Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
1193~95 (
~ITL~ OF THE INVENTION
l!APPARATUS ~D SYSTEM FOR PRE~ARING
~ATA CARDS AND M~LER FORMS AND FOR
LATTACHING DATA CARD; TO RESPECTIV~LY
~SSOCIATED ~$P.IIER ~ORMS.
3ACKGROUND OF THE INVENTION
Field of the_Invention
This invention relates to a system for automatically attachlng¦
data cards to respectively associated mailer forms and especially
to a system which receives information ~rom a common data source
for embossing and/or encoding a mag~etic stripe on the data cards
and for printing the mailer forms with corresponding information.
The system controls the subsec~ent processing and handling of
cards and forms to assure ~hat the cards are attached to their
properly corresponding, respectively associated for~s.
Descr~ption of the Prior Art
. .. ..
There exist, 1~ the prior art, system-~ for automati~:ally
matching embossed data cards with pre-printed mailer forms and for
attaching the da~a cards to their matching, respectively associatec
pre-printed mailer forms. One such prior art system is manu-
factured and sold under the trademark "DATA-MATC~" by Data Card
Corporation, assignee of the present application, and affords
highly reliable, high speed operation. The system includes an
optical character reader for rezding the pre-printed forms and an ¦
embossed character reader (ECR) or a mzynetic stripe reader or
reading data correspondingly embossed or encoded on the data cardO
The ~wo sets of data thus read are then compared to verify that a
match exists. When the re~uisite nu~ber of corre~tly matched
cards for a given form is available, they are simultaneously
attached to that formO
" ll C ~ ~932~ (
~ ~ ,
Prior axt systems of the type of the ~DATA- ~TCH~ inserter
are desisned to function as in~ependent systems, implying that
separate apparatus is employed .o emboss/encoae the credi~ cards
and to print the mailers, prior ~o the supply of the mailer forms
and data cards to the DATA-MATC~ inserter. These independen~
opera,ions introduce the potential of errors particulaxly as to
j mis-matching of cards and forms~ For example, if a card is lost
or if cards are out of sequence in the supply thereof relative to ¦
¦the corresponding ~equence of the pre-prin~ed mailer forms, a mis-¦
match error will be detected by the sys~em; moreover, if any
mailer form is printed imperfectly such that it is not readable by
. the DATA-MA~C~ inserter or is incorrectly xead, or should other
defects exist whether in reading or transporting the form, an
. error condition will occur. ~he DATA-MATC~ inserter pexmits
operator intervention ~o correct for the circumstance of an
erroneous machine detec~ion of a mis-match condition (e.gO, ~ form
is correct but has been misxead by the system resulting in an
erroneous mismatch error condition). ~owever, where either the
foxm or a required card therefor is in fact defectiYe, or a card i~ ;
missing, there is no recovery capability in the sense that the
imperfect form and any associated cards must be rejected, sinc~
replacements are not readily a~ailable~
There is therefore a need in the industry for a system which
automates the totality of involved runctions, n~mely the embossing
and/or encoding of the data cards as well as the printing of the
foxms and the attachment of the appropriate nu~ber of co~rectly
matching cards to the respectively associated forms. Moreover, I
i there is a need in the industxy for a sys~em which permits
~¦ recovery of operations when an error condition occurs. By ~ay of
example, in a system whlch combines and automztes all OL the
--2~
requisite functions as above described, reprinting of
defective forms or re-embossing of defective cards can be
achieved such -that, means normal automated processing
results in rejects of either forms or cards, the system
can print substitute or replacement forms or produce
substitute or replacement cardst as required, such tha~
at the end of a run, all cards and forms have been
successfully gen~rated and assembled. There is also a
need for a low-cost such system, suitable for use by low-
volume issuers of credit cards and thus one which, while
not having the speed of operation of the DATA-MATCH
inserter, nevertheless is available in a less complex
3 mechanism and at lower cost for such lower-volume card
issuers.
SUMM~RY OF THE INVENTION
An object of an aspect of the present inven-
tion is to provide a system for the attachment of data
cards to mailer forms which overcomes the deficiencies
of prior art systems.
In particular, it is an object of an aspec-t
of the present invention to provide a system for the
attachment of the correct number of data cards to
properly matching mailer forms, but which does not
require reading of data from either ~he cards or forms,
or comparison of the data ~or verification that there
is a match hetween the data of a particular data card
and its corresponding mailer form.
An object of an aspect of this invention is
to provide a system wherein up to two data cards are
~a3~
held in position while a mailer form, haviny predetermined
slots of slanted divergent configuration, passes thereby
and is flexed to pick up, within the slots, the respectiYe
ends of the data cards and thereby retain them with the
mailer form.
An object of an aspect of this invention is to
provide electronic circuitry for controlling the placement
of identifying information on respective data cards and
for employing corresponding identifying information,
provided by a common data source, to print or otherwise
provide desired information on a mailer form which will
be associated with the corresponding data cards. The
apparatus is always subject to operator intervention,
wherein an operator responds to an error signal and takes
steps to correct the cause of the error.
Various aspects of the invention are as follows:
A system for attaching data cards authorized
to be issued for predetermined accounts and coded with
predetermined card account information, ~o respectively
associated carrier forms having corresponding predetermined
form account information printed thereon, said system
including means for operative connection to a co~non
data ba~e containing the account information for both
the cards and the forms for a plurality of accounts,
and comprising:
coding means for supplying predetermined card
account information and predetermined form account
information, said coding means including means for
deriving the predetermined card account information and
the predetermined form account information from the
common data base and means for coding the predetermined
--4--
~ ~33~
card account information, for a given account, on first
and second blank data cards;
means for supplying blank carrier forms in
individual succession;
printing means~ operatively connected to said
coding means, for receiving the predetermined form account
information for the given account and for printing the
predetermined form account information for the given
account on one of the blank carrier forms in timed relation-
ship synchronized with the coding of the predetermined
card account information for the given account on the
first and second blank data cards;
a card attachment station;
means for transporting the coded first and
second data cards from said coding means to said card
a-ttachment station; and
means for transporting the printed one of the
carrier forms to said card attachment station in timed
relationship synchronized with the transport of the coded
first and second data cards to said card attachment station;
said card attachment station including means
~or receiving and releasabl~ holding the irst and second
coded data cards in a desired pickup positiont and means
for attaching the first and second coded data cards for
the given account to the corresponding printed one of
the carrier forms.
