
delivered into the reject envelope bin.
CA 02368036 2002-O1-30
Envelopes delivered onto main track bed 60 are
positioned by vacuum gripper drum 84 for the inserting
operation in inserting station 32. Following the inserting
operation, envelopes are delivered from the inserting
station 32 through a nip between a spring-loaded pressure
roller arrangement 104 and a driven conveyor belt
arrangement 107 that rides about a pulley arrangement 108.
Envelopes are delivered into fall region 74 in the same
orientation as received; i.e. with leading edge 100 leading
and envelope flap 98 trailing. The envelope falling into
fall region 74 is guided by a deflector bar 106 so that it
settles against first sloping wall 70 of vacuum belt
transporter/diverter unit 36.
Referring now to FIG.3, continuously revolving vacuum
aripper drum 84 schematically depicted therein comprises a
first and a second face disc 110 and 112 mounted on a drum
116, which in turn is rotatably supported upon a drum axle
118 in accordance with conventional practise. Various
mechanisms (not shown here) are included in this assembly, in
conventional manner to perform the required customary
gripper functions.
Face discs 110 and 112 are provided with a plurality of
vacuum holes 121 and 121' open to the discs' peripheries.
Vacuum holes 121 and 121' are disposed about the disc
peripheries in a plurality of groups, whereby each group is
disposed in a predetermined relationship to the drum gripper
mechanism in positions corresponding to locations whereupon
envelopes are carried. Vacuum is automatically valued to
each group before an envelope is released by respective
grippers on the gripper drum 84. Consequently, an envelope
released by grippers remains held to vacuum gripper drum 84
upon vacuum holes 121 and 121' until it is properly
delivered to its substantially horizontal registered
position on main track bed 60.
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11
Referring now to FIG.3A, a fragmented portion of the
inserter mechanism of inserting station 32 (FIGS.1 and 21 is
shown therein. The various components are disposed in mutual
positional relationships representative of an early stacte of
the inserting operation. FIG.3A depicts pertinent components
disposed in the lower region of insertinct station 32 as weJ.l
as components particularly involved and associated with the
inserting operation that are disposed on, in, and beneath
the main track bed 60 (FIG.2?. The view of FIG.3A represents
a region located approximately in the middle of FIG.2 in
enlarged form and includes details that have been omitted
from FIG.2 for the sake of clarity.
An~upper portion of vacuum gripper drum 84 (FIG.3) is
shown here comprised in inserting station 32. Further
comprised in inserting station 32 are stop fingers 125',
suction cups 125A, a pair of opening fingers 125B mounted on
revolvable shafts 125C, insert pushers 126, and spring-
loaded drop rollers 126A. A horizontally disposed top plate
126B having a trailing end 126C is partially shown. Also ,
indicated here is a leading portion of conveyor belt
arrangement 107. An envelope 127 is shown disposed
substantially horizontally in a registered position to which
it has been delivered by vacuum gripper drum 84. 8nvelope
127 has a top side 127A, a bottom side 1278, and a flap
127C. Flap 127C.is held open in a slightly downwardly
directed orientation by and below trailing end 126C of top
plate 126B.
An air nozzle 123 directs a timed blast of compressed
air flow over the upper surface of flap 127C into the
envelope to assist opening of the envelope prior to the
insertion operation. Air flow is valued on as an envelope is
delivered to its insertion position. The air flow also
serves to force the envelope against its positional
registration stops, for instance against stop fingers 125,
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12
and aids in holding the envelope downwardly. Air flow is
shut off once the insertion operation has begun. Also shown
here is an insert stack package 198 disposed upon top plate
126B and being propelled by insert pushers 126 toward the
right for insertion into envelope 127. Positional
registration stops can alternately be provided in form of
stop fingers which are raised from.beneath the upper surface
of conveyor belt arrangement 107 in appropriately timed
manner.
According to more particular aspects of the apparatus
and method of the invention, the travel motion of the
uppermost tips of insert pushers 126 in the course of a
complete insertion cycle is indicated by phantom lines as
locus pattern 'L'. Locus pattern 'L' follows approximately
an horizontally elongated noose-shaped form. Insert pushers
126 axe translated in a vertical plane along locus pattern
'L' without changing angular orientation during the travel
motion of an insert cycle. Insert pusher 126 is shown in a
position during the beginning of an insertion cycle. Other
salient positions are also indicated by dotted lines by
pusher position 126', representing a low position near the
end of the retraction portion of an insertion cycle, and by
pusher position 126", representing the end of the retraction
portion and the early beginning of the insertion portion of
an insertion cycle. The apex of the travel motion of insert
pusher 126 at the point of travel direction reversal on the
right end of locus pattern 'L' is designated as insertion
end 'I'.
It should be recognized that a plurality of identical
components are usually present in appropriately parallel
positions perpendicularly to the plane of the depiction in
front of or behind each such component, as is customary in
mail handling equipment. For example, there is a plura~_ity
of stop fingers 125, suction cups 125A, insert pushers 1%6,
CA 02368036 2002-O1-30
13
drop rollers 126A, etc. Moreover, the depiction omits
- obstructing components that could be detrimental to clarity
of understanding.
As hereinbefore described, vacuum gripper drum 84
conveys envelopes in a clockwise direction upwardly to a
horizontal position, as indicated by envelope 127 in FIG.3A.
Envelope 127 is delivered to this position through a Qap
between trailing end 126C (of top plate 1268) and the
periphery of vacuum gripper drum 84 onto an insertincr
station surface. At this time, opening fingers 125B have
orientations that are approximately 80 degrees from the~_r
shown orientation so that their tips substantially point
toward one'another. The envelope is stopped when its leading
edge is intercepted by stop fingers 125. Stop fingers 125
are automatically rotated into the position shown to stop an
envelope, and are rotated out of this position to release an
envelope for farther transport by conveyor belt arrangement
107.
As an envelope has been delivered to the insertion
position shown, and air flow into the envelope from nozzle
123 has been initiated, suction cups 125A descend and,
having vacuum valued thereto, attach to top side 127A.
Suction cups are then lifted up, lift the envelope's top
side 127A and the envelope forms an open pocket.
Opening fingers 1258 are now rotated by their shafts
125C (one finger clockwise and the other one anticlockwise)
by approximately 80 degrees into the orientation indicated.
so that their tips slide into the opened pocket of the
envelope; i.e. beneath top side 127A. This finger position
and orientation is now substantially along and parallel to
the internal side edges of the opened envelope. Opening
fingers 1258 have a substantially rectangular or square C-
channel-shaped thin-walled cross-section, whereby the C-
channel is disposed with a side wall facing downwardly and
CA 02368036 2002-O1-30
14
its open side facing toward the middle of envelope 127 in
a the orientation shown in order to reliably guide insert
stack package 198 into envelope 127 during the subsequent
insertion operation. For the latter purpose, opening fingers
are customarily also provided with ramp-like leading edges.
As indicated, the height of fingers 1258 is somewhat reduced
in direction toward their tips and their tips are smoothed
and slightly rounded off to avoid sharp edges that might
catch on the envelope during finger rotation therein and on
inserts during insertion thereof.
Envelope 127 has now been readied for insertion, as
hereinabove described, and insert pushers 126, that have
risen from beneath top plate 1268 and that have intercepted
insert package 198 along its trailing edge, move
horizontally toward the right and push insert stack nackaQe
198 between opening fingers 1258 into envelope 127. As
indicated by insertion end 'I' of locus pattern 'L', insert
pushers 126 push insert stack package 198 to a position
vicinal to the hinge line of the envelope flap 127C.
