Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02368032 2003-03-04
1
ON-EDGE STALKER
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 :o apparatus and method for
handling high volume mail and, in particular, it relates to
in-line rotary inserter devices having a pl.ural.ity 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
r r
CA 02368032 2002-O1-30
2
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
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 a 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.
r 1.
CA 02368032 2002-O1-30
2a
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 an on-edge stacker for stacking envelopes,
comprising: means for receiving and transporting envelopes;
means including a conveyor belt for accumulating envelopes;
means for stacking and delivering envelopes to said means for
accumulating; and means for diverting envelopes received by
said means for receiving and transporting, said means for
diverting being operative in diverting envelopes to said
means for stacking; wherein said means for receiving and
transporting comprises an upper level including means for
conveying envelopes therealong; and wherein said means for
stacking and delivering comprises stacking spider means for
capturing diverted envelopes delivered thereto and for
delivering envelopes side-on-side onto said conveyor belt on-
edge substantially in vertical orientation; and wherein said
means for diverting comprises: a lower level disposed beneath
said upper level; a divert gate disposed in said upper level,
said divert gate being selectively openable to intercept and
to divert envelopes to said lower level; and means for
propelling diverted envelopes along said lower level for
delivery to said stacking spider means, said means for
propelling including a rotatable paddle arrangement having
substantially radially oriented paddles, said paddles being
CA 02368032 2002-O1-30
2b
operative in engaging trailing edges of envelopes diverted to
and disposed in said lower level and propelling the envelopes
toward said stacking spider.
In accordance with another aspect of the present
invention there is provided an on-edge starker for stacking
envelopes, comprising: means for receiving and transporting
envelopes; means including a conveyor belt for accumulating
envelopes; means for stacking and delivering envelopes to
said means for accumulating; and, means for diverting
envelopes received by said means for receiving and
transporting, said means for diverting being operative in
diverting envelopes to said means for stacking; wherein said
means for receiving and transporting comprises an upper level
including means for conveying envelopes therealong; and
wherein said means for stacking and delivering comprises
stacking spider means for capturing diverted envelopes
delivered thereto and for delivering envelopes side-on-side
onto said conveyor belt on-edge substantially in vertical
orientation, said stacking spider means including at least
one revolving spider wheel that is driven and suspended in a
floating manner so as to be free to move substantially
horizontally against a spring-load in a direction away from
said means for accumulating; and wherein said means for
diverting comprises: a lower level disposed beneath said
upper level; a divert gate disposed in said upper level, said
divert gate being selectively,openable to intercept and to
divert envelopes to said lower level; and means for
s
CA 02368032 2002-O1-30
2c
propelling diverted envelopes along said lower level for
delivery to said stacking spider means.
In accordance with yet another aspect of the present
invention there is provided an on-edge stacker for stacking
envelopes, comprising: means for receiving and transporting
envelopes; means including a conveyor belt for accumulating
envelopes; means for stacking and delivering envelopes to
said means for accumulating; and means for diverting
envelopes received by said means for receiving and
transporting, said means for diverting being operative in
diverting envelopes to said means for stacking; wherein said
means for receiving and transporting comprises an upper level
including means for conveying envelopes therealong; and
wherein said means for stacking and delivering comprises
stacking spider means for capturing diverted envelopes
delivered thereto and for delivering envelopes side-on-side
onto said conveyor belt on-edge substantially in vertical
orientation; and wherein said means for diverting comprises:
a lower level disposed beneath said upper level; a divert
gate disposed in said upper level, said divert gate being
selectively openable to intercept and to divert envelopes to
said lower level; and means for propelling diverted envelopes
along said lower level for delivery to said stacking spider
means; and wherein said stacking spider means includes at
least one revolving spider wheel having a plurality of spaces
between legs thereof for receiving diverted envelopes
delivered thereto, said means for propelling including a
CA 02368032 2002-O1-30
2d
rotatable paddle arrangement including substantially
radially-oriented paddles, said paddles being operative in
engaging the trailing edge of envelopes disposed in said
lower level and propelling the envelopes toward said stacking
spider, said means for propelling including synchronizing
means for controlling the timing of actuation of rotation of
said paddles in dependence upon the angular position of said
spaces, so dependence upon the angular position of said
spaces, so that an envelope is propelled into
one of said plurality of spaces.