A system for attaching data cards authorized
to be issued for predetermined accounts and coded with
predetermined card account information, to respectively
associated carrier forms havi.ng predetermined form account
information printed thereon, comprising:
means for supplying identifying information
-4a-
~93~5
i.n synchronized timed relationship for each of a plurality
of accounts, said identifying information including predet-
ermined card account informakion and a print signal including
number of cards per form data and predetermined form
account information, said number of cards per form data
indicating the required number of data cards to be
attached to a respectively associated carrier form for
a gi~en account;
coding means for receiving the predetermined
card account information from said means for supplying
identifying informat:ion and for coding the predetermined
card account information on the data cards;
a card attachment station;
means for transporting in succession, the coded
5 data cards to said card attachment station;
electronic control means, operatively connected
to said means for supplying identifying informa-tion,
for receiving the print signal, for providing, as an
output, the predetermined form account information, and
~0 for sending a second card request signal ~o said coding
means, in dependence upon the number of cards per form
data, after a first of the coded data cards for a given
account is received a.t said transporting means;
means for supplying blan~ carrier forms in
5 individual succession;
means, operatively connected to said electronic
con~rol means, for receiving the predetermined form account
information from said electronic control means and for
printing, on one of the blank carrier forms, the
predetermined ~orm account information corresponding
to the predetermined card account information coded on
the da~a cards for ~he given account, said printlng
-~h~
3~
occurring in timed relationship synchronized with the
coding of the predetermined card account information
on the data cards by said coding means; and
means for transporting the printed one of the
carrier forms past said card attachment station after
the transport of the coded data cards for the gi~en
account to said card attachment station;
said card attachment station comprising means
for receiving and releasably holding the coded data cards
for the given account and means for attaching the coded
data cards to the respectively associated printed carrier
form for the given account;
said coding means including means for generating
an error signal if the print signal is being generated
when the second card req~lest signal is received by said
coding means.
The system and apparatus of the present
invention have a number of novel features, as set forth
below. A data card is embossed, encoded, prin-ted, or
otherwise formed and is then fedt ~or example, by a con-
veyor belt transport mechanism, to a card transfer and
pickup station. If more than one data card is to be
attached to a particular mailer form then the second data
card is embossed, encoded, printed, or other~ise formed
and is then fed to the card transfer and pickup stationO
When the required number of data cards reaches the trans-
fer and pickup station, the card(s) are moved transversely
so as to be placed in a position for insertion on a mailer
form.
In timed relationship to the card processing
and transporting functions, serially connected~ blank
-4c-
~32~i
mailer forms are fed from a form supply by a paper drive
system, past a printer station and -to the pickup or
insertion station Print data from the data card indicia
or code forming apparatus is fed to the printer station
for printing information on the mailer form correspond- -
ing to the information which is used to form the partic-
ular data card or cards. For example, a particular data
card may be embossed with the name and account number of
an individual li.e., the account holder); in timed rela-
tionship, corresponding infoxmation, which may include
the account holder's name and address, is printed
-4d-
~ ~ ~ 3 ~
on a mailer form currently positioned at a print station.
The mailer form is then fed to the data card pickup station
to pick up the card(s).
For this purpose~ each individual mailer is provided
with two se-ts of dive~gent slots spaced to receive the ends
of two corresponding data cards held at the pickup station.
As the mailer form approaches the pickup station, spring
fingers deflect portions of the mailer form adjacent the
divergent slots, thereby opening the slots. As the printed
mailer form moves past the held data cards, the respective
ends of each data card are received within the opened,
divergent slots, and when the remote ends of the divergent
slots engage the lower edge of each card, the form picks up
the cards and remo~es them from the card pickup station.
As the printed mailer form is picking up the cards,
the succeeding mailer form is being transported toward the
form printing station. Transport of the forms continues
until the succeeding form is at the print station. At that
time, the hurst line (i.e., a pre-perforated line) delinea-
~ 20 ting the trailing edge of the printed form containing
.~
caxds and the succeeding, blank form currently at the
print station, is positioned at a burster station. During
this time, the card~carrying mailer form is checked by a
detection device positioned a predetermined distance past
the card pickup station to determine if the proper number
of cards are attached to the mailer form. At the burs-~er
station, the mailer forms are te~sioned and gripped and
a bursting bar is moved trans~ersely of the plane o~ the
forms to burst~ or se~er, the mailer forms alon~ the burs-t
line. ~e burst~ card~carrying mailer form then is advan
ced in~o a folder mechanism.
In the folder mechanism~ the form is folded. If-the
~ 3~
etection device determined that a particular mailer form does
;not have the correct number of data cards associated there-~ith,
the defective1y ~illed mailer form will be automatically rejected
¦from the folder in~o a 'orm reject area. ~.ssuming the required
~umber of cards has been picked up by the form, the card-filled
and folded mailer form is then fed to an output stacker. An
operator can then remove the folded mailer LOr~.S ror stuffing into
mailing envelopes; optionally, an envelope stuffing machine may ~e
attached to receive the folded mailer forms and automatic~lly stuf,
the folded mailer forms into mailing envelopes.
In an optimum embodiment of the present invention, semi-
automa~ic error recovery is performed. I an error signal is
generated (or example,-because O~r a card jam, a form jam or a
missing second card), the operator may clear the system of all
cards and forms and rewind the data ~ape to the position where
the error has occurred. The operator may then restart the auto-
matic processing of the systemO In this manner, once a particul~r
tape run is finished, all of the data cards are attached to their
corresponding mailer forms and no ~urther processing (Lor example,
manually generating cards or forms in which the errors have been
ound) is necessary.
The system and apparatus of the present invention have
signiicant advantages over the prior art in that no sep~rate
equipment is required for form printing, no readers for either
lorms or cards are required, and the complexity or the system is
substantially reduced, making machine operation and error recovery
simple.
These together with other objects ~nd adv2nt2ges, which will
become subsequently apparent, reside in the details of constru~.io~
and operation as more fully herelnafter described and claimed,
1.
1193ZO'-
~eference being had to the accompanying drzwings forming z pzrt
hereof, wherein like numerals refer to like parts throushouk.
~RIEF DESCRIPTION OF THE DRA~INGS
Figure 1 is a perspective view or the overall system of the
~resent invention;
Figure 2 is a left side eleva~ional view depicting, in block
format, the bzsic components comprising the printer, burster,
older and card pickup stations;
Figure 3 is a top plan view of ~he data card transpor~
~echanism, card diver~er structure, and card pickup station; .