Thereafter, insert pushers 126 retract along locus pattern
'L', as indicated by arrows thereupon. Vacuum to suction
cups 125A is vented and valued off by now and drop rollers
126A descend into the insert-filled envelope 127 and nip it
in spring-loaded manner onto driven conveyor belt
arrangement 107, whilst stop fingers 125 are pivoted out of
the way of the envelope. Other drop rollers can be provided
and moved downwardly to nip the envelope in other
appropriate locations along the envelope.
Envelope 127 is frictionally engaged by conveyor belt
arrangement 107, withdraws from opening fingers 1258, and is
propelled toward the right. Fingers 1258 are thereafter
rotated approximately by 80 degrees back to the orientation
with tips pointing substantial?y toward one another. The
insert-filled envelope is delivered into fall region 74
CA 02368036 2002-O1-30
(FIG.2).
- The translational motion of insert pushers specifically
along locus pattern 'L' is provided in order to achieve two
main objectives; the horizontal straight-line inserting
motion and the rearward and simultaneously downwardly curved
retraction motion. Insert stack oackaqes, being conveyed by
pin conveyor 34 (FIG.1) in main track bed 60 alor_g main base
62 by pusher pins 196 (FIG.7), are seriatim transported to
the approximate region indicated in the. location of insert
stack package 198 disposed upon top plates 126B in FIG.3A.
Insert pushers 126 must be moved out of the way of a
next insert stack package being.conveyed to this region and
are, therefore, disposed beneath top plates 126B at that
time, as indicated by locus pattern 'L' and, for instance.
insert positions 126' and 126" therealong. Thereafter,'
insert pushers 126 are translated upwardly and eventually
toward the right, so that they are raised through gaps
between top plates 126B, engage the trailing edge of insert
stack package 198, and push it horizontally to the right
into envelope 127, as hereinbefore described.
Once insert package 198 is inserted in envelope 127,
insert pushers retract from insertion end 'I' and gradually
sink downwardly beneath, top plates 126B along the path
indicated by locus pattern 'L'. This rearward and downward
retraction, however, must not interfere with the next
envelope being delivered upon vacuum Qripper drum 84 in
clockwise direction upwardly. This is an important reason
for the downwardly curved path with fast downward and
rearward retraction of insert pushers 126, while
simultaneously allowing clearance for delivery of the next
envelope and, also simultaneously; permitting an early
downward retraction of insert pushers to provide clearance
for delivery of the next insert stack package. Travel
distances and spacings between successive insert packages
CA 02368036 2002-O1-30
16
are thusly kept to a minimum.
The described translational motion of insert pushers
126 is provided by a drive mechanism that comprises a
trolley upon which insert pushers are mounted. The trolley
is free to travel horizontally upon a trolley bar
arrangement which is cam-driven vertically up and down. The
horizontal motion of the trolley is provided by an endless
chain drive. Appropriate dimensional and phase relationships
between these trolley drive arrangements achieve the locus
pattern 'L'.
Referring now to FIGS.3B and 3C, an embodiment of an
insertion jam detection arrangement is shown therein, in
particular with respect to apparatus and method aspects of
the invention. The insertion jam detection arrangement is
disposed in inserting station 32 (FIGS.1, 2, and 3A1 and.
broadly, comprises a horizontal and a vertical
retroreflective sensing arrangement. More particularly, the
horizontal sensing arrangement comprises a photosensor 128
and a retroreflective target surface 128A. The vertical
sensing arrangement comprises a pair of photosensors 1288
and 128C (hidden behind 128B) and a pair of retroreflective
target surfaces 128D and 128E that are disposed upon the too
surface of each of the opening fingers 1258. Target surfaces
128A, 128D, and 128E are of conventionally used
retroreflective material, for instance retroreflective
adhesive tape or pads as customarily used in conjunction
with photosensors. Envelope 127 is shown in the same
position as also depicted in FIG.3A, being disposed in
inserting station 32 in readiness for insertion, Opening
fingers 125B are shown with their tips disposed in the
r
opened pocket of envelope 127.
A horizontal sensing beam 229 is directed by
photosensor 128 onto target surface 128A and is reflected
back into the photosensor. Photosensor 128 detects any
CA 02368036 2002-O1-30
17
interruption of the beam 129. Beam 129 travers-es at least
the entire length of envelope 127 slightly above the upper
surface of the opened envelope so that an obstruction of the
beam in this region will be detected. For example,
interruption of the beam 129 will occur as a consequence of
malfunctions caused by damaged, misaliqned, and buckled
envelopes having been fed to inserting station 32, or by
envelopes having been buckled or curled up by opening
fingers 125B, for instance if suction cups 125A malfunction...
Overall, any undesirable lifting up of a portion of the
envelope 227 into the path of the beam 129 results in
detection of a fault condition. Beam 129 also senses
problems caused by and during insertion of insert stack
packages. For instance, jamming by piling up of insert and
envelope material will be detected. Sampling of the '
photosensor signal at appropriate times during the insertion
cycle provides signals that are capable of discerning the
type of malfunction more specifically.
Vertical sensing beams 1298 and 129C are directed by,
photosensors 128B and 128C, respectively, toward target
surface 128D and 128E, respectively, and are reflected
thereby back into the respective photosensors, provided that
the beams are not interrupted. In the depictions in FIGS.3B
and 3C, opening fingers 125B and therewith target surfaces
128D and 128E hive t_ntered into the opened pocket of
envelope 127. Consequently, sensing beams 129B and 129C are
interrupted by the top side of the open envelope 127.
Vertical sensing beams 1298 and 129C primarily serve to
detect the presence of a correctly opened envelope (having
both fingers 125B inserted therein) by sampling of the
signals generated by photosensors 128B and 128C at the
appropriate time during the insertion operation. ht has been
found that the insertion jam detection arrangement, as
described, is capable of detecting most, if not all, fault
CA 02368036 2002-O1-30
18
conditions that can potentially occur in the course of
insertion. In case of detection of a fault condition,
appropriate action is taken automatically under computer
control, for example either by subsequent diversion of
jammed material or by stoppage of the equipment and by fault
location indication for the machine operator's attention.
Referring to FIG.4, a speed change device 130 is
disposed within each insert feeder module, and serves to
selectively change drive speed of the insert feeder
operation. In a particular embodiment such speed change is
selectable between a normal speed and half speed (in a
relationship to the speed of the pin conveyor 34). In
general though, other ratios can be used; for instance 1 to
1/3, 1 to 1/4, and the like. Speed change device 130
comprises an angle drive box 132 for driving the mechanism
of insert feeder module (for instance 20) via a box axle
134, a box drive shaft 136 upon which a first and a second
pulley 138 and 140 are mounted on either side of angle drive
box 132, and a first and a second clutch pulley 142 and 1~4.
both pulleys being borne in free-running manner upon a
clutch drive shaft 146, and each pulley comprising a clutch
half coaxially disposed therewith; namely a first clutch
half~148 being comprised in first clutch pulley 142 and a
second clutch half 150 being comprised in second clutch
pulley 144.
Further comprised in speed change device 130 is a
clutch shaft 152 disposed coaxially upon clutch drive shaft
146 between first and second clutch pulleys 144 and 146.
Clutch shaft 152 is secured to clutch drive shaft 146 or it
can be of unitary construction therewith. A double-sided
claw clutch 154, including a clutch securing means 156, is
borne coaxially slideably upon clutch shaft 152. Claw clutch
154 is selectably securable to clutch shaft 152 by clutch
securing means 156 to either engage first clutch half 148
CA 02368036 2002-O1-30
19
(as shown) or second clutch half 150 for driving of'either
first clutch pulley 142 or second clutch pulley 144,
respectively. Clutch securing means 156 can be any
conventional device used for such purposes (for instance
screws) and claw clutch 154 can be slideably keyed upon
clutch shaft 152 in conventional manner. Appropriate
bearings (not specifically shown here) are provided for box
drive shaft 136 and for clutch drive shaft 146. Clutch drive
shaft 146 is provided with an inserter drive pulley 158
secured to one end thereof. An inserter drive belt 160
provides motive power to inserter drive pulley 158 from a
here not shown motor-driven jack shaft that is located in
main base 62 of the inserter apparatus.