In accordance with still yet another aspect of the
present invention there is provided a method of on-edge
stacking of envelopes, comprising the steps of: receiving and
transporting envelopes in and along an upper level of a
diverter section; diverting envelopes selectively from said
upper level to a lower level of said diverter section;
propelling diverted envelopes from said lower level into
spaces between legs of a spider wheel, the step of propelling
including the steps of: rotating a paddle arrangement having
substantially radially-oriented paddles; engaging trailing
edges of envelopes with said paddles; and moving envelopes by
said paddles toward said spider wheel; rotating said spider
wheel; delivering envelopes from said spaces of said spider
wheel onto a conveyor belt on-edge substantially in vertical
orientation; and stacking and accumulating envelopes
delivered onto said conveyor belt in side-on-side
relationship; wherein the step of diverting includes;
x Z
CA 02368032 2002-O1-30
2e
selectively opening a divert gate in the floor of said upper
level; and intercepting envelopes that are transported during
the step of receiving and transporting with the opened said
divert gate and thereby directing envelopes to said lower
level.
In accordance with still yet another aspect of the
present invention a method of on-edge stacking of envelopes,
comprising the steps of: receiving and transporting envelopes
in and along an upper level of a diverter section; diverting
envelopes selectively from said upper level to a lower level
of said diverter section; propelling diverted envelopes from
said lower level into spaces between legs of a spider wheel;
rotating said spider wheel; delivering envelopes from said
spaces of said spider wheel onto a conveyor belt on-edge
substantially in vertical orientation; and stacking and
accumulating envelopes delivered onto said conveyor belt in
side-on-side relationship, the step of stacking and
accumulating comprising a step of suspending said spider
wheel in floating manner so as to be free to move
substantially horizontally against a spring load in a
direction away from said conveyor; wherein the step of
diverting includes: selectively opening a divert gate in the
floor of said upper level; and intercepting envelopes that
are transported during the step of receiving and transporting
with the opened said divert gate and thereby directing
envelopes to said lower level.
CA 02368032 2002-O1-30
2f
In accordance with still yet another aspect of the
present invention there is provided a method of on-edge
stacking of envelopes, comprising the steps of: receiving and
transporting envelopes in and along an upper level of a
diverter section; diverting envelopes selectively from said
upper level to a lower level of said diverter section;
propelling diverted envelopes from said lower level into
spaces between legs of a spider wheel; rotating said spider
wheel; delivering envelopes from said spaces of said spider
wheel onto a conveyor belt on-edge substantially in vertical
orientation; and stacking and accumulating envelopes
delivered onto said conveyor belt in side-on-side
relationship, the step of stacking and accumulating
comprising a step of suspending said spider wheel in floating
manner so as to be free to move substantially horizontally
against a spring load in a direction away from said conveyor;
wherein the step of diverting includes: selectively opening a
divert gate in the floor of said upper level; and
intercepting envelopes that are transported during the step
of receiving and transporting with the opened said divert
gate and thereby directing envelopes to said lower level.
In accordance with still yet another aspect of the
present invention there is provided an on-edge stacker for
stacking envelopes, comprising: means for receiving
envelopes; means including a conveyor belt for accumulating
envelopes; means for stacking and delivering envelopes to
said means for accumulating; and means for propelling
o s
CA 02368032 2002-O1-30
2g
envelopes from said means for receiving to said means for
stacking and delivering; wherein said means for stacking and
delivering comprises stacking spider means for capturing
envelopes provided by said means for propelling and for
delivering envelopes side-on-side onto said conveyor belt on-
edge substantially in vertical orientation, said stacking
spider means including at least one revolving spider wheel
that is driven and suspended in a floating manner so as to be
free to move substantially horizontally against a spring-load
in a direction away from said means for accumulating.
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 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
CA 02368032 2002-O1-30
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;
FTG: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 irlserter station
indicated in FIGS.1 and 2A;
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 ins~rter
of the invention;
i y
CA 02368032 2002-O1-30
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
transporter/diverter unit of the present invention;
FIG.8A is a schematic fragmental vertical section view
of a portion of the unit of FIG. B;
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.20;
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 enlargement of a middle
portion of the view in FIG.13, showincx 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
r
CA 02368032 2002-O1-30
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, a.nd
coordination of individual units and modules interconnected
therewith, a display/control console 52 to display
CA 02368032 2002-O1-30
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 (undex
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
E CA 02368032 2002-O1-30
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
120,22,24,26), 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, 25. The upper
portion of envelope feed station 30 includes an envelope
hopper 66 and a hopper mechanism 68. A transverse pass H4,
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 grippes drum 76,
a second grippes drum 78 for transporting envelopes conveyed
thereto by first grippes drum 76, a flap opener 80 to open
envelope flaps of envelopes transported by second grippes
drum 78, and an envelope conveyor device 82, including an
adjustable~upper belt device 83, for conveying of envelopes'
from second grippes drum 78 to a vacuum grippes drum 84.
