Abstract: A transport system for conveying sheet material along a feed path. The transport system includes an electro-dynamic propulsion system for moving sheet material, or a stacked collation of sheet material, along a support deck which defines the feed path. More specifically, the electro-dynamic propulsion system includes at least one guideway and a ferromagnetic element disposed internally of the guideway. The guideway includes a magnetic coil to produce a variable magnetic field. By varying the flux density and polarity of the magnetic field the ferromagnetic element may be propelled within the guideway. An abutment member is coupled to the ferromagnetic element, extends through the elongate opening of the support deck and engages an edge of sheet material. A processor is operative to control the electro-dynamic propulsion system and, accordingly, the rate of travel and position of the sheet material along the feed path.

Abstract: A print interface system includes a printer integrated in combination with a sheet handling system such as a mailpiece inserter. The print interface system facilitates the handling of sheet material in various operating modes, including conventional printing, duplex printing, and mailpiece creation modes. The system includes an interface module having upper and lower housing segments defining first and second feed paths. A first feed path directs sheet material to a stacking surface of the upper housing segment and a second feed path directs sheet material to a downstream module of the sheet handling device. A repositionable diverter bifurcates the path exiting the printer to direct sheet material to one of the two feed paths. Furthermore, the upper housing segment is pivotally mounted to the lower housing segment to provide internal access to one of the first and second feed paths.

Abstract: System and methods of controlling a plurality of motors based on a motor motion attribute, such as rotor position, velocity, or acceleration, which simulate the properties of a mechanical differential, including a pure differential, a limited slip differential, and/or a locking differential. The method may be employed in a number of applications, including, without limitation, a paper handling system, such as an inserter, to control the nips of a pinless cutter of an inserter, and in a vehicle.

Abstract: An apparatus is provided for altering the spatial orientation and/or direction of sheet material. The apparatus includes an input deck for receiving sheet material along an input feed path, an output deck for forwarding sheet material along an output feed path, and an orbit nip roller assembly disposed adjacent to and aligned with the input and output decks. The orbit nip roller assembly includes a primary and secondary roller defining a roller nip which lies substantially parallel to the input and output feed paths. The secondary roller is adapted to be bi-directionally displaced in an arc about the periphery of the primary roller such that the roller nip orbits the primary roller from a first radial position to a second radial position.

Abstract: A mail inserter has a first web driver to move a web from a web supply and a second web driver to feed the web to a cutter for cutting the web into sheets, wherein the first and second web drivers have different velocity profiles to allow a web loop to form between the web drivers. The loop is variable between a maximum size and a minimum size. When the loop reaches the minimum size, the first web driver is running at its maximum speed. At this point the first web driver is decelerated at a rate such that when the first web driver stops, the web loop is at its maximum size. The acceleration of the first web driver is at a constant rate which is inversely proportional to the difference between the maximum loop size and the minimum loop size.

Abstract: An ingestion assembly is provided for a singulating apparatus having a conveyor system for moving a stack of sheet material along a feed path. The ingestion assembly is spatially positioned above the conveyor belt and includes at least one singulating roller driven in a direction opposing the motion of the conveyor belt. The ingestion assembly comprises an assembly support rotationally mounting the singulating roller at a downstream end portion and pivotally mounting to the singulating apparatus at an upstream end portion. A movable guide mounts to the assembly support and is positionable relative thereto as a function of a force vector imposed on the guide by the sheet material. Additionally, the moveable guide includes a surface operative to guide the sheet material into a singulating interface which is formed between the singulating roller and the conveyor system. In operation, sheet material enters the throat of the ingestion assembly and contact is made with the moveable guide.

Abstract: A roller assembly for conveying stacked sheet material along a feed path. The roller assembly includes a first roller adapted for rotation within a housing, a second roller pivotally mounting about an axis to the housing and opposing the first roller to define a roller nip, a spring biasing mechanism operative to bias the second roller about the pivot axis toward the first roller to effect optimum frictional engagement of the roller nip with the face surfaces of the stacked sheet material and a transmission assembly operative to (i) transfer rotational motion of the first roller to the second roller, (ii) drive the first and second rollers in opposing directions to convey the stacked sheet material along the feed path, and (iii) facilitate pivot motion of the second roller about the pivot axis to vary the spacing of the roller nip and accommodate stacks of sheet material which vary in thickness.