First box pulley 138 is connected with first clutch
pulley 142 by a first belt 162. Second box pulley 140 is
connected with second clutch pulley 144 by a second belt
164. In the embodiment shown in FIG.4, second clutch pulley
149 is one half the diameter of the first clutch pulley 142,
while pulleys 138 and 140 are of the same diameter. The
shown clutch engagement results in a first drive speed
transmitted to angle drive box 132. The alternate selectable
clutch engagement results in a drive speed transmitted to
angle drive box 132 that is one half of the first drive
speed. Other preselectable drive change ratios can be chosen
by appropriate relationships between pulley diameters.
The half speed facility is generally preselected when
inserts may be difficult to handle at high speeds, as for
instance given by inserts from very thin materials. In such
cases, for example, two feeder modules are used to provide
the same more difficult to handle inserts, each mod.u7.e
operating at one half of the speed of other insert feeder
modules. This provides the capability of high delivery rate
without a need for slow-down of the entire apparatus.
CA 02368036 2002-O1-30
Referring now to FIG.5, insert thickness detector 28,
disposed in every feeder module (for instance 20), comprise:
an insert gripper drum disc 166 of an insert gripper drum
employed for delivery of inserts from a hbpper to pin
conveyor 34. Thickness detector 28 further comprises a
detector caliper assembly 168 and a Hall sensor device 170.
First and second anvils 172,174 are adjustably secured to a
face of drum disc 166 and are spaced apart by 180 degrees.
Peripheral surfaces of anvils 172,174 are flush with or
slightly raised above the periphery of insert gripper drum
disc 166. Detector caliper assembly 168 comprises a caliper
arm 176, a follower roller 178 mounted at one end of arm
176, a permanent magnet 180 mounted at the other end of arm
176, a caliper pivot 182 upon which arm 176 is rotatably
borne, and a tension anchor spring 184 spring-loading arm
176 so that roller 178 rides upon the periphery of disc 166
and over anvils 174. Spring 184 is anchored to an anchor 18f~
that is secured to the module's frame. Caliper pivot 182 any
Hall sensor device 170 are also secured to the inserter
module frame. Hall sensor 170 senses lateral displacement ou
the magnet 180 and generates a corresponding electrical
signal which is a measure of the thickness of an insert
passed between disc 166 (or anvils 172,174) and roller 178.
For example, an insert 1-88 is indicated in a proper position
while being conveyed by and upon the gripper drum (disc
166).
In operation, the insert gripper drum revolves about
its axis carrying inserts gripped upon its periphery and
transporting such inserts in generally conventional manner.
Anvils 172,174 are adjusted to have their peripheral
surfaces concentric about the axis of rotation of gripper
drum disc 166, as the periphery of the latter may not be
sufficiently concentric to serve as a reference. The signal
generated by the Hall sensor 170 corresponds to the radius
CA 02368036 2002-O1-30
21
followed by follower roller 278 about the axis of rotation
of disc 166. Consequently, the signal from the Hall sensor
provides a measure of insert thickness calipered between
roller 178 and an anvil. '
Anvils 172 and 174 are not required in another
embodiment, wherein the Hall sensor provides reference
signals corresponding to disc periphery radii in insert-
carrying locations in absence of inserts thereupon. These
reference signals are computer-stored and compared with the
insert thickness signals obtained when an insert is presen~..
Consequently, lack of concentricity of the periphery of di.~c
166 is compensated.
Insert thickness detector 28 is used in insert feeder
modules particularly as a so-called "miss and double
detector" to detect faulty equipment operation such as giv=:n
by an absence of an insert or the presence of more than on<
insert thickness. In general, Hall sensor signals are
compared with preset limits, corresponding to thickness
ranges, to allow for permissible thickness variations and
tolerable dimensional structural changes.
Yet another embodiment of an insert thickness detector,
designated by the numeral 28A, is shown in FIG.5A. An inse:-t
gripper drum 166A and a caliper assembly 168A are borne an~:.
mounted on a common frame structure 167. Caliper assembly
168A comprises a fixed Hall sensor device 170 and caliper
arm 176A. The latter is pivotably borne upon a caliper pivot
182A which is mounted in a fixed position with respect to
frame structure 167. Caliper arm 176A has a follower rollez
178 freely rotatably mounted at one end thereof. The other
end of caliper arm 176A is provided with a permanet magnet
180 whose magnetic field is sensed by Hall sensor device
170.
A pulley 171, mounted on the axle of the insert grippE°r
drum 166A, is commonly driven at the same angular velocity
CA 02368036 2002-O1-30
22
' as the insert gripper drum. A further pulley 173 is freely
rotatably borne upon a shaft that is mounted in a fixed
position with respect to common frame structure 167. Pul~.ey
173 is driven from pulley 171 via a belt 173A. A precisi~~~
caliper roll 173B is coaxially mounted with pulley 173 and
driven thereby. A point on the periphery of caliper roll
1738 is always disposed so as to substantially coincide with
a cylindrical surface within which falls the periphery of
the insert gripper drum 166A. Caliper roll 1738 and follower
roller 178 are both disposed in substantially the same
vertical plane which is located on one side and in the
vicinity of one face of insert gripper drum 166A. The nip
formed between roll 173B and roller 178 intercepts
overhanging portions of inserts being transported upon drum
166A. In absence of inserts being calipered, follower roller
178 contacts caliper roll 1738 and is driven thereby. This
contact is enforced by spring loading of caliper arm 176A by
torsion spring 184A.
The transmission ratio between drum 166A, pulleys 171
and 1?3, and caliper roll 1738 is such that the peripheral
velocities of insert aripper drum 166A and caliper roll ~73B
are identical. Belt 173A is resiliently elastic,
particularly along its length, in order to ar_comodate
velocity fluctuations between the two pulleys.
In operation, when an insert, for instance indicated
insert 188, is transported upon insert gripper drum 166A,
.the insert is also nipped between caliper roll 173B and
follower roller 178, and is driven thereby substantially at
the speed of the gripper drum periphery. Follower roller 178
is displaced by the insert thickness, and magnet 180 is
correspondingly displaced from its reference position along
Hall sensor device 170. The difference between the Hall
sensor signals in absence and in presence of a nipped insert
provides an accurate measure of insert thickness. As inserts
CA 02368036 2002-O1-30
23
extend beyond both sides of the insert qripper drum into the
nip region between caliper roll 173B and follower roller
178, lack of concentricity, vibration, and other aripper
drum periphery deviations do not affect the measurement,
because caliper roll 173B is rigidly borne in the frame.
structure of the apparatus and is not subject to errors due
to such causes. The elasticity of belt 173A facilitates also
calipering of relatively thick inserts, as the belt will
stretch to adapt to corresponding fluctuations in velocity
of caliper roll 173B.
Referring now particularly to FIG.6 in conjunction with
FIGS.1, 1A and 2, 2A, skew detector arrangement 54 is
disposed on and above main track bed 60 and comprises a skew
detector bridge 190 having a plurality of downwardly-J.ooking
photosensors mounted therein. A plurality o.f retroref~ectors
192 is disposed below skew detector bridge 190 upon the
upper surface of main track bed 60. Skew detector bridaP 190
is indicated in dotted lines in FIG.6. Pin conveyor 34
(indicated by dash lines) is disposed beneath the surface, of
main track bed 60 and comprises, in two parallel rows, a
plurality of equi-spaced upwardly-pointing pusher pins 196
(two of which are shown here) which protrude above the main
track bed through slots 194 and which move therein along the
track bed. A typical insert stack package 198 (indicated by
phantom lines) is shown as it is pushed along the surface of
track bed 60 by pusher pins 196, being conveyed thereby from
inserter modules to envelope inserting station 32.