Grippes drums 76 and 78 (and their operation) are of
generally conventional kind. Envelope diverter 33 is
disposed proximate to the delivery end of envelope conveyor
CA 02368032 2002-O1-30
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 cuo 90 is
disposed upon the periphery of rotor 88 whose rotation (and
valuing of vacuum to sucker cup 90) is synchronized anal
properly phased with the rotation of second qripper drum 76,
so that the flap of an envelope transported by second
qripper 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 eguipped
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. Conseguently, .
withdrawal of an envelope from the bottom of stack 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 78 results in an
orientation of the envelope (upon second gripper drum 78),
as it passes by flap opener 80, having unopened flap 98
facing toward flap openex 80. At this time, sucker cup 90
grabs envelope flap 98 by vacuum action and hinges it about
CA 02368032 2002-O1-30
g
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 zelea ed
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 82>
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 for 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 ran no longer be gripped by the next
grippers (of vacuum gripper drum 84) passing by. Stop gate
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.
2
CA 02368032 2002-O1-30
Envelopes delivered onto main track bed 60 are
positioned by vacuum grippes 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 aetainst first sloping wall 70 of vacuum belt
transporter/diverter unit 36.
Referring now to FIG.3, continuously revolving vacuum
grippes 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
grippes 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 grippes
mechanism in positions corresponding to locations whereL~pon
envelopes are carried. Vacuum is automatically valued to
each group before an envelope is released by respective
c~rippers on the grippes drum 84. Consequently, an envelope
r
re~eased'by grippers remains held to vacuum grippes drum 84
upon vacuum holes 121 and 121' until it is properly
delivered to its substantially horizontal registered
position on main track bed 60.
CA 02368032 2002-O1-30
11
Referring now to FIG.3A, a fragmented portion of the
inserter mechanism of inserting station 32 (FIGS.1 and 2) is
shown therein. The various components are disposed in mutual
positional relatiozzships representative of an early stage of
the inserting operation. FIG.3A depicts pertinent components
disposed in the lower region of inserting station 32 as we?_1
as componezzts 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 225B mounted on
revolvable shafts 125C, insert pushers 126, and spring-
loaded drop rollers 126A. A horizontally disposed top plate
1268 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. Envelope
127 has a top side 127A, a bottom side 1278, and a flap
1276. Flap 127C is.held open in a slightly downwardly
directed orientation by and below trailing end 126C of top
plate 1268.
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,
CA 02368032 2002-O1-30
w
12
and aids in holding the envelope downwardly. Air floor 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 a_,s
locus pattern 'L'. Locus pattern 'L' follows approximately
an horizontally elongated noose-shaped form. Insert pushers
126 are 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
r
positions perpendicularly to the plane of the depiction in
front of or behind each such component, as is customarv i_n
mail handling equipment. For example, there is a plura3_itY
of stop fingers 125, suction cups 125A, insert. pushers 1%6,
~ CA 02368032 2002-O1-30
13
drop rollers 226A, etc. Moreover, the depiction omits
obstructing components that could be detrimental to claxitv
of understanding.
As hereinbefore described, vacuum c~ri.pper 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 gap
between trailing end 126C (of top plate 1268) and the
periphery of vacuum gripper drum 84 onto an insertinct
station surface. At this time, opening fingers 125B have
orientations that are approximately 80 degrees from their
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 125B are now rotated by their shafts
1250 (one finder 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 125B have a substantially rectangular or square
channel-shaped thin-walled cross-section, whereby the C-
channel is disposed with a side wall facing downwardly ar_d
r
CA 02368032 2002-O1-30
14
its open side facing toward the middle of envelope 227 in
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 cu tomarily also provided with ramp-like leading edges.