Abstract: A sortation bin module having a conveyor and diverter module for pneumatically securing, releasing and diverting selected mailpieces to a bank of sortation bins. The conveyor module includes a conveyor surface for transporting sheet material along the feed path and a pneumatic system for developing a pressure differential across the conveyor surface to hold the sheet material on the conveyor surface during transport. The diverter module includes a diverter surface for sorting sheet material from the conveyor surface, i.e., diverting sheet material from the feed path. The diverter module, furthermore, includes a pneumatic system for developing a pressure differential across the diverter surface to hold the sheet material on the diverter surface during sortation. The conveyor and diverter surfaces are also arranged such that the surfaces oppose each other to define a transfer interface.

Abstract: A mail stack unloading device for use in a mail stacker to unload a stack of mail pieces in the mail stacker. The mail stacker has a pair of stack supports, located at a small angle from a vertical line, for supporting the mail stack as the mail pieces enter the mail stacker along a stacking path when the stack supports are in a stacking position. The stacker also has a platform or tongue connected to the stack supports such that the platform is positioned beneath the mail stack below the stacking path. During unloading, the platform is caused to move upward beyond the stacking path in order to engage with the stack, allowing the stack to be lifted. Then the stack supports are caused to forward beyond the vertical line in order to tip the lifted stack into a container.

Abstract: A shield assembly is provided for use in combination an ink jet printer and is operative to provide a smooth planar surface for printing on a print media. The described embodiment includes a shield having first and second contact surfaces to define an opening therebetween. The opening of the shield assembly is aligned with the print head of the ink jet printer for permitting the deposition of ink through the opening. The assembly further includes a pivot mount operative to pivot the shield about a rotational axis which is substantially parallel to the feed path of the print media and orthogonal to the motion of the print head. Moreover, the assembly includes a means for pivoting the shield about the rotational axis in a first and second direction thereby causing one of the contact surfaces to engage the print media upstream of the print head when depositing ink on the print media.

Abstract: A weighing system is provided to measure the article weight by first and second weight measurement devices. The first and second weight measurement devices each include a platform adapted to accept an article traveling along an upstream processing path and a device for sensing article weight as the article traverses the platform. Furthermore, the platforms of the first and second weight measurement devices define weight acquisition paths which are substantially parallel to one another. A diverter mechanism is provided to direct articles from the upstream processing path to one of the first or second weight acquisition paths. The diverter mechanism is controlled by a system processor which directs articles to one of the weight measurement devices depending upon its status, i.e., whether the path is available to receive another article for measuring weight. By diverting mailpieces to parallel weight acquisition paths, throughput is enhanced by multiple weight measurements occurring simultaneously.

Abstract: A method for producing mailpiece content material for use in a mailpiece inserter. The method includes the steps of: creating an electronic application file of the mailpiece content material, generating print stream data from the software application and converting the print stream data into object-oriented data. The object-oriented data is then parsed or segmented to form a plurality of data sets. The data sets may be comprised of one or more data packets and include an object dictionary for indexing the data. Each data set may then be processed to produce mailpiece content material for use in the mailpiece inserter. Processing may include the steps of reconstituting the data into a plurality of logical documents in the form of pages, mailpiece documents, mailpieces, or an entire mailpiece data run file.

Abstract: An apparatus for handling mailpieces produced by a mailpiece insertion system, comprising at least one mailpiece stacking assembly and a combination support/conveyor deck. The mailpiece stacking assembly accepts a plurality of mailpieces, i.e., as they are created by a mailpiece insertion system, and aligns the mailpieces to define a mailpiece stack. The support/conveyor deck is operative to convey mailpiece containers along a mailpiece handling path and includes loading and transport sections. The loading section is, furthermore, adapted to alternately reposition each of the mailpiece containers from an in-plane position to an out-of-plane position relative to the mailpiece handling path. The in-plane position is operative to transport the mailpiece containers along the mailpiece handling path while the out-of-plane position is operative to spatially reposition each of the mailpiece containers for alignment with a side edge of the mailpiece stack.