Photosensors in skew detector bridge 190 are directed
toward retroreflectors 192 so that the presence of an insert
stack is sgnsed. In particular, the sensing operation is
timed in synchronism with the conveying motion of pin
conveyor 34. Broadly the apparatus and method of the present
invention provides for sensing of leading and trailing edges
of insert stark pack~oe 198 in a plurality of transverse
CA 02368036 2002-O1-30
24
locations across main track bed 60 over retroreflectors 192.
More particularly, detected signal levels of individual
photosensors are compared for transversal incidence timing
by sensing of relative obstruction of retroreflector areas
by insert stack package edges. In a more specific
embodiment these signal are evaluated in dependence on
machine speed, thusly establishing limiting tolerance levels
for permissible skew and other misalignments as a function
of machine speed. Limiting tolerance levels are
preprogrammable in order to provide allowance for different
insert materials and, particularly, to establish automatic
rejection thresholds for insert stack package skew and
misalignment.
Referring now to FIG.7, an insert diverter 56 is
depicted in side elevation as it is disposed upon main base
62. Also indicated here is a pusher pin 196 of pin conveyor
34 as it pushes insert stack package 198 along upper surface
of main track bed 60 (from left to right). Broadly, insert
diverter 56 comprises a diverter housing 200, an insert
reject catch tray 202, and a divert pulley system 204.
Although disposed within main base 62, a selectively
positionable two-position reject gate 206 including, its
actuating mechanism is a part of insert diverter 56. In a
more particular embodiment of the invention, divert pulley
system 204 comprises a motor-driven divert drive
roller/pulley 208, a motor-driven belt drive pulley 210, and
a triple pulley belt arrangement 212 including an endless
divert belt 214. Belt arrangement 212 comprises a floating
idler pulley 216 which is carried by a here not shown lever
that freely pivots about the axis of belt drive pulley 210
and that is spring loaded in a clockwise direction against
an adjustable stop. This lever also carries an idler lever
pivot 222 which is linked by a here not shown link to the
axle of a take-up pulley 218. This link is spring loaded
CA 02368036 2002-O1-30
about the axis of pivot 222 in counter-clockwise direction
to keep divert belt 214 tensioned. A fixed idler pulley 220
is borne in fixed position within housing 200. Resiliently
' tensioned divert belt 214 is driven by belt drive pulley
210. It should be understood that a plurality of
substantially identical components is disposed in spaced
parallel arrangement perpendicularly to the plane of thN
depiction, as is customary in sheet material handling
mechanisms.
In operation, the apparatus and method of the invention
provides for diversion of an insert stack package when
reject gate 206 is raised to its upward reject position 224
from its by-pass position below the surface of main track
bed 60. The insert stack package (such as package 198, for
example) is consequently pushed onto reject Gate 206 by thF
normal conveying motion from pusher pins 196. The insert
package is thuslv guided into a reject nip region 228
between divert belt 214 and divert drive roller/pulley 208.
The package is Grabbed in nip region 228 and lifted up~Tardly
away from the path of pusher pins 196, is carried about
roller/pulley 208, and is thereby transferred into reject
catch tray 202. Reject gate 206 is thereafter returned to
its by-pass position 226. Positioning of reject gate 206 is
performed in conventional manner, for example by a spring-
loaded solenoid in response to appropriate energizing
signals that are, for example, supplied from main computer
50 (or from a subsystem thereof). Insert stack packages ,
stigmatized as faulty (for example misaligned or skewed) are
thusly diverted.
Another preferred embodiment of the in-line rotary
inserter apparatus is shown diagrammatically in FIG.1A. The
left hand portion of FIG.1A is identical to the left portion
of FIG.1 (including also envelope feed station 30 and a
vacuum belt transporter/diverter unit), but differs from
CA 02368036 2002-O1-30
26
FIG.1 in that unit 36, now designated 36A, is somewhat
modified. Unit 36A now feeds (toward the right) a turnover
module 40A via a diverter section 47A. Turnover module 40A,
in turn feeds a sealing module 38A which is further
connected to and feeds a postage meter module 49A via a lift
gate section 48A. On-edge stackinq/diverter unit 42, fed
from postage meter module 49A, is substantially the same as
unit 42 shown in FIG.1 (and FIGS.11-15) and can be further
r_onnected to additional handling equipment 46.
Diverter section 47A can be substantially similar tn
the device depicted in FIG.7 and as described in conjunction
therewith, although other diverters can be employed instead.
Diverter section 47A serves to divert unsealed envelopes
either for normal operation processing reasons or when fault
conditions occur.
Referring now to the embodiment shown in FIG.2A (for
instance also in conjunction with FIG.1A), it will be seen
that the depiction is in many respects substantially
identical to FIG.2, except that the vacuum belt
transporter/diverter unit, now designated with the numeral
36A, comprises a transverse pass 64A having a substantially
horizontal surface 70A with a short fall region 74A
thereabove. Further in this embodiment, the envelope
conveyor device, now designated with the numeral 82A,
includes an upper belt device 83A following a somewhat
different belt path (than device 83 of FIG.2), and the
envelope diverter, now designated with the numeral 33A,
includes a deflector and belt device 86A (and. excludes stop
gate 86 of FIG.2). The embodiment of FIG.2A will be
described hereinafter only in regard to those aspects
differing significantly from the aspects of FIG.2. In other
respects, reference should be made to foregoing detail
descriptions given in conjunction with FIG.2.
CA 02368036 2002-O1-30
27
Vacuum belt transporter/diverter unit 36 of_ FIG.2 can.
feed other modules or subsystems as depicted, for instance.
in FIG.1A and, similarly, vacuum belt transporter/diverter
36A of FIG.2A can feed other modules or subsystems as
depicted, for instance, in FIG.1, provided suitable
transition means are interposed to adapt the respectively
sloping and horizontal envelope orientations along the
envelope transfer delivery path.
Referring to FIG.2A, envelope conveyor device 82A
comprises a pair of driven endless belts disposed one above
the other. Upper belt device 83A includes a generally
straight lower portion in nipping contact with the upper
portion of the lower belt. An upper portion of the upper
belt device 83A is partially carried and driven by a pulley
having substantially the same diameter as second gripper
drum 78 and forming a part thereof, as indicated in FIG.2A.
Envelopes axe delivered by and upon second gripner drum 78
to the nip between upper belt device 83A and the upper
portion of the lower belt, and axe transported thereby
toward the left.into proximity of vacuum gripper drum 84 in
readiness for pick-up by appropriate grippers of drum 84.
According to wn ambodiment of the invention, an
envelope diverter 33A comprises a deflector and belt device
86A and an envelope reject bin 85C. Deflector and belt
device 86A of the diverter 33A is disposed in the region
between envelope conveyor device 82A and vacuum qripper drum
84, and comprises a deflector 85 and an endless belt 85B
driven about a pair of pulleys. The axle of the upper pulley
serves also as pivot 85A about which deflector 85 is
selectively pivotable between two positions. In accordance
with the apparatus and method of the present invention,
deflector 85, in the position indicated, offers an upper
deflector surface to envelopes delivered thereto, so that an
envelope resting upon this upper deflector surface can be
CA 02368036 2002-O1-30
28
picked up by the next grippers of vacuum gripper drum 84.