As indicated, the height of fingers 125B 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 pa.ckac~e
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 enuelope 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 fractionally engaged by conveyor belt
arrangement 107, withdraws from opening fingers 1258, and is
r
propelled toward the right. Finders 125B are thereafter
rotated approxima.tsly by 80 degrees back to the orientation
with tips pointing substantially toc~rard one another. The
insert-filled envelor~e is delivered into fall region 74
~7
CA 02368032 2002-O1-30
iFIG.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 backaaes, beincr conveyed by
pin conveyor 34 (FIG.1) in ma,'_n track bed 60 along main tease
62 by pusher pins 196 (FIG.7), are seriatim transported to
the approximate region indicated in the location of insez~t
stack package 198 disposed upon top plates 1268 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 1268 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 2268, engage the trailing edge of ir_sert
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 1268 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 d?rection upwardly. This is an important reason
for the downwardly curved path with fast downward and
rearward retraction of insert pushers 226, while
simultaneously allowing clearance for delivery of the next
envelope and, also simultaneously, permitting an early
downward retraction of insert pushers to provide clearance
fo-r delivery of the next insert stack package. Travel
distances and spacings between successive insert packages
t a
CA 02368032 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 3Ai aid.
broadly, comprises a horizontal and a vertical
retroreflective sensing arranaement. More particularly, the
horizontal sensing arrangement comprises a photosensor x.28
and a retroreflective target surface 128A. The vertical
sensing arrangement comprises a fair of photosensors 1288
and 128C Chidden behind 128B) and a pair of retroreflective
target surfaces 128D and 128E that are dist~osed upon the too
surface of each of the opening fingers 125B. 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 225B are shown with their tips disposed in the
opened pocket of envelope 127.
A horizontal sensing beam 229 is directed by
photosensor x28 onto target surface '128A and is reflected
back into the photosensor. Photosensor 128 detects any
CA 02368032 2002-O1-30
17
interruption of the beam 129. Beam 129 traverses 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
envelot?es having been buckled or curled up by opening
fingers 225B, far instance if suction cups 125A malfunction.
Overall, any undesirable lifting up of a porta.on of the
envelope 227 into the path of the beam 129 results in
detection of a fault conditior_. 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 129B and 129C are directed by,
photosensors 128B and 1280, respectively, toward target
surface 128D and 128E, respectively, and are reflected
thereby back into the respective photosensars, provided that
the beams are not interrupted. In the depictions in FIGS.38
and 3C; opening fingers 125B and therewith target surfaces
128D and 128E have t~~nte.r. ed into thN~ opened pocket ofi
envelope 127. Consequently, sensing beams 129B and ~.29.C a.r_e
interrupted by the top side of the open envelope 127. ,
Vertical sensing beams 129B and 1290 primarily serve to
detect the presence of a correctly opened envelope (having
both fingers 1258 inserted therein) by sampling of the
r
signals generated by photosensors 228B and 128C at the
appropriate time during the insertion operation. It has been
found that the insertion jam detection arrangement, as
described, is capable of detecting most, if not all, fault
r
CA 02368032 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 ether 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 angla drive box 132 for driving the mechanism
of insert feeder module (for instance 20) via a box axle
234, 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 i42 and 144,
both pulleys being borne in free-running manner upon a
clutch drive shaft 146, and each pulley comprising a clutoh
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 254, 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 enqaae first clutch half 148
1 . CA 02368032 2002-O1-30
19
(as shown) or second clutch half 150 for drivinct 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 252 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 258 from a
here not shown motor-driven jack shaft that is located in
main base 62 of the inse_rter apparatus.
First box pulley 238 is connected with first clutch
pulley 142 by a first belt 162. Second box pulley 140 is
connected with second clutch pulley 244 by a second belt
164. In the embodiment shown in FIG.4, second clutch pulley
144 is one half the diameter of the first clutch pulley 242,
while pulleys 238 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 materia7.s. in such
cases, for example, two feeder modules are used to provide
the same more difficult to handle inserts, each module
operating at one half of the speed of other insert fender
modules. This provides the capability of high delivery rate
without a need for slow-down of the entire apparatus.
,, CA 02368032 2002-O1-30
Referring now to FIG.5, insert thickness detector 28,
disposed in every feeder module (for instance 20), comprises
an insert gripper drum disc 266 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 1?0.
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 1.76 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 18~,
that is secured to the module's frame. Caliper pivot 182 ana.