~ igure 4 is a rear elevational view of the structure of
Figuxe 3;
Figure 5 is a side elevational view, partly in cross-section,
taken generally along lines 5-5 o ~igure 3 showing the card
pickup station;
Figure 6 is a view similar to Figure 5, showing the relati~e
positioning of the mailing form and data card just prior to
attachment of the data card on the form;
Figure 7 is a fra~mentary portion of a cross-sec~ional view
taken generally along lines 7-7 of Figure 5i
~ igure 8 is a perspective ~iew of the data card retention
structure of the card pickup station;
Figure 9 is a perspective view of the divergent slot configu- ¦
ration of an individual mailer rorm, the slot opening spring-
biased finger structure, and two data cards,in position re.ady for
,pickup thereby;
l Figure 10 is a perspective view of a fragmentary portion of a
mailer form containing two data cards;
Il .
'I .
,; .
l l (
3Z95ii
Fisure 11 is a perspective view of ~he clu~cn drive mechanis~.
for driving ~he form output feed rcllers znd .he folder inpu~
rollers
~ igure 12 is a top plan view of the _o-m burster s~ructure in
a normal, rest position;
Figure 13 is a top plan ~iew of the form burster structure in
an advanced, activated position;
Figure 14 is a left side elevational view of the form burster ¦
struc~ure, partly in cross-section, take~ generally along lines
14-14 of Figure 12;
Fig~ire 15 is a left side elevational view OL the fonm burster
structure, partly in cross-section, taken generally along lines
15-15 of Figure 13;
Figure.16 is a block diagram illustrating the electro~ic
control circuitry 30 of Figure 2 and other related circuitry;
Figures 17A-17D comprise a flow chart illustrating the oper-
ation of the system of the present inventioni and
Figure 18 illustrates the Lormat of the data on the magnetic
tape which may be employed as the common data source in the
present invention.
D SCRIPTION OF T~E PREFERRED E.~BODIMENT
Figure 1 illustrates the o~7erall system of the present inven-
tionv The form printing and card a,tachment apparatus (or inserter;
of the present invention is identiried by n~meral 20. Apparatus
for encoding and embossing, printing, molding or otherwise forming
thc data cards is indicated, in general, by re'erence numeral 22
(hereinafter, referred to as the embosser/er.coder 22). In the
preferred embodiment, an embossing/encoding machine substan~izlly
corresponding to the Data Card Series 400~ embossing machine is
l!
--8
3~3~ ~
I used, that machine being described in U. S. Pa~ent 4,088,216 the
I disclosure of which is hereby incorporz~ed `~y re~erence. A co.~mon
supply of card account and identifica~ion aata, such as from
magnetic tape, is employed for bo~h the embosser/encoder 22 and
the form printing and card attachment z~paratus 20, as later
described in detail. In the preferred emboaiment, an embosser/
encoder employing a magnetic tape aata input as illustrated in
Figure 10 of the '216 p2tent is employed; however, the tape format
and internal data handling o the embosser/encoder disclosed in ~he
216 patent are modified in accordance with the present invention.
Referring to Figur~! 2, the iorm printing and card attachment
apparatus 20 receives a supply 26 of serially connected, blank
mailer forms 25 and includes printer and paper drive apparatus 28,
and electronic control circuitry 30. A photocell Z7 detects
whether there are any mailer forms present, and a photoceli 29
detects when a given, Ol current,- mailer form 25 is in a "top of
form" position, ready for printins thereon. ~he electronic ccntrol
circuitry 30 receives a~:count identiiication iniormation corres
ponding to that inormat:ion cuxrently employed by the embosser/
encoder 22 for forming 1:he data card for that account, to control
the printer and paper dxive apparatus 28 for printing the corres-
ponding mailer form for those cards. That is, after the first of
a required number of data cards (1 or 2) is formed in embosser/
encoder 22, correspo~ding accoun~ identi,ication information is
transmitted to the electronic control circuitry 30 for use by ~he i
form printing and card attachment apparztus 20.
Figure 18 illustrates the data format on the magnetic ta~e
for a given account. Rlthough many other ~ormats are ?ossible an~
come within the scope of this invention, the form2t of Fig.
~3~
18 is especially well adapted to the processing functions
to be performed by the present system. Particularly, the
requisite data and inEormation for successive forms N-l, N,
N+17...is formatted in serial succession. For a given
Form N, the embosser/encoder 22 receives the EMBOSSIENCODE
DATA as read from the tape and forms a data card with cor-
responding~ embossed and~or encoded identification informa-
tion. This data typically includes at least an account
number or other unique identifying number, and may include
the name and other identification information ~e.g., expi-
ration date) of the card or account holder and the
account itself. The magnetic tape also carries PRINT DATA
which is sent by embosserlencoder 22 to the electronic
control circuitry 30 where it is processed and sent to the
printer and paper drive apparatus 28. The PRINT DATA
includes PRINT CODE data le.g.~ the same account number as
for the EMBOSS~ENCODE DATA and~ typically, not only the
name but also the mailing address for the card or account
holder)~ NU~BER OF CARDsJFoRM data lindicating the number
2~ o~ cards for the particular form)~ and ~INE LOCATION AND
PRINT ~NFORMATION data ~indicating the printing format).
If a second card is to be placed in a particular mailer
form, "CAP~ 2 EMBOSS~ENCODE DATA" will be present on the
tape~ The embosser/encoder 2~ will read the CARD 2 EMBOSS~
ENCODE D~TA and will emboss and~or encode a second card.
If a second card is not needed for a particular form,
"CARD 2 EMBOSS~ENCODE DATA" i5 omitted.
1 0
1~L93Z9~
The zpparatus of this inven,ion prints ,he identification
information on a mailer 'orm after the first o' a required nu~er
of d~ta cards has been emDossed, bu. prior to ,he attacnment of
~any data cards to the associa'ed form. As later described, the
sequence and timing of the transfer o print data to the appzratus
28, ir. relation to embossing/encoding 'unctions, guarantees ,hat
the intended correspondence of the printe~ form and embossed/
encoded cards is achieved. After ~he identification information
has been printed on the mailer ~orm 25 and the desired number o,
cards have been received at the card pickup station 32, the printed
mailer form 25 is transpor~ed past the pickup station, to pick up
the associated cards as previously described. In this manner,
the form printing and card attachment apparatus of the s~~s';em of
the present invention effectively eli.mi~ates the source of errors
encountered in reading and matching operations which are required
in prior axt systems which assemble pre-prin~ed forms and pre
emb~ssed/encoded cards, yet still assures that only the ~roperly
corresponding mail~er forms and da~a cards are assembled.
In the form printing and card attachment apparatus 20, a card
input and pickup station 32 receives the embossed/encoded cards
from the topper ~echa~ism (see Fig. 10 of U. S. Paten, No.