Deflector 85 is pivoted into the other position
anticlockwise by a small angle so that the right-hand. scoop-
like face of deflector 85 scoops and diverts therealong a
delivered envelope downwardly. The leading edge of a thusly
downwardly deflected envelope will contact the right-hand
side of belt 85B, and will be driven thereby farther
downwardly until it falls into bin 85C. The envelope
diverter 33A serves to selectively divert envelopes (for
instance, reject or faulty envelopes) before they can reach
inserting station 32.
FIGS.8, 8A, and 8B depict detail aspects of vacuum belt
transporter/diverter unit 36A and show a delivery end
portion of conveyor belt arrangement 107 for conveying from
inserting station 32 envelopes filled with inserts. FIG. BA
shows additional details in the shortfall region 74A of the
transverse pass 64A in a partial side view similar to the
view of this region Given in FIG.2A. Conveyor belt
arrangement 107_conveys envelopes into fall region 74A of,
transverse pass 64A and deposits envelopes onto surface 70A
of vacuum belt transporter/diverter unit 36A.
In broad aspects of embodiments, vacuum belt
transporter/diverter unit 36A comprises surface 70A of a
support structure for the unit, first and second parallel
vacuum belts 232 and 234 having a plurality of vacuum
openings 236 disposed in a region therebetween in surface
70A (or in a block mounted in surface 70A), at least one
Guide rail 238 and one adjustable rail 240, and a mounting
bar 242 fixed on surface 70A. In more particular aspects,
vacuum belt transporter/diverter unit 36A further comprises
a pair of fall brushes 244 disposed in the vicinity of and
above the delivery end of conveyor belt arrangement 107, at
least one adjustable spring-loaded pressure roll unit 246,
and at least one drive pressure roll 248 spring loaded
CA 02368036 2002-O1-30
29
against a driven roll that is disposed beneath surface 70A.
In more particular a..soects, vacuum belt transporter/diverfier
unit 36A includes a monitoring photosensor 250 and a raised
envelope scanner 252, a deflector 254 including bristles
254A disposed upon the deflector's lower surfacz. and brush.
arrangements 255 included in adjustable pressure roll unit
246.
It should be recognized that vacuum belt
transporter/diverter unit 36A is substantially symmetrical
about a vertical plane disposed through the middle of
conveyor belt arrangement 107, although the depiction in
FIG.8 shows one side partly fragmented.
In respect to further apparatus and method aspects of
the invention, first and second vacuum belts 232 and 234 are
driven endless belts having their upper surface disposed
substantially slightly above surface 70A, so that an
envelope can be transported upon these belts. In particular,
an envelope delivered by conveyor belt arrangement 107 onto
these belts in the region above vacuum openings 236 clings
securely to the belts by the action of vacuum fed via vacuum
openings 236 (from a vacuum source here not shown). A thuslv
delivered envelope is deflected downwardly by fall brushes
244 and by deflector 254, and is stopped by raiJ_ 240.
Bristles 254A are oriented in direction of the envelope
delivery movement and serve to reduce envelope bounce upon
delivery. Rail 240 provides for registration of~ an envelope
edge, and is repositionable by adjustable fastening means
256 to accommodate different size envelopes.
Guide rails 238, curved along their leading ends, serve
to guide opposed envelope edges into definite positional
registration therealong and along rail 24. Pressure roll
units 246 each comprise an idler roller mounted in a spring-
loaded crank device whose position is relocatable by a block
257 along an adjustment rail 257A. Units 246 also include
CA 02368036 2002-O1-30
brushes~255 mounted thereon with bristles directed
downwardly and angled to facilitate delivery of envelopes
thereunder. Brushes 255 serve to push envelopes onto belts
232 and 234, particularly as envelopes are transported by
the belts toward one or the other side and away from the
region of vacuum openings 236. Idler rollers of pressure
roll units 246 are positioned above and spring loaded onto
belt 234. Pressure roll units are adjustably relocatable t~_
accommodate different envelope sizes, so that envelopes
transported by belts 232 and 234 are engaged by the nip
between the idler roll and belt 234 before they leave the
influence of vacuum in the region of vacuum openings 236,
and so that envelopes remain engaged in this nip at least
until they are transported in the nip between drive pressu:~a
roll 248 and a driven roll therebeneath. Drive pressure roil
248 is an idler roll mounted upon a crank arm, and is spri-.g
loaded against the driven roll therebeneath.
A monitoring photosensor 250 is shown in surface 70A c..i
the left side of drive pressure roll 248 for purposes of
sensing and monitoring envelopes being delivered to farthe~:-
equipment. Sensor 250 facilitates supervisory and control
functions of multiple subunit arrangements, for instance,
via computer 50.
In respect to further more particular aspects of
embodiments of an apparatus of the invention and a method of
operating the apparatus, FIG.SB shows details of a raised
envelope scanner 252 (also indicated in FIG.8). Raised
envelope scanner 252 comprises a beam emitter 258 generating
a light beam 258A and includes a beam pick-up 259 arranged
in line therewith. Emitter 258 emits beam 258A angled across
a corner formed between surface 70A and guide rails 238
through slots 260 (in rail 238) and 260A (in surface 70A).
Beam 258 is intercepted by an envelope transported through
vacuum belt transporter/diverter unit 36A, provided the
CA 02368036 2002-O1-30
31
envelope is correctly registered between rails 238 and 240
° and provided that its inserts are properly fully inserted.
This is indicated by envelope 261 (in dashed lines) ha~Tinq
flap 261A raised. If inserts are, for instance, incompletely
inserted and protrude past the flap hinge edge, the en«?lope
flap is stiffened in a more horizontal orientation.
Consequently, such an envelope is not disposed upon surface
70A in the vicinity of Guide rail 238 subsequently to its
delivery to and during transport by vacuum belt
transporter/diverter unit 36A, and it will not be scanr..ed
while passing by raised envelope scanner 252. Such an
envelope may ride with its stiffened flap upon rail 238.
Other faulty envelopes, such as for example having damaged,
bulged, improperly folded or other insert faults can also
result in absence of a interception by scanner 252. Thus
scanner 252 serves to detect such malfunctions.
In operation of vacuum belt transporter/diverter unit
36A, an insert-filled envelope is delivered with flap-edge
trailing by conveyor belt arrangement 107 onto vacuum belts
232 and 234. Vacuum is fed to the bottom of the envelope via
vacuum openings 236 to pull the envelope onto the belts, and
the envelope is transported on and by the belts either to
the right or to the left, depending on the direction of belt
motion. The envelope is further transported to the side of
the unit and to farther equipment through a nip between
drive pressure roll 248 and a driven roller therebenPath. A
reversing Qearina and clutch arrangement can be provided to
reverse the drive to vacuum belts 232 and 234 and to thusly
facilitate selective quick change over and diversion of
envelopes to the right or the left. For example, as
indicated in FIG.1A, vacuum belt transporter/diverter unit
36A can deliver insert-filled envelopes via a reject
diverter section 47A to a turnover module 40A and farther to
a sealing module 38A.
CA 02368036 2002-O1-30
32
Referring now to FIGS.9 and 9A, key aspects of turnover
module 40A depir_ted therein comprise a module frame and
housing 262, idler pulleys X63, 264, and 265, and a driven
pulley 266. All four pulleys are disposed substantially in
the same plane and are rotatably borne. Pulleys 2.65 and 266
have their centers disposed in fixed positions with respect
to housing 262. In a particular embodiment, pulleys 263 and
264 revolve about horizontal axles Which are spring-loaded
downwardly. These axles can move by a small distance
substantially vertically between stops in the spring-loaded
range. One stop is set to provide a fixed smallest gap
between upper and lower pulleys. The other stop is
adjustable to provide a maximum gap between upper and lower
pulleys. For instance, axles of pulleys 263 and 264 are
first axles of approximately horizontally oriented sprina-
loaded cranks whose second axles are rotatably borne in
module frame and housing 262. The angle of spring-loaded
crank rotation is limited by and between the two stops.