Half sensor device 170 are also secured to the inserter
module frame. Hall sensor 170 senses lateral displacement or
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
transportsng 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 02368032 2002-O1-30
21
followed by follower roller 178 about the axis of rotation
of disc 156. 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 axe computer-stored and compared with th~~
insert thickness signals obtained when an insert is presenv::.
Consequently, lack of concentricity of the periphery of di.5c
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 detectc?:,
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
1&8A 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 roller
178 freely rotatably mounted at one end thereof. The other
end of caliper arm 176A is provided faith a permanet magnet
180 whose magnetic field is sensed by Hall sensor device
1.7 0 .
A pulley 171, mounted on the axle of the insert grippr~r
drum 166A, is commonly driven at the same angular velocity
J,
CA 02368032 2002-O1-30
22
as the insert qripper drum. A further pulley 173 is freely
rotatably borne upon a shaft that is mounted in a fixed
position with respect to common frame stxucture 167. Pul~..ey
173 is driven .f.rom pulley 171 via a belt 173A. A nrecis?_<:~n.
caliper roll 1738 is coaxially mounted with pulley 173 anal
driven thereby. A point on the periphery of r..alioer roli_
i73B is always disposed so as to substantially coincide with
a cylindrical surface within which falls the periphery o.f_
the insert gripper drum 166A. Caliper roll 1738 and follower
roller 178 are both disposed in substantially the same
vertical plane which is 7_ocated 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 173B 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 173, and caliper roll 173B is such that the peripheral
velocities of insert cxripper drum 1.66A and caliper roll '! 73B
are identical. Belt 173A is resa_liently elastic,
particularly along its length, in order to accomodate
velocity fluctuations between the two pulleys.
In operation, when an insert, for instance indicated.
insert 288, is transported upon insert gripper drum 166A.
the insert is also nipped between caliper roll 1738 and
follower roller.178, and is driven thereby substantially at
the speed of the aripper drum periphery. Follower roller i78
is displaced by the insert thickness, and magnet 180 is
correspondingly displaced from its reference position aloncr
Hall sensor device 17~J. The difference between the hal7_
sensor signals in absence and in presence of a nipped insert
provides an accurate measure of insert thickness. As inserts
CA 02368032 2002-O1-30
23
extend beyond both rides of the insert qripper drum into the
nip region between caliper roll 1738 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 1738.
Referring now particularly to FTG.6 in conjur_ction with
FIGS.2: 1A and 2, 2A, skew detector arrangement 54 is
disposed on and above main track bed 60 and comprises ~ skew
detector bridge 190 having a plurality of downwardly-J_ookin
photosensors mounted therein. A plurality o.f retrorefl.ectors
192 is disposed below skew detector bridge 190 upon the
upper surface of main track bed 60. Skew detector bridaP 7.9t?
is indicated in dotted lines in FIG.6. Fin conveyor 34
(indicated by dash lines? is disposed beneath the surface.oi
main track bed 60 and comprises, in two parallel rows, a
plurality of egui-spaced upwardly-pointing pusher pips x_96
(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 sensed. 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 f.or sensing of leading and trailing edges
of _i_nsert stark par_k.aoe 198 in a plurality of transverse
' ~ CA 02368032 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 re~roreflector areas
by insert stack package edges. In a more specific
embodiment, these signal are evaluated in dependence on
machine speed, thusTy establishing limiting tolerance leve~_v
for permissible skew and other misalignments as a function
of machine speed. Limiting tolerance levels are
preprogrammable in order to provide allowance for differeW.
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 surfac<=
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 222 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
' c CA 02368032 2002-O1-30
about the axis of pivot 222 in counter-clockwise direction
to keep divert bei.t 214 tensioned. A fixed idler pulley 220
is borne in fixed pos~.tion within housing 200. Resiliently
tensioned divert belt 214 is driven by belt drive pul)_w
210. It should be understood that a plurality of
substantially identical components is disposed in spaced
parallel arrangement perpendicularly to the plane of the
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 aate 206 by the
normal conveying motion from pusher pins 196. The insert
package is thuslv auided into a reject nip recrion 228
between divert belt 214 and divert drive roller!pulley 208.
The package is grabbed in nip region 228 and lifted upuTardly
away from the path of pusher pins 196, is carried about
roiler/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
r
inserter apparatus is shown diagrammatically in FIG.1A. The
left hand portion of FIG.1A is identical to the left portion
of FIG.1 (includincr also envelope feed station 30 and a
vacuum belt transporter/diverter unit), but differs from
CA 02368032 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,
iri 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 stacking/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
connected to additional handling equipment a6.