Abstract: A platen structure to facilitate the transport of stacked sheet material conveyed along a transport deck of a sheet feeing apparatus. The platen structure comprises first and second segments connected by means of a compliant coupling. The first segment of the platen is operative to engage a face of the stacked sheet material and apply a stabilizing normal force thereon. The second segment of the platen is operative to engage and travel synchronously with a moving surface of the transport deck. Furthermore, the first and second segments are connected by means of a compliant coupling which is operative to facilitate the relative angular displacement of the first and second segments about at least one axis while maintaining the relative linear displacement therebetween about at least one of the other axes. The platen structure ensures reliable sheet material run-out by compensating for a reduction in sheet material weight as the final or last sheets of the stack are singulated/separated.

Abstract: A vacuum deck for a mailpiece insertion module including a plurality of friction drive belts, a support plate slideably supporting the drive belts, a repositionable backstop assembly disposed along the feed path of the envelope for arresting the motion of the envelope when disposed in a first position and permitting the conveyance along the feed path when disposed in a second position, a means for developing a pressure differential across the envelope for urging the envelope into frictional engagement with the friction drive belts, and a breaker plate disposed over and across an upstream portion of the friction drive belts to reduce friction drive forces developed along an upstream end portion of the envelope. In another embodiment of the invention, the pressure differential means is bifurcated such that the pressure differential developed across the breaker plate is lower than the pressure differential developed along the support plate and downstream of the breaker plate.

Abstract: A transport and alignment system is provided for handling stacked sheet material on a support deck including first and second belts each having a portion thereof disposed parallel to the support deck. Each of the belts includes a plurality of spaced-apart fingers which engage the edges of the stacked sheet material and define a pocket therebetween. The transport and alignment system further includes a drive mechanism for independently driving the first and second belts to effect concurrent and relative motion of the fingers. Concurrent motion of the fingers transports the stacked sheet material along the support deck while relative motion of the fingers opposed edges of the stacked sheets of material. The transport and alignment system is described in the context of a stitcher and chassis module of a mailpiece inserter.

Abstract: A system and method for processing mailpiece content material in a mailpiece inserter including a printer integrated with the mailpiece creation system. The integrated printer receives print stream data from a software application and prints the mailpiece content material based upon command signals from a system controller. The system further includes at least one device disposed downstream of the printer for issuing a signal indicative of the rate that content material is processed by the inserter. The system controller monitors the throughput rate of the at least one downstream device and issues a command signal indicative thereof. The system and method of the present invention employs a page-based language monitor to throttle the print stream data received by the printer to vary the printing rate of mailpiece content material.

Abstract: A method for adaptively controlling a Radio Frequency IDentification (RFID) system having a plurality of interrogating antennas and RFID tags. The method comprises the steps of establishing a timeout setting indicative of the time that each interrogating antenna powers a read field during a respective read period and a threshold time period indicative of the time required to transmit energy/exchange data between the RFID tag and the interrogating antenna. A period differential is then calculated which is indicative of the difference between the timeout setting and the time elapsed for the final RFID tag within a respective read field to communicate its RFID tag information. The timeout setting for each interrogating antenna may then be adaptively tuned or varied in accordance with the period differential. To expedite and/or refine the adaptive tuning feature, a variance may also be calculated indicative of the difference between the threshold time period and the period differential.

Abstract: A method for enhancing the accuracy a Radio Frequency IDentification (RFID) system which may exhibit inconsistent RFID tag reporting behavior. The method includes the steps of (i) establishing a timeout setting indicative of the time that each interrogating antenna transmits RF energy within a respective read field, (ii) evaluating/comparing reporting results over multiple interrogation cycles to determine when an RFID tag exhibits inconsistent reporting behavior within the read field and (iii) increasing the timeout setting of the respective interrogating antenna to enhance the energy harvested by an RFID tag/device during each interrogation cycle. In lieu of, or in addition to, increasing the timeout setting, the method evaluates the responses received over multiple cycles and accepts such responses as being valid only when the same response is obtain over consecutive/sequential interrogation cycles.

Abstract: A system for electrically connecting first and second electronic devices wherein the devices are movable relative to each other. The system includes an electric cable having end segments and a medial segment therebetween wherein each of the end segments connects to one of the first and second electronic devices. A tensioning mechanism maintains a tensile load on the medial segment of the electric cable while a guide mechanism directs movement of the electric cable in response to relative motion between the first and second electronic devices. Moreover, a strain relief mechanism is operative to mitigate the transmission of tensile loads from the medial segment to either of the end segments such that the end segments are substantially unloaded in response to movement of the devices.