An endless flat belt 267 is carried in figure-eight
form by the four pulleys in such a way that~the mutually
contacting cross-over belt portions form a one hundred and
eighty degree twist about one another in the stretch between
the left pulleys (263, 266) and the right pulleys (264,
265). In a particular embodiment of the invention, endless
flat belt 267 is produced by twisting a~straight flat belt
by seven hundred and twenty degrees and by joining the ends
to one another. As carried upon the four pulleys, mutually
contacting cross-over belt portions twist in clockwise
direction about one another to provide clockwise turnover of
envelopes, as indicated in FIG.9A by arrow 268, when
envelopes are transported from right to left through
turnover module 40A. In illustration of the method of
operating the turnover module, a typical entering envelope
269 is shown in phantom lines being delivered to the pin of
CA 02368036 2002-O1-30
33
the cross-over belt portions. A typical egressina envelope
269' is shown in phantom lines being. delivered from the nip
of the cross-over belt portions, having been turned from a
flap-up to a flap-down orientation.
Th2 fixed smallest gap between upper and lower pulleys
is set to facilitate nipping and transport passage between
the belt portions of a thinnest envelope to be handled. The
other stop is adjusted to a gap between upper and lower
Dulleys to facilitate nipping and transport passage between
the belt portions of the thickest envelope to be handled.
Referring now to FIGS 10 and 10A, features of sealing
module 38A shown therein comprise a first belt conveyor 270
and a second belt conveyor 272 upon which envelopes are
conveyed, a flap moistening section 274, a flap sealing
section 276, and a frame structure 278 on which the various
components are mounted. A typical envelope 280 is shown (in
phantom lines? as it is delivered from turnover module 40A
to flap moistening section 274. Envelope 280 is oriented
substantially in a horizontal plane having its still open,
flap oriented substantially vertically and pointing
downwardly.
Broadly, flap moistening section 274 comprises a spray
nozzle 282 for issuing of a water spray onto the inner
surface of flaps of envelopes that intercept the sbray wY~ile
being conveyed through flap moistening section 274. The
spray is particularly directed at the gummed portion of
envelore flaps, and is provided preferably in form of a fan
pattern that has a well-defined fan angle and pattern
thickness extent in order to reduce moistening of other than
flap surfaces of an envelope. In a particular embodiment,
the fan pattern is preferably oriented in a generally
lateral and vertical plane, but can be alternately oriented
in other generally lateral planes. For example, suitable
spray nozzles can be of a conventional shear type having a
CA 02368036 2002-O1-30
34
slit exit and providing high liquid shear forces to break ua
flow into droplet spray. In a particular alternate
embodiment, spray nozzles are advantageously of a fluidic
oscillator type which break up flow into~relatively well-
defined droplet spray patterns. An appropriate nozzle of tr_
latter type is described, for instance in U.S.Patent
4,184.636.
First belt conveyor 270 comprises a driven endless bel'
arrangement having an upper belt surface 284 oriented
substantially horizontally for conveying of envelopes
through sealing module 38A. Disposed at least in the regior_
of flap moistening section 274, a plurality of pressure
rolls 286 is spring loaded onto upper belt surface 284 to
form a nip for nipping and thereby more securely conveying
envelopes through sealing module 38A. Second belt conveyor
272, commonly driven with first belt conveyor at the same
speed, is provided with pressure rolls 290 for exerting of
pressure onto a moistened and folded closed flap of an
envelope whilst the envelope is conveyed under rolls 290 on
top of belt conveyor 272.
A closing guide 292 is disposed in a region that leads
into flap sealing section 276. Guide 292 serves to interce~.~
moistened envelope flaps and to bend the flaps upwardly into
substantially closed orientation, so that the flap can be
sealed subsequently by compression action between second
belt 272 and pressure rolls 286, as an envelope is conveyea
through flap sealing section 276. As indicated in FIGS.10
and 10A, guide 292 has a compound shape, being curved both
downwardly and laterally in direction toward an incoming
envelope, and is disposed entirely beneath the horizontal
envelope conveying plane (given by the upper surface of
second conveyor belt 272). Guide 292 intercepts and slides
along the outer surface of an envelope flap fed thereto,
while gradually pushing the flap into its closed
CA 02368036 2002-O1-30
position.
In a method of operation of sealing module 38A,
envelopes are fed thereto seriatim in the orientation and
pOSltion shown by typical envelope 280. As an envelope is
conveyed by first belt 270 (toward the left) past spray
nozzle 282, its flap is moistened over its gummed region by
spray from this nozzle and, while the envelope is conveyed
farther to the left into the nip between second belt 272 and
pressure rolls 290, the flap is closed by closing Quide 292.
Thereafter, rolls 290 in combination with belt 272 seal the
flap while the envelope is conveyed to the left hand side of
the sealing module and delivered therefrom to farther
equipment. A photosensor 294 can be provided to detect
ingress of an envelope in order to actuate a solenoid valve
to feed water to nozzle 282 during passage of the enveloise,
so that water is sprayed only when a flap requires
moistening. Alternately, spraying can be continuous while a
continuous stream of seratim envelopes is conveyed.
It should be recognized that the generally vertical
orientation of the downwardly pointed envelope flap during
the spray moistening operation is particularly advantageous.
For all practical purposes, this orientation avoids wetting
of the envelope body and of inserts contained therein.
Moreover, spray droplets that miss a flap or that bounce off
or flow down on the flap cannot wet the envelope. The latter
droplets are collected in a here not specifically shown tray
with appropriate wall shields and are drained away. It
'should be further recognized that nozzle 282 (and its
operating pressure) is preferably chosen to provide a spray
with droplet sizes above those which could form a
significant proportion of floating mist in order to minimize
moistening of machine parts. Consequently, preferable
droplet sizes are chosen to be above approximately 100
microns, and are preferably substantially in a range abo«e
CA 02368036 2002-O1-30
36
about 200 microns and larger.
Sealed envelopes are delivered by sealing module 38A.
for instance, to a lift gate section 48A that is indicated
in FIG.1A. Lift Gate section 48A is provided for gassing
sealed envelopes delivezed thereto onward to postage meter
module 49A (FIG.1A). Lift gate section 48A includes a
transport conveyor mechanism of conventional kind and is
arranged to facilitate lifting and tilting of its structure
out of the way to permit, for instance, a machine operator
to pass from one to the other side of the equipment when
operation is interrupted. Envelopes delivered by lift gate
48A are processed in postage meter module 49A and are
delivered therefrom to on-edge stacking/diverter unit 42.
Postage meter module 49A is a conventional apparatus as
customarily employed in mass-processing of mailable
articles, and will not be further described herein.
Referring now to FIGS.11-15, on-edge stacking/diverter
unit 42 is depicted therein. FIGS.11, 12, and 14 include
fraamental depictions of turnover module 40 (for instance,
as indicated in FIG.1> which delivers envelopes to on-edoe
stacking/diverter unit 42. It should be understood that, in
alternate embodiments of the invention, turnover module 40
ran be replaced by other system modules that can deliver
envelopes to unit 42. In particular also, this reference to
module 40 is intended to alternately also refer to postagY
meter module 49A, for instance in an arrangement as
indicated in FIG.1A.
In broadest aspects of an embodiment of the apparatus
and the method of the invention, on-edge stacking/diverter
unit 42 co~prises a diverter section 350 to selectively pass
on or divert envelopes, a stacker section 352 for stacking
of diverted envelopes and including a stacking spider 353,
and accumulator 44 for accumulating stacked envelopes.