Diverter section 47A can be substantially similar to
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 tfor
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), anal the
envelope .diverter, nova designated caith 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 02368032 2002-O1-30
27
Vacuum belt transporter/dive.rter unit 36 ~f 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 r_espectivelv
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 aripper
drum 78 and forming a part thereof, as indicated in FIG.2A.
Envelopes are delivered by and upon second gripper drum 78
to the nip between upper belt device 83A and the t7pper
portion of the lower belt, and axe transported thereby
toward the left.into proximity of.vacuum gripper drum 84 ~.n
readiness for pick-up by appropriate grippers of drum 8~.
According to an ambodiment of the invention, an
envelope div.erter 33A comprises a deflector and belt device
86A and an envelope reject bin 85C. Deflector anal belt
device 86A of the diverter 33A is disposed in the region
between envelope conveyor device 82A ar_d vacuum qripper drum
84, and comprises a deflector 85 and an endless belt 85E
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 ba
CA 02368032 2002-O1-30
28
picked up by the next grippers of vacuum gripper drum 84.
peflector 85 is pivoted into the other position
anticlockwise by a small angle so that the night-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 858, and will be driven thereby farther
dpwnwardly until it falls into bin 85C. The envelope
diverter 33A serves to selectively divert envelopes (for_
instance, reject or faulty envelopes) before they oan 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~short fall 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 mountino
bar 242 fixed on surface 70A. In more particular aspects,
vacuum belt transporter/d~verter unit 36A further comprises
a pair of fall brushes 244 disposed in the vicinity of ar..d
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 02368032 2002-O1-30
29
against a driven ro7.1 that. is disposed beneath surface 70A.
In more particular ~..~~,ects, vacuum belt transporter/divert-ea~
unit 36A includes a monitoring photosensor 250 a.nd a raised
envelope scanner 252, a deflector 254 includi_na b_r_,'_stles
254A disposed upon the deflector's lower surface, and br usb.
arrangements 255 included in adjustable pressure roll ~_,.n~t
246.
It should be recognized that vacuum belt
transporter/diverter unit 36A is substantially symmetrical
about a vertical plane disposed through the mZddle 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 i T1 t.~ae region alcove vacuum openings 236 c1 i ngs
securely to the belts by the action pf vacuum fed. via vacuu?r~
openings 236 ( from a vacuum source here not shoran.) . A. tr,,,~s1_v
delivered envelope is deflected downHTardly by fa1_1_ brushes
244 and by deflector 254, and is stopped by rai7_ 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 enve:Lop
edge, and is repositionable by adjustable fasten.in!~ means
256 to accommodate different size envelopes.
Guide rails 238, curved alon_a, 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 r ail 257A. Units 246 also include
CA 02368032 2002-O1-30
~rushes~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 ale 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 pressure
roll 248 and a driven roll therebeneath. Drive pressure ro_1
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 cry
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.8B shows details of a raised
envelope scanner 252 (also indicated in FIG.8). Raised
envelope scannex 252 comprises a beam emitter 258 generatirxg
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 02368032 2002-O1-30
31
envelope is correctly registered between rails 238 and 240
and provided that its inserts are properly fully inserted.
Th is is indicated by envelope 261 (in dashed lines) ha,W_nc~
flan 261A raised. If inserts are, for instance, incomplet~lv
inserted. and protrude past the flap hinge edge, the en~7e1_ope
flap is stiffened in a mote horizontal orientation.
Consequently, such an envelope is not disposed upon surf_acF
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 scanned
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-edcte
trailing by conveyor belt arrangement 107 onto vacuum belts
232 and 23,4. Vacuum is fed to the bottom of the envelObe 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 diract,'_on 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 therebeneath. A
reversing gearing and clutch arrangement can be provided to
reverse the drive to vacuum belts 232 and 234 and to thusly
facilitate selectlVe quick change over and diversion of
envelopes to the right or the left. For example, as
indicated in FIG.1A, vacuum belt transporterldiverter unit
36A can deliver insert-filled er_velopes via a reject
diverter section 47A to a turnover module 40A and farther to
a sealing module 38A.