4,088,216) or the embosser/encoder 22 by way of a card transport
mechanism (Fig. 3) and mo~es the cards into position Lor card
pickup ~y ~he associated, printed mailer form 25. The serially
connected mailer forms 25 are fed upwardly 50 that the corres-
ponding printed form 25 proceeds u?wardly past the card input and
pickup station 32 where it engages and picks up the associated
l,ldata cards, removing same from the card pickup station 32~
il The movement of the serially connected form5 25 con~ir,ues
until the burst line delineating between the card-carrying printed
. :
~33~
li .
¦Irom 25 and the succeeding blank form 25 is ?osi~ioned a. burster
¦Istation 34. The succeeding lorm 25 is then a~ the "~op of form"
position, as detected by a signzl from ?hotocell 29. 3urster
Ist2tion 34 separates the card-carrying printed mailer -orm 25 from
the following, serially-connected blank mailer forms 2~ and the
~czrd-c~rryins printed mailer form ~5 is then sent to a folder
station 36.
A pair of photocells 37 detects whether or not the required
number of cards are properly inserted in maller form 25 before the
form 25 is folded. After the card-carrying printed mailer form 25
is folded by the folder station 36, it is fed to an output stac~er
38. A "folder-out" photocell 39 is used to generate a detection
signal indicating that the card-carrying mailer form 25 has exited
folder station 36; so the detection signal is supplied to the
electronic control circuity 30 which thereby monitors tne elapsed
time of travel of the form through the rolder, for jam detection.
An operator then removes the successfully assembled and properly
folded card-carrying mailer forms in a stacked group from stacker
38 for fux~her processing, e.g., stufflng into mailing envelopes
for mailing~to the designated recipients of the cards. In an
alternative embodiment, an automatic envelope stuffer may be
attached to the output OL the form printi~g and card attachment
l apparatus 20 so that the card-carrying printed forms 25 may be
I automatically StUfLed into envelopes. I the photocells 37 detect
¦la defectively filled foxm (e.g., a form containing less than the
~required number of cards or in which the cards are askew) the
latter is rejected, after leaving .he rolder 36, into a form
reject area 40 rather than to stac~er 38.
Referring ~o Figures 3 and 4 of the dr~wings, the card input
and pickup station 3~ will now be described. A pair of data card
~12-
-liL93;Z9~;
transport belts 42 are supported by pulleys 44 and dr,iven by 2
lldrive pulley 46 mounted on the ~rive shaft 48 of a track motor 50.
¦~ card (e.g., as shown at 72) is pushed onto ~he transport belts
142 by solenoid driven arm 33 posltioned a, ~he output of the topper~
~echanism of the embosser/encoder 22 znd is transferred by belts
., 42 in the direction indicated by arrow A in Fiyure 3, in~o the form
printing and card attachment apparatus 20. A photocell 43 de~ects
the pxesence of the card on the transport belts 42 and generates a
de~ection signal. The card is transported on the transport belts
42 until it reaches either a first bin (pocket) 45 or a second bin
(pocket) 47. A rotary solenoid 49 and its attached bracket arm 51
and pinch roller 53 axe actuated in dependence upon whether one or
two data cards are required for a given account, and thus for
attachment to a corresponding mailer form 25. When the bracket
arm 51 is in the position illustrated in solid lines in Figure 3,
the data card will be caught between belts 42 and pinch roller 53
a~d will not drop into bin 45 but will be transported to bin 47.
When the bracket arm 51 is moved to the position indicated b~ the
dotted lines in Figure 3, the data card will drop into bin 45. If
only one card is required the bracket arm 51 is maintained in the
dotted line position, as seen in Fig. 3, so that the single card
will drop into bin 45. Thus, the rotary solenoid 49 is selectively
actuated in dependence upon the nu~ber OL cards required to be
inserted (NUMBER OF CARDS/FORM, ~ig. 18). Photocells 55 and 57
detect the presence of cards in bins ~5 and 47, respectively,
j,and generate detection si~nals. ',
,I Figures 5 and 6 are side elevational views of the apparatus
Il .
for attaching a data card(s) on mailer form 25, in relat~on .o
'Icard bin 45 of the card input and pickup station 32, illustrating
,two different states of operation. As notea above, if only one
-~.3-
1193Z9s
card is recuired this card will drop in the bin 45 znd i~ o aata
cards 72 are requlred, the second data c2rd 72 is dropped into bin
147 ~not shown in Figs. 5 and 6). A slideable ~ransverse plate 52
has fixedly attached thereto a T~sha?ed guice block 54 received
and supported in sliding engagement by a support mount ~6 (~ig.
7). A thrusting apparatus 57, including a rctary solenoid ;8, an
eccentric linkage 60, an extension 64 and a sprins 66, reciprocates
the transverse pla~e 52. Transverse plate 52 includes an upright
. plate portion 68 which cooperates with a corresponding pivotable
cl&mp member 70 (one for each of bins 45 and 47) to releasably
engage data card 72 therebetween. Thus, one or a pair of da~a
cards 72 may be simultaneously held in position at the card pickup
station 32 in the bins 45 and 47. .
¦ As best seen in Figure 8, the pivotable clamp membex 70,
¦having a contact member 78 and a lever 76 with an abutment 76a, is
pivotally mounted by shaft 7Oa to pla~e 52 and biased against the
associated upright plate 68 by ~ coil spring 74 to clamp the card
72 in po~ition (~ig. 6). Pivotable member 70 is~pivoted away from
upright plate 68 to an open positicn, by abutment 76 engaging a
stationary stop 77 (Fig. ~), to receive a data card 72 there-
between. After data card 72 is positioned between upright plate
68 and contact member 78 (Fig. 6), the transverse plate 52 i5
moved toward the left, i.e., in the direction indicated by zrrow B
in Pigure 5, to the position shown in ~igure 6, releasing, or
freeing, lever 76 from stztionary block 77; the coil spring 74
thereupon rotates the pivotal clzmp member 70 and causes the
contact member 78 to grip the data card 72 against the inner
. surface of upright plate 68. When the trznsverse plate 54 com-
pletes its movement to the far left (Fig. 6), the data card 72 (or~
pair of cards) is then ln proper position or pickup by its
-14-
3~
associzted printed mziler form 25. ',
Figure S shows the printed mailer form 25 znd the s2ring
biased fingers 80 which contact and de.lect the form portion
adjacent to the slots to open the slots to a card receiving posi-
tion. An upright guide 82 is provided wi~h slots 84 through which
the spring biased fingers 80 protrude. The spring biased fingers
80, as best seen in Pigure 9, are mounted on a pivot rod 86, which i
is biased by a coil spring 88 so that the fingers 80 are spring
biased to a righ~~most position (clockwise direction), as shown in
Figures 5 and 6.