CA 02368036 2002-O1-30
37
In more particular aspects of an embodiment, re-ferring
- now to FIGS.11 and 12, diverter section 350 comprises a base
structure 354 (common also with stacker section 352?, an
upper level 356 for receiving, diverting, and passing on of
envelopes delivered thereto, and a lower level 358 to which
envelopes are diverted for stacking.
Upper level 356 comprises a plurality of conventional
pressure rollers 360 that provide pressure onto envelopes
against a drive roll 362 and a drive belt 364 which thusly
convey envelopes upon upper level (to the right). Furthea
comprised in r_he floor of upper level 356 is a selectively
operable hinged divert gate 366 that is shown in its closed
position flush with the floor of upper level 356 and whose
open position is indicated by dashed lines. Additiona~lv,
the floor of upper level 356 comprises a photosensor 368 for
sensing of envelopes leaving toward the right side to
subsequent envelope handling equipment, a rear wall 370 and
an adjustable aliqner 372; the latter two serving for
alignment of envelopes therebetween, being adjustable to
different envelope widths. Aligner 372 is provided with a
partial cutout above divert gate 366 to permit opening of
the latter. Above the floor of lower level 358, in the
vicinity of the hinge of gate 366, is disposed a guide strip
373 to guide downwardly diverted envelopes onto the floor.
Guide strip 373 is, for example, of Teflon or other low-
friction material to promote downwardly sliding deflection
of envelopes along its lower surface.
Lower level 358 comprises selectably operable
adjustable length-stops 374 and 376 that are ganged togetha_r
for common~positional shifts along rear wall 370 to provide
selectable envelope offset in stacking. Further, lower level
358 comprises an adjustable aligner 372' that is ganged with
aligner 372. A7_igner 372' is spaced from the floor of lower
level 358 to form an opening adequate to clear envelopes
CA 02368036 2002-O1-30
38
propelled therethrough. Further comprised in and beneath the
floor of lower level 358 is a photosensor 378 for detection
of envelopes diverted thereupon, a pair or rotatable paddles
380 mounted upon a common shaft that is borne beneath ty~N
floor of lower level 358, and an upper and a lower pair of
rotating nip rolls 382 and 384, respectively, each pair
being borne upon a separate shaft. One of the pair of ni.p
rolls is motor-driven, so that a nipped envelope is
transported toward stacking spider 353.
A curved arm 385 of resilient flat spring material is
freely pivotably disposed in the envelope path between nip
rolls 382,384 and stacking spider 353, as indicated in
FIGS.13 and 14, so that an envelope propelled along this
path is restrained from bouncing (and possibly misaligning)
once it has left the nip of the rolls. Arm 385 is secured to
a pivotable mount 386. Mount 386 is mounted within the
structure of the lower level 358. Arm 385 is held in the
position shown by its weight and allows an envelope to pass
slidingly thereunder.
Paddles 380 are selectively commonly rotatable in
increments of 180 degrees with respect to the position shown
in FIG.13 by a motor via a conventional solenoid-actuatable
one-half revolution clutch in response to appropriate
control signals. When rotated, ends of paddles 380 protri3.de
and move through appropriate clearance slots in floor of
lower level 358 so that their motion propels an envelope
disposed thereupon into the nip between rolls 382 and 384.
For example, an envelope 388 (shown in phantom lines in
FIG.11) falls from upper level 356 to lower level 358,
having been diverted by gate 366. This envelope is then
i
indicated as envelope 388' (in FIG.13) subseguent to its
diversion and disposed upon the floor of level 358. A
subsequent selective operation of paddles 380 (clockwise)
propels envelope 388' to the right.
CA 02368036 2002-O1-30
39
Referring now also to FIGS.1.3 and 14, in further
- particular aspects of the invention, stacker section 352
comprises a horizontally slidably adjustable table 390 that
is partially borne in and upon base structure 354 in a
telescoping manner, and stacking spider 353 which is borne
in table 390 and which is motor-driven via a selectively
energizable clutch in clockwise direction. Spider 353
includes a timing disc revolving commonly therewith and a
photosensor sensing the position of the disc (not shown
here). As will be described hereinafter in more detail,
stacking spider 353 is borne in table 390 in floating
manner, being free to move for a short distance in a
substantially horizontal plane away from accumulator 44.
Stacking spider 353 is spring-loaded toward accumulator 94.
Table 390 includes an upper surface 392 and a stacking
surface 394. Upper surface 392 is disposed at substantially
the same level as or slightly lower than the surface of the
floor of lower level 358. Stacking surface 394 is disposed
at a lower level than upper surface 392 and adjoins a
downwardly curved extension thereof.
Stacking spider 353 further comprises a pair of
parallel spider wheels 396 and 396' commonly mounted and
driven by a shaft 398. Spider wheels are identical in shape,
having disposed about their peripheries a plurality of
equally spaced spider legs 400 of generally sawtooth-like
shape in a trailing orientation in respect to their normal
clockwise direction Qf rotation. Spaces between spider legs
400 are such that a stuffed envelope can easily be disposed
therein, as indicated for example by envelope 402. Spacing
between spider wheels 396 and 396' is somewhat less than the
length of the shortest envelope that is required to be
handled by the equipment. Slidable adjustment of table 390
is provided for adaptation of the equipment to different
size envelopes, in particular to different widths and it .s,
CA 02368036 2002-O1-30
40
therefore, ganged to the adjustment of aligners 372 and 372', as
indicated by dotted lines of gang connection 404 (FIG.13).
Accumulator 44 is substantially a conventional stack accumulator
device that is customarily used to accumulate flit articles, such as
documents, envelopes, and the like side-on-side in vertical orientatioa-~_.
Accumulator 44 is borne on table 390 and comprises a powered conveyor
belt arrangement 406 having its upper surface disposed slightly above
stacking surface 394. It comprises a back plate arrangement 408 that
includes an L-shaped back plate 410 having permanent magnets 412
attached to its bottom surface for repositionable attachment seating
upon the upper surface of the belt of belt arrangement 406. Back plate
410, in the manner of a "magnetic bookend", can be removed and replacec?
for instance for removal of an envelope stack. Alternately, other back
plate arrangements of conventional type can be used, as fox instance a
back plate slideably (with relatively high friction) and hingeably bore
upon a rod suspended on a side above an accumulating stack (above belt
arrangement 406). The latter arrangement allows upward.hinging of the
back plate about the rod for removal of stack 414. Powered conveyor be':t
arrangement 406 facilitates orderly accumulation of a stack by
incrementally moving on-edge stacked envelopes in unison in response t~~.
increasing stack thickness detected by a photosensor. This photosensor
detects horizontal movement of stacking spider 353 due to increase of
stack thickness.
iThen only short stacks of envelopes are to be handled in
accumulator 44, conveyor belt arrangement 406 need not be powered, but
can be free-running. In this case, sensing of stack accumulation is not
needed and stacking spider 353 need not be arranged in the indicated
floating manner.
Envelope stack 414 has an offset portion 416 disposed therein to
illustrate the result of the hereinabove described selectable envelope
offset capability comprised in lower level 358. For instance, to
distinguish a particular set of diverted envelopes (for example by
specific zip codes), the indicated offset capability is provided so th~:t
CA 02368036 2002-O1-30
41
offset portion 414 may be recoqnizsd and selectively hand7.ed
subsequently to its accumulation.
Referring now to FIG.15, further particular aspects of
an embodiment of the apparatus and method of the invention
are shown. Stacking spider 353 is suspended in a floating
manner as it is borne in table 390, and is provided by a
floating drive suspension arrangement 500. Spider wheels 396
are borne on and revolved by shaft 398. Arrangement 500
serves to drive and suspend shaft 398 so that stacking
spider 353 is free to move for a short distance in a
substantially horizontal direction toward the left and away
from stacking surface 394 (toward which it is spring
loaded).