CA 02368032 2002-O1-30
32
Referring row to FIGS.9 and 9A, key aspects of tur~?oVer
module 40A depicted therein comprise a module frame and
housin_q 262, idler pulleys ?63, 264, and 265, and a driven
pulley 266. All four pulleys are disposed substantially in
the same plane and are rotatably borne. PulleysW65 and 266
have their centers d~_sposed 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 lo~ler
pulleys. For instance, axles of pulleys 263 and 264 are
first axles of_ approximately horizontally oriented sprinn-
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 tuxzzover module, a typical entering envelope
269 is shown in. phantom 1a_nes being de?ivered to the nin o.f
D
CA 02368032 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-urn to a flan-down orientation.
The fixed smallest gap between. upper and lower_ pulleys
is set to facilitate nipping and transport passage bet~ePn
the belt portions of a thinnest envelope to be handled. The
other stop is adjusted to a gap between upper and lower
pulleys 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 convevar 272 upon which envelotaes axe
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
do~anwardly .
Broadly, flap moistening section 274 comprises a spray
nozzle 282 for issuing of a water spray onto the inner
surf ace of f laps of envelopes that intercept the spray tal-~ i. le
being conveyed through flap moistening sect~_on 274. The
spray is particularly directed at th.e gummed portion of
envelope 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 02368032 2002-O1-30
34
slit exit and providing high liquid shear forces to break u~
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 tY_~=
latter type is described, for instance in U.S.Patent
4,184,636.
First belt conveyor 270 comprises a driven endless belt
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 or
top of belt conveyor 272.
A closing guide 292 is disposed in a region that lead:.
into flap sealing section 276. Guide 292 serves to intercede
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 FTGS.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 2?2). Guide 292 intercepts and slides
along the outer surface of an envelope flap fed thereto,
while gradually pushing the flap into its closed
" ~ CA 02368032 2002-O1-30
position.
In a method of operation of sealing module 38A,
envelopes are fed thereto seriatim in the orientation and
position 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 conveVad
farther to the left into the nip between second belt 272 and
pressure rolls 290, the flap is closed by closing guide 29?...
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 waive
to feed water to nozzle 282 during passage of the enve)o~~e,
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
s
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 xange above
i r
CA 02368032 2002-O1-30
36
about 200 microns and larger.
Sealed envelopes are delivered by sealing module 38A,
for instance, to a lift gate sect.ior~ 48A that i.s indicated
in FIG.1A. Lift crate section 48A is provided far passin~c
sealed envelopes delivered 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.
deferring now to FTGS.12-25, on-edge stackina/diverter
unit 42 is depicted therein. FIGS.11_, 12, and 14 include
frac~mental depictions of turnover module 40 (for instance,
as indicated in FIG.1) which delivers envelopes to on-edge
stacking/diverter unit 42. It should be understood that, in
alternate embodiments of the invent?_on, turnover module 40
can 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 postage
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 cox~prises a dlverter section 350 to selectively pass
on or divert envelopes, a starker section 352 for stacking
of diverted envelopes and including a stacking spider 353,
and accumulator 44 for accumulating stacked envelopes.
' ' CA 02368032 2002-O1-30
37
Ln more particular aspects of an embodiment, re.ferr_incr
now to FIGS.11 and 12, diverter section 350 comprises a base
structure 354 (common also ~~~ith 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
prassure rollers 360 that provide pressure onto envelobes
against a drivE roll 362 and a drive belt 364 which thuslv
convey envel open upon. upper level (to the r?_ght ) . Fu.rthe?_
comprised in the floor of upr~er level 356 is.a selectively
operable hinged divert crate 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. Additiona7_ly,
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 alianer 372; the latter t.wo servincr 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, i.s 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 together
for common~positional shifts along rear wall 370 to provide
selectable envelope offset in stacking. Further, lower leVp'_
358 comprises an adjustable align.er 372' that is ganged with
aligner 372. Aligner 372' is spaced from the floor of IoTaer
Level 358 to form an opening adeauate to clear envelopes
CA 02368032 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 na.ddles
380 mounted upon a common shaft that is borne beneath t4~e
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 n?_n
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 sass
slidinaly thereunder.
Paddles 380 arm selectively commonly rotatabla in
increments of 180 degrees with respect to the position shown
in FIG.13 by a motor via a conventional solenoid-actuatabJ_e
one-half revolution clutch in response to appropr.~.ate
control signals. When rotated, ends of paddles 380 prot_rv.;,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 3&&. this envelope is then
indicated as envelope 388' (in FIG.13) subseauent 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 02368032 2002-O1-30
39
Referring now also to FIGS.1.3 and 14, in further
particular aspects of the invention, sticker 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 snider 353 is borne in table 390 in floating
manner, being free to move for a short distance in a
substantially horizontal plane away from aCCUr~ulator 44.