Relerring to ~igure ~, as each printed mailer form 25 moves
upwardly, the individual spring biased fingers 80 extend through
slots 8-4 in the upright guide 82 to contact and deflect the form
portions 90 adjacent the slots 92 to open the slots 92. The
opened slots 92 receive the lower end corners of the cards 72, and,
as the ~orm 25 continues its'upward travel, the bottoms 95 of the
divergent slots 92 engage the lower, or trailing, edges of the
cards 72, as shown.in Figure 10, removing the data card(s) 72 from
ensagement by the upright plate 68 and contact member 78 (Fig~ 6).
The printed mailer for,m 25, with the data card(s) 72 held thereby,
is theA burst and fed upwardly by rollers 94 and 96 (Fig. 11)
until it is in a position to be gripped by dxiven rollers (driven
through a belt 126 in Fig. 11) in the folder s'ation 36.
Reerring to Figure 11, upper feed rollers 94 and 96 are
mounted upon an idler shaft 98 and a driven shaft 100, respective-
ly. The idler shaft 98 is supported for free rotation in bearings
mounted on support frame members (not shown) while the driven
shalt 100 is sLmilarly suyported in bearings and has a drive
pulley 102 fixed at one end ~hereof. The drive pulley 102 ls i,n
.urn driven by belt 104 and drive pulley 106. Lower feed rollers
~L~93~
108 and 110 are mounted on idler shaft 112 and driven
shaft 114, res,ectively~ A gear 116 is driven by pinion
118 affixed to the output shaft 120 of motor 122. Motor
122 is selectively energized under control of the elec-
tronic control circuit:ry 3U. The driven shaft 10~carries at its opposit:e end from the drive pulley 102, a
drive pulley 124 for clriving a belt 126 which-powers the
folder mechanism of the folding station 36. The folding
station 36 may be of the type disclosed in co-pending
Canadian Patent No. '1"102,605, Donald W. Hewitt et al and
assigned to the assignee of the present application.
~see Figs. 32-36 of Patent No. 1,102,605~.
Figures 12-15 show features of the burster
mechanism of the burster station 34 for separating the
printed mailer form 25 from the serially connected supply
of forms 25. A U-shaped channel member 128 IFig~ 14~
has mounted therein an elongated spring 130 which ~iases
a:..resilient pad 132 to ~he open edge of U-shaped channel
member 128. A complementary member 134 is mounted for
transverse movement on a support plate 136 and is restrain-
ed against such transverse movement by retainer springs
138. When a rotary-electro-solenoid 140 is actuated~ it
moves an arm 142 with a roller 144 thereon to force the
complementary member 134 towards and against the mailer
forms 25 (see Figs. 12 and '15) to engage same against
the U-shaped channe~ member 128 ~Fig. 15).
Once the burst (perforation) line between the
mailer forms 25 is taut,, burster knife 146 is advanced
by linkages 148 actuated by movable plate 150 mounted on
and driven by electro-solenoid 152, to burst an individual
mailer from 25 from the successi~2 serially-connected form.
16
lP932~5
The tangential relationship of the unequal length
linkages 148 causes burster knife 146 to move in a
totally parallel manner. After the bursting action
takes place, both electro-
-].6a-
~L93~95
solenoids 140 and 152 are de-energized to permit sprinys
138 to retract all the elements to their inactive or rest
positions ~Fiy. 12),
Figure 16 is a block diagram illustratiny the inter-
connection between embosser~encoder 22, the motors, printerand electronic control circuitry 30 of the present inven-
tion.
A console 154 includes a display 156 and a control
switch panel 158. The display 156 will indicate various
conditions in the system.~ for example, no paper, jam,
error, no card, etc. The panel 158 includes a CLEAR
) switch, ADVANCE switch, REVERSE~REPRINT switch and ON~OFF
LINE switch.
The CLEAR switch is employed to initialize the
microcomputer network of the ~orm printing and card
attachment apparatus 20. The card transport lor track)
motor 50 is turned on to clear any cards from the transport
belts 42 and a mailer form 25 is then advanced, burst,
folded and discharged into the form reject area ~0.
) 20 The ADVANCE switch is func-tional only when the
inserter is of~ line.. When this switch is actuated to a
first position, a form 25 i.s ad~anced, burst f~lded and
rejected.
The REPRINT switch is functional only when the
inserter is off line. If the switch is in the ~EPRINT
position the inserter wi.ll reprint the previous form 25
and discharge the reprin~ed form 25 in the form rejec1-
area 40~
~193Z95
The ON/OFF LINE switch is used to selec, the ON LII~E or OF~
IIILINE status of the inserter. Af~er the system has genera.ed zn
error message, actuation of this switc~ clears the error.
In zn optimum e~bodiment, an additional RER~ switch 16; is
connected to CPU circuitry 162 and the embosser/encoder 22. Ac~,u-
ation of the RERUN switch provides for semiautomatic error
ecovery as described in the operation section below.
The electronic control circuitry 30 lncludes the central
processing unit circuitry 162, input/output (I/O) interface
circuitry 164, sensor interface circuitry 166, stepper motor
driver circuitry 168 and solenoid driver circuitry 170.
The rPU circuitry 162 includes a central processing unit
(CPU), programmable peripheral in~erfaces, an erasable programmable
read-only memory (E~ROM) and a random access memory (RP*l). The
EPROM contains the instructions o the system program which the
CPU follows to initiate and control all operations. The R~M
provides the CPU with the capacity to store and retrieve data and
instructions. In à preferred embodiment, the CPU i5 an 8-bit
¦microprocessor and the EPROM comprises our 2~ x 8 EPROM chips.
The input/output interîace circuitry 164 functions as an
interrace between the CPU and the embosser/encoder 22 and solenoid
driver ci.rcuitry 170. It should be noted that embosser/encoder 22
has its own CPU for controlling the embossing operation. The
input/output (I/O) interface circuitry 164 also contains a program-
ma~le timer/counter used to generate car~ check and stepper motor
interrupts.
The sensor interface circuitry 166 inter aces the CPU with
various photocells and switches in the system. The "Paper" input
to sensor interface circuitry 166 is connected ~o photocell 27
(Fig. 2). The "~opper Full" input to interLace circuilry 166 may-
"
.
-18-
~.19329~
be connected to a microswitch (not shown) for detectins when the
output stacker 38 is full. ~he ~TOF" input to ser.sor in~erface
circuitry 166 is connected to the top-of-fo~m pnotocell 29 (Pis.
2). The "Card In" input to sensor inter~ace circuitry 166 is
connected .o track photocell 43 (Fig. 3). The "Card In ~in 1"
input to sensor interface circuitry 166 is connected to the bin 1
photocell 55 (Fig. ~). The "Card In Bin 2" input to sensor inter-
face circuitry 166 is connected to the ~in 2 photocell 57 (~ig.