Arrangement 500 comprises a worm reducer gearbox 502.
The output of gearbox 502 is provided via shaft 398. Gearbox
502, driven by an input shaft 504, is supported via rocker
arm means 506 whose one end is securely mounted within table
390. Additionally, gearbox 502 is supported in spring-loaded
manner by spring loading means 508. Means 508 comprises a~
Guide rod 600 that is secured, at one end thereof, to a post
602. Post 602 is rigidly affixed to table 390. The free end.
of rod 600 extends through a clearance hole in a bracket 504
that is rigidly attached to or is a part of the housing of
gearbox 502. A compression spring 606 is threaded over guide
rod 600 and, in pre-compressed manner, extends between post
602 and bracket 604 and thusly forces gearbox 502 toward the
right. A mechanical stop in form of a stop collar 607 limits
the possible travel distance of gearbox 502 toward the
right. Stop collar 607 is secured to the free end of rod 600
and contacts bracket 604 at the limit of floating travel of
gearbox 50~.
Input shaft 504 is coupled via a pin coupling 608 to
drive axle 700. Axle 700 extends through and is borne by
post 602 in an appropriate bearing therein. A drive pulley
CA 02368036 2002-O1-30
42
702, that is attached to the end of axle 700, is driven via
a belt (not shown here) by a drive mechanism. Pin coupling
608 couples the rotation of axle 700 to input shaft 504,
while permitting axial displacement (as well as a small
amount of angular misalignment) therebetween.
It will be understood that rocker arm means 506
comprises at least two parallel rocker arms or a unitary
rocker arm having adequate bearing lengths and rigidity to
provide the required support for gearbox 502. This support
must avoid substantial angular and axial displacement of
shaft 398; in other words, skewing and rocking motions of
spider wheels 396 must be avoided.
With reference to FIGS.11 through 15, in operation of
on-edge stacking/diverter unit 42, envelopes are seriatim
delivered thereto in horizontal orientation and in alignment
substantially along rear wall 370 upon the floor of upper
level 356. If divert gate 366 is in its closed position.
envelopes are conveyed toward the right for delivery to
farther equipment. If divert gate has been opened, for
instance by a solenoid, an envelope is diverted to lower
level 358, as indicated by envelope 388. Guide strip 373
aids in the proper diversion. Envelope 388 falls onto the
floor of lower level 358, as indicated by envelope 388'
(FIG.13), in the region between length-stops 374 and 376 and
between rear wall 370 and aligner 372'.
Subsequently actuated clockwise rotation of paddles 380
propels envelope 388' toward and into the nip between rolls
382,384 and, thereby, into a space between spider legs 400.
Once an envelope has settled in spider wheels 396 and is
carried initially upwardly thereby, arm 385 pivots upwardly,
being lifted by the envelope disposed thereunder, slides
along and out of the way of the envelope, and thereafter
pivot back by gravity. Moreover, the action of arm 385
ensures that a delivered envelope does not bounce or
CA 02368036 2002-O1-30
43
otherwise move out .from its proper location between spider
leas 400 during the initial onward movement.
Appropriate timing of actuation of paddles 380 to
assure that an envelope is propelled into a space between
legs 400 is obtained by the action of the timina'disc and
photosensor arrangement of stacking spider 353. Eneraization
of the clutch to paddles 380 is inhibited at such times when
a propelled envelope would impinge upon a spider lea 400.
Spider wheels 396,396' carry envelopes to stacking
surface 394 and deposit them edge-on. Additionally, trailing
edges and tips of spider legs continue to push deposited
envelopes side-on-side onto the accumulating envelope stack
424.
Referring now also particularly to FIG.15, in response
to increasing stack pressure, spider wheels 396 move back
resiliently (to the left) by the action of the floating
drive suspension arrangement 500, allowing stack 424 to
increase in thickness. A photosensor 706 secured to the
floating body of Gearbox 502 is partially obstructed by a~
stationary flag 708. The drive of conveyor belt arrangement
406 is energized in response to sensing of flag 708 by
photosensor 706. and belt arrangement 406 incrementally
moves the accumulated stack 414 toward the right. Conseauent
stack pressure relief allows spider wheels 396 to follow.
When flag 708 is no longer detected by photosensor 706, the
drive of belt arrangement 406 is deenergized. As a result.
stack pressure is maintained within appropriate limits and
orderly stacking is provided, regardless of the thickness of
an accumulating stack.
In general, various photosensors provide signals for
tracking of handled envelopes and inserts throughout the
apparatus assembly. Interdependent control of various
actuations under supervision of main computer 50 (and
subsidiary controls and microprocessors) is provided
CA 02368036 2002-O1-30
44
throughout the in-line rotary inserter device of the
- invention. The various sensors particularly also facilitate
asynchronous operation in further handling of envelopes that
have had inserts inserted therein. Whereas synchronous
operation may be utilized, asynchronous handling capability
is preferred in view of the advantages offered. It will be
understood in this respect that transporting of inserts and
envelopes to inserting station 32 is a substantially
synchronous operation to the extent that appropriate timing
of arrival of mutually associated envelopes and inserts at
inserting station 32 is essential.
Referring now again to FIGS.3 and 1A, main computer 50
is interconnected with subsystems and subunits, also
including power supplies, drive motors, pumps and blowers,
sensors, detectors, actuators, display stations, control
stations, and other electrically operated and electrical
signal-generating components either directly of via
subsidiary or intermediate control and supervisory units.
The latter can include microprocessors to automatically
control and supervise the operation of individual units in
preprogrammed manner under the overall control of computer
50. For example, sensing of malfunctions, damaged, defective
or misaligned items, and consequent diversion and rejection
thereof, as well as compensation therefor in subsequent
operation, is automatically handled by main computer 50 in
preprogrammed manner, as the computer tracks inserts and
envelopes individually sequentially and associatively with
their associated complementary counterparts.
Moreover, main computer 50 provides auxiliary system
control functions, such as, for example, automatic start-un
(and shut-down) sequencing of power and particularly of
motor power supplies for reducing power surges and
consumption land noise). In this respect, computer 50
controls selective powering-up of a plurality of pumps f_~a-r
CA 02368036 2002-O1-30
air, vacuum, and water in appropriate sections in accordance
with particular momentary demand, and computer 50 further
controls automatic cycling of pumps, selective shut-down of_
motors consequent to timed inactivities, shut-down of
malfunctioning subsystems, and the like. Individual
malfunction display and reset control stations for
individual inserter modules and other subsystems are located
in the vicinity of corresponding units and are
interconnected with computer 50. Whereas central overriding
control by computer 50 is provided through display/control
console 52, individual local malfunction display and reset
stations are provided in appropriately interlocked manner
for local operator convenience, to localize malfunctions,
and to direct and assure local attention by operators in
case of malfunctions.
In brief recapitulation of the general overall
operation of the in-line rotary inserter device, inserts are
fed from a plurality of inserter modules onto a moving pin
conveyor whereupon one or more inserts are accumulated in~
insert stack packages that are conveyed to an inserting
station. Envelopes are fed to the inserting station, are
inserted therein with insert stack packages, and are
transported farther through sealing and turnover modules.
Sealed and turned-over envelopes are stacked in at least one
accumulator. Prior to being stacked, sealed and turned-c>ver_
envelopes can be conveyed through a postage meter module fox-
appropriate metering (franking).
While the invention has been particularly shown and
described with reference to preferred embodiments thereof,
it will be, understood by those skilled in the art that
various changes and modifications in form and details may be
made therein without departing from the spirit and scope of
the invention.