Stack_in~x spider 353 is sp_rina-loaded toward accumulator a_4,
Table 390 includes an upper surface 392 and a stackina~
surface 394. Upper surface 392 is disposed at substantiallv
the same level as or slightly lower than the surface of the
floor of lower level 358. Stackinct 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 leas 400 of generally sawtooth-like
shape in a trailing orientation in respect to their normal
clockwise direction Qf rotation. Spaces between spider leers
400 axe such that a stuffed envelope can easily be disposed
therein, as indicated for example by envelope 402. Spacing
between spider wheels 39H and 396' is somewhat less than the
length of the shortest envelope that is reauired r_o be
handled by the equipment. Slidable adjustment of table 390
is provided for adaptation of the eauipment to different
size envelopes, in particular to different widths and it _s,
CA 02368032 2002-O1-30
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 orientaticzr_.
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 replaced.
for instance for removal of an envelope stack. Alternately, other back
plate arrangements of conventional type can be used, as for instance a
back plate slideably (with relatively high friction) and hingeably borr:e
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 tt~
increasing stack thickness detected by a photosensor. This photosensor
detects horizontal movement of stacking spider 353 due to increase of
stack thickness.
When 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 02368032 2002-O1-30
41
offset portion 414 rnay be recoanizad and selectively h.andLed
subseauentl y to i is _a.ccumulation.
Referring now to FIG.15, further particular aspects of
an embodiment of the apparatus and method of the inver_tion
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 tree 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 Qearbox 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 loadincr means 508. Means 508 combri.ses a~
guide rod 600 that is secured, at one end thereof, to a post
&02. Post 602 is rigidly affixed to table 390. The free end.
of rod 600 extends through a clearance hoJ_e in a brar_ket 504
that is rigidly attached to or is apart of the housing of
gearbox 502. A compression spring 606 is threaded over guide
rod 600 and, in pre-compressed manner, extends betiaeen 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 502.
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 bearin~x therein. A drive pulley
r
CA 02368032 2002-O1-30
42
702, that is attached to the end of axle 700, is driven via
a belt (not shown hers) 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
m>>.st avoid substantial anctular and axial displacement of
shaft 398; in other words, skewing and rocking motions of
solder wheels 396 must be avoided.
With reference to FIGS.11 through 15, in operation of
on-edge stacking/diverter unit 42, envelopes axe seriatim
delivered thereto in horizontal orientation and in alicrn.ment
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 in~.tially 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 02368032 2002-O1-30
43
otherwise move out .f_rom its proper location between spider
leas 400 durino the initial onward movement.
Appropriate timing of actuation of paddles 380 to
assure that an envelope is propelled into a spare between
legs 400 is obtained ~by the action of the timinG'disc and
photosensor arrangement of stacking spider 353. EnerGization
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
414.
Referring now also particularly to FIG.15, in response
to increasing stack pressure, spider wheels 396 move back
resiliewtly (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
statior_ary 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 incrementa)..ly
moves the accumulated stack 414 toward the right. Gonseouent
stack pressure relief allows spider wheels 396 to fallow.
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 photasensors provide signals fo_r
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
r
CA 02368032 2002-O1-30
dd
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.1 and 1A, main computer 50
is interconnected with subsystems a_nd 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. Far 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-L~.p
(and shut-down) sequencing of power and particularly of
motor power supplies for reducing power surges and
consumption (and noise). In this respect, computer 50
controls selective powering-up of a plural ity of pumps f<:~-.r.
' e. CA 02368032 2002-O1-30
air, vacuum, and water in appropriate sections in accordance
uTith particular momentary demand, and computer 50 further
controls automatic cycling of pumps, selective shut-down of
motors consequent to timed inact~_vzties, shut-down of
malfunctioning subsystems, and the like. Individual
malfunction display and reset control stations for
individual inser_ter 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 overal l
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 faither through sealing and turnover modules.
Sealed and turned-over envelopes are stacked ir_ at ~_east. one
accumulator. Prior to being stacked, sealed and tur_n.ed-cwN.r_
envelopes can be conveyed. through a postage meter modul_~::: for-
appropriate metering (franking).
Wh le 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.