4). The "Right Card In Form" input to sensor interface 166 is
connected to one of the pair of photocells 37 (Fi~. 5). The "Left
Card In Form" input to sensor interface 166 is connected to the
other of the pair of photocells 37 (not shown in the drawings).
The "Folder Out" lnput to sensor interface circuitry 166 is con-
nected to photocell 39 (Fig. 2). The remaining two inputs to
sensor interface circuitry 166 ("Envelope Switch" and 'IStuffer
Out") are activated in an optional embodiment of the inserter of
the present inventlon i~ which an envelope stuffer 173 is connected
to the output o the inserter. The "Envelope Switch" input is a
signal indicating whetner or not the envelope stuffer 173 is
attached to the system and the "Stuffer Out" input is a signal
indicating the output of an envelope from the Stuffer 173.
The stepper motor drive circuitry 168 is connected to the CPU ¦
and the stepper motor 172 for energizing the windings of the
stepper motor 172 either indi-~idually or in pairs ~o advance .:ne
rotor o~ the stepper motor 172 through its 8-step cycle.
The solenoid driver circuitry 170 includes transistor drivers
174 and 176 for drivins the solenoids and the print wires of
printer 178, respectively. The transistar arivers 174 are used to
drive the various solenoids in the inserter system and have the
Collowing outputs: Card Transfer, Insert, Clam?, Kni~e, Rejec,
and Forms Counter.
~32~
The "Card Transfer" ou~put is connected ~o rotary solenoid 49
(Fig. 3). The "Insert~ output is connected to rotary solenoid 58
(Fig. 5). The ~Clamp~ output is connected to rot~ry solenoid 1~0
(Fig. 12~. The ~'Knife~ output is connected to rotary solenold 152
(Fig. 12). The ~Reject~' ou~put is connected to a rot~xy solenoid
(not shown) for controlling the actuation of ~he form reject
mechanism. The "Forms Counter" output is an o~tional output which
may be connected to a solenoid (not shown~ used in co~nting the
number of forms.
The printer 178, which is a part or printer and paper drive
apparatus 28, is a standard matrix wirehead printer. The prin~-
head is driven by an AC synchronous motor which also drives
ratchet mechanisms for advancins the print ribbon. The CPU
controls the print motor and provides wire control words to Lhe
printhead through transistor drivers 176 in order to actuate the
desired cumbination o wires. A printer control signal from the
CPU includes a ribbon advance signal, printhead forward ~ignal and
printhead reverse signal, provided through switches 180, 182 and
lB4, respecti~ely, for driving th~ printhead to print several
lines of indicia~
Figures 17A-17D comprise a rlow chart illustrating ~he sort-
ware for the system of the present invention.
Referring to Figure 17A, after the system is turned on and
initialized, the CPU determines whether or not a run request
exists (RUN REQUEST). If no run request is present then the
transport motor 50 is turned off (TURN XPORT MOTCR O~F) and the
CPU determines whether a console request is present (CO~SOL~
REQUEST). If a run request is present then ~he run moGe is begun
(RUN).
, 1, , .
-20~
I ~i932~
I
In the run mode, the CPU first detenmines ~he~her .he emboscer'~
encoder 22 is set up for embossing operations (EM~ PP~ESENT~. If
~the embosser/encoder 22 is not -o be used 'or e~.~ossing, ~hen the
stand alone mode is entered (SET U~ PRINT ~D LIN~ LOC DAT~ POR
STAND ALONE MODE). If, as is the usuzl case, the embosser/e~coder
22 is to be usPd for embossing, then the CPU determines whether
the e~bosser/encoder 22 is ready (E.MB REP~Y). I' the embosser/
encoder 22 is ready then 2 d~ta request is sent to the embosser/
encoder 22 (SEND DATA ~EQU~ST TO E~ ext, the CPU again deter-
mines whether the embosser/encoder 22 is ready (EMB R~ADY) and, if
it is, then a data type byte is fetched ~rom the embosser~encoder
22 (FETCH DATA TYPE BYTE FROM EMB~. After the data type byte has
been ~etched, the CPU determines whether the data is print type
data (PRINT DATA). If it is print type data, then the system goes
into a read mode of operation (READ). If it is not print type
data, then the CP~ de~ermines whether it is line location data
(LL ! DATA) or a malxltenance request (MAINT REQ) and processes the
data accordingly.
Referring to ~igure 17B, in the read mode of operation, the
CPU determines whether the data is ready to be read (CHAR READY)
and, if i~ is, then data is fetched from ~he embosser/encoder 22
for reading (FETC~ CHAR ~ROM EMB). If the characters are ~roperly ¦
read they are stored in memory (CHPR OK and STO~E C~AR). I' thexe ¦
is an error (E~ROR),.the data is reread. At the end o~ a block of
data, an end code is received ~.N~ CODE) and the CPU then.deter-
ines whether the embosser/ encoder 22 is re2dy to proceed (EM~
READY). Arter the data has been chec~ed (FETCH CHECX SUM C~AR
FROM EMB and CHECK SUM OK), the CPU determines whether it is print
data or line location data (DATA TYPE), a~d the data ls processed
accordingly (PROCESS LINE ~OC DATA AND SET PLP ACTIVE 2nd PRO OE SS
PRINT DATA AND SET PRT ACT).
.,
-21~
1 ~93~
A- er the print data and line loca~ion Ga,a have been pro-
cessed, the transport motor 50 is turnea on (~PORT ~lOTOR GN) and
the system is pl2ced in the transDort and print cycle mode o~
operation (XPC).
Referring to Figure 17C, in the transport and print mode,
the CPU first determines i it hzs sent a czrd received s~atus
signal to the embosser/encoder 22 (SEND C~D ~CVD STATUS TO E2~).
If the signal has been sent, ~hen the CPU sends 2 send card request
status signal to the embosser/encoder 22 (SE~D CARD REQUEST STATUS
TO EMB) and a card is transported down the track (C~L XPORT
TRA~SPORT CAR3DOWN TRACK & P~ACE). If no card 72 is received, the
CPU then determines whether there are any cards 72 left in the
e~bosser/encoder 22 ~CARDS LEFT = 0). If no cards 72 are left in
the embosser/encsder 22, then the system ceases to inquire as to
card status. If there are cards 72 left in the embosser/encoder
22, the CPU determines wnether a card request has been sent to the
embosser/encoder 2~. (SEND CP~D REQUEST TO E~). If a card request
has been sent, the CPU de~ermines whether the embosser/encoder 22
has an available card 72 tEMB HAS CARD AV~IL). If a card 72 is
available, then the card request status signal is sent to the
embo~ser/encoder 22 (SEND CARD REQUEST STA~ TO EMB). If no czrd
72 is available, then a request to transfer cards down ~he track
is made (CALL XPORT TRANSPORT CARD DO~ TR~CK & PLACE). If no
c~rd request has been sent to the embosser/encoder 22, then the
CPU determines whether there is a card 72 at the track entry
photocell 43 (CARD AT TRACK ENTRY PHOTOCELD). If there is no card¦
72 at the ~rack, then the .ransport mechanism is called. I there
is a card 72 at the track entry photocell 43, then a requested
card received status signal is sent to the embosser/encoder 22
(ACTIVATE REQ CARD RCVD STAT TO BE SENT TO E.~) and the trans~or.
mechGrlism is again called.
--:~2 -
~1~33Z9~i
Once the transport has been called, or ir the trznsport has
not been called (for example, i~ there are no cards leC,)~ .he CPu
then determ~nes whether the print buffe~ is active [PRT ~U~FER
jlACTI~). If the print bufrer is acti~, then printing is begun
(CALL PRINT MAINTAIN PRINTING). If the print bufer is not active,l
then the CPU determines whether there are any cards 72 leCt (CARDS I
L FT = 0). If there are no cards 72 left, then the CPU determines ¦
whether the last card received status signal has ~een sent to the
embosser/encoder 22 (LAST CARD RCVD ST~T SENT TO ~M3). If this
signal has been sent, then the transport and print cycle is
completed (SET XPC DONE). If there are cards left or if the last
card received status signal has not been sent to the embosser/
encoder 22, then the CPU determines whether the transport and
¦print cycle has been completed (XPC DON~). If the printing cycle
¦has not been completed, then the system is recycled back to the
¦beginnlng o the transpor~ and print cycle mode.
¦ Referring ~o Figure 17D, if the printing cycle hzs been
¦completed, then th`e insert cycle mode of operation is begun (CYC~E
I~. A delay operation totalling a delay of 500 milliseconds is
conducted to steady the form (DELAY 500 ms). Next, the insert
control operation is called (C~IL IC INSERT CONTROL) and the mailer
form 25 is transported to pick up the cards 72. Transport of the
forms 25 is halted when the succeeding form 25 is at the top o'
form position (CAL~ STOF MOVE FORM TO NEXT FOR~), and the bursting
operation is called (C~LL BC 3URST FO~) to burst the completec
mailer form 25. Next the folder operation is called (CALL FOLDER
FOI,D FORM A~D STACK OR STUFF) and the completed form is Colded and
stacked or optionally stuffed into an envelope. The system is
then checked for errors. If there are no errors, then the CPU
determines whether the stacker hopper 38 is lull ~STAC~ER ~OPPER
,
,,
~23-
i
L93
FU~L) and, if the stac~er hopper 38 is no. full, tne sys_em goes
~into the run mode of operaticn again (R~). If the s~ac.~er ho2per
38 is .full, then a full message is di.splayed on display ~anel 156
(DISPI.AY FU~L MSG).
The operation of the system is as follows. Once the form
printing and card attachment apparatus 20 and the ernbosser/encoder
22 have been turned on, the CPU circuitry 162 activa~es the AC
transport drive motor (track motor 50) when it has active print
data and print line position codes from the embosser/encoder 22.
Alster a card is topped (the raised characters are coatedl the
solenoid driven arm 33 pushes the data card 72 onto the transport
belts 42. Three photocells (photocells ~3, 55 and 57) monitor the
successive positions o~ the card 72 while it is transported. When
the card 72 passes photocell 43 (Fig. 3) the CPU activates a
software t~mer and sends an acknowledgment signal to the embosser/
encoder 22 to indicate that the card 72 has been received. It
should be recalled xecalled that embosser/encoder 22 has its own
CPU (and associated memory, etc.) for cornmunicating with the CPU
circuitry 162 of the inserter system 20. If the embosser/encoder
CPU does not receive this acknowledgment signal within a preset
time interval, it halts system operatipn and displays an error
messzge on the em~ossex console (not shown). The software timer
activate~ by the CPU ~ircuitry 162 is used to insure that the card
travels the distance between pho.ocell 43 and the photocell 55
(mounted over the first bin 45) in a predete.rmined length oS
time. When the card 72 reaches photocell 55, the timer is dis-
cbled (Fig. 4).
A setting desisnat.ing the ra.io of cards per mailer fo~n
(NU~'~ER O~ CARDS/~O~M data, Fig. 18) determines whe.her .he iirst
¦Icaxd 72 drops in bin 45 or continues on to hin 47. Ir the ratio
.
-2~-
~ 3~
ecuals 1, the card 72 Ialls into bin 45 anG trzr.s?ort is comDlele.
If ,he r2tio equals 2, rotary solenoid ~9 is energized znd Dinch
roller 53 srips the card asainst the trans?ort belts 42, thereby
~reventing it from falling into bin 4~. The card 72 acco.Glngly
is transported to bin 47. A so,tware timex is asain em~loyed .o
insure that the card 72 travels the distance from phot~cell 55 to
photocell 57 within a predetermined time interval. ~hen the
second card reaches bin 45, the rotary solenoid 49 is not energized
so that the second card 72 drops into bin 45 (~ig. 4~.
When the lorm printing znd card attachment apparatus 20 is
ready to process a form and cards, it sends a request for a czrd
and PRINT DATA to the embosser/encoder 22. If a particular mailer
form 25 requires two cards 72, the CPU circuitry 162, upon receipt
of the ~irst card 72, sends a request for a second card to the
embosser/encoder 22. I~ the second card 72 is available, the
embosser/encoder 22 sends the second card 72 twhich has already
been embossed by this time) to the form printing and card attach- ¦
ment apparatus 20. ~owever, if the embosser/encoder 22 is holding
a card 72 and PRINT DATA (i.e./ it is data for the succeeding
mailer form 25), the CPU for the embosser/encoder 22 detects an
error (i.e., the proper second card 72 for the present form is
missing); the system thereupon is shu, ao~m ~nd an error mess2ge
is displayed on the embosser console (not shcwn). It is then
~ecessary ror the operator to clear the inserter by actu2ting ,he
,CLEAR switch. This causes the prln,ed form 25 to pick up the
',!Lirst card 72, and the form 25 (carryiny only the first of two
,required cards) is folded and rejected into the form reject area
40. Prior to the generation of the error message, the card for
~t:~e next form has already been embossed and rema~ns in e~bosser/
encoder 22. The operator may actuate the ON LINE swl,ch to restart
the system.
-25-
(
~ ~Lg~
¦I Tn an optimum e~odiment, upon noting an error ressage, tbe
o?er2tor may ac-ua.e the RERUN switch 165 .o re,ect all for~s
remaining in the Lorm printing znd card attachment appara~us 20
I,and zll cards remaining in the em~osser/encoder 220 The zctuation
1I~ OL the RERUN switch 165 also sends a signal LO the em~osser/encode~
22 .o cause the e~bosser/encoder 22 to reverse the magnetic tape
(~is. 18) to the data portion where the error sisn21 was yeneratec
znd restart the system. In this manner, once an entire magnetic
tzpe has been processed by ~he system of the present inven ion,
there are no indi~idually defective forms or cards which need to
be corrected.
The LOrm printing and card attachment CPU also monitors the
photocells 5~ and 57 to insure that the cards 72 drop into the
bins properly. If a card jams or hanss up at any point during
transport or in dropping into one of bins 45 and 47, the entire
system is halted and a card error message appears on the display
156. Similarly, if a form 25 jams, an error signal is generated.
The operator will then manually clear the jammed form and may
reprint the jammed form by actuating the REPRINT switch which
causes a reprinted form to be burst and fed to the form reject
area 40. The operator then takes the cards out of the jammed form
z~d places them in the xeprinted form. The system is then re-
star.ed by actuating the ON LINE switch~
Il The printer 178 receives identiication inLormation from the
¦¦storage device (e.g., magnetic tape) in the embosser/encoder 22 by
way of CPU circuitry 162 and prints indicia on the mailer form 25
zs the card 72 (the first card, if two cards zre required) is bein~
.ransported to the czrd attachment mechanism. As mentioned above,
,he prinLer 178 comprises a stzndard matrix printer, .or exzmple,
a 5 x 7 dot mztrix pri~ter. The paper photocell 27 detects whether
-26-
Il ~.193;Z95
or no~ .here is another mailer fxom 25 in the form prin~ing ana
card att2chment apparatus 20. ~he "to? Oc for~" photocell 29
checks for a "top of form~ hole in the mailer form 25 because ~he
mailer form 25 must be a~ the "top of form" position when ?rintins
begins.
ACter printing is completed and the card(s) is loaded in~o
,he bin(s) 45 (and 47), the CPU causes .he stepper mo_or 172 to
advance ~he mailer from to a pre-inser. position. In Lhis position~
.he lower edge of the mailer form 25 is approximately l/2 inch
¦below the printhead, and the divergent slots 92 in the mailer form ¦
125 axe just below the level of the card(s) 72. q'he CPU 162 then
¦energizes rotary solenoid 58, thereby czusing upright plate 68 to
¦be moved ayainst mailer form 25 so that the spring biase~ fingers
¦80 open the s1ots 92 in the mailer form 25. After a 200 milli-
¦second delay the CPU activates the stepper motor 172 to advance
,he succeeding (blank) mailer form to the top of form position, 25
monitore~ by photocell 29. As the printed mailer form 25 advances,
¦the card(s) 72 is (are) received in the opposite ends thereof in
¦the corresponding slots 92 of the mailer form 25.
¦ When the succeeding mailer form 25 reaches the ~top of form~
¦position, following the pickup of the card(s) 72, the card-carrying
printed mailer form is ready to be separated from the remaining
serially connected mailer forms 25. First, the C~U sets a 50
~millisecond delay to allow the mailer forms 25 to stabilize.
IIINext, rotary solenoid 140 (Fig. 12) is energized to secure the
- burst line between the card carrying, printed mailer form and the
!' succeecing blank mailer form 25 against U-shaped channel member
128. After a lO0 millisecond delay, the CPU energizes rotary
solenoid 152, thereby driving burster knife 146 Cor~ard to sepa-
rate the mailer forms 25 along the burst line. Then the CPU
-27~
1 -~.193Z~ii
,
li de-energizes rotary solenoids 190 and 1~2 a~d sets a 50
millisecond delay to allow burster knife 146 and roller 144
Il to re~ract.
¦l Af ,er the card-carrying ~rinted maller f~r~ 25 has bGen
burs~, lt is then trans~orted through folaer station 36
where it is folded along pre-formed old lines.
From folder station 36, the card-carrying printed
mailer form 25 is fed to output'stacker 38. Alternatively,
the mailer form 25 may be fed to an envelope stuf~er 173.
Ater turning on folder motor 122, the CPU checks to
see if the cards 7~ are properly inserted in the mailer form
25. A card 72 is properly inserted if the hole 93 at the
bottom of the card receiving area of the mailer form 25 is
approximately 2/3 covered. Using timers, the CPU checks to
see if the photocells 37 sense light for the proper lencth of
time as the mailer form 25 travels past them. If a card 72
is not inserted far enough, or if it totally covers hole 93,
the CPU circuitry.162 detects the error and energizes a
reject solenoid (not shown) so that the mailer form 25 is
outputted in the form reject area 40. An error messaqe then
appears on inserter display 156 and system o~eration is .
halted. The CPU circuitry 162 also checks to see if mailer
rorm 25 remains in the folder station 36 less than two
seconds by monitoring photocells 37 and 39. ~hen an acceptable
mailer form 25 clears photocell 39, a forms counter (not
shown) is incremented. The stacker station 38 has an AC
drive motor 186 which is activated simultaneously with the
activation of folder motor 122. If the CPU circuit~y 162
detects any errors in the mailer form at any ,ime in the
~ insertion cycle, then the reject solenoid is activated and
i the form is rejected into the form reject area 40.
-28-
~ ~ 93295
The system of the present in~ention may be
implemented in numerous ways. The data cards may be
coded in any suitable manner7 for example~ by emboss-
ing, printing or encoding a magnetic stripe carried
by the data cards. Similarly, the carrier forms may
be marked in any suitable manner, for examplet by
printing or coding the carrier forms. In addition,
although for convenience the system has been shown to
accommodate eithex 1 or 2 cards, it readily can accom-
modate 3 or 4 cards per form. In the latter instance~the CPU circuitry 162~ upon receipt of the second card,
sends a request for the card to the embosser/encoder 22.
Thusy the 3rd and 4t~ cards are processed in the same
manner as the irst and second cards~
The many features and advantages of the inven-
tion are apparent from the detailed sepecification and
thus it is intended by the appended claims to cover all
such features and advantages of the system which fall
within the true spirit and scope of the invention.
Further, since numerous modifications and changes will
readily occur to those s~illed in the art7 it is not
desired to limit the in~ention to the e~act construc-
tion and operation shown and described, and accordingly
all suitable modifications and equivalents may be
resorted to, falling within the scope of the invention,
-29-
