Abstract: A method for supplying envelopes to an inserter system, including the steps of providing an envelope supply structure having an exit point, providing at least first and second supply paths from the exit point of the envelope supply structure and providing a common path from the at least first and second supply paths. Individual envelopes are fed from the envelope supply structure to a selected one of the at least first and second supply paths wherein the envelope is conveyed to a holding area in the selected supply path and from the holding area of the selected supply path it is conveyed to the common path. The envelope then travels from the common path to an envelope insertion area wherein prearranged documents are caused to be inserted into the envelope.

Abstract: The present invention relates to an input system for feeding one-up sheets from a paper web to a high speed mass mailing inserter system. The input system includes a feeding module for supplying a paper web having two web portions in side-by-side relationship. A merging module is located downstream in the path of travel from the feeding module and is operational to feed the two web portions in an upper-lower relationship so as to reorient the paper web from the side-by-side relationship to an upper-lower relationship. A separating module is located downstream in the path of travel from the merging module and is operational to receive the paper web in the upper-lower relationship and separate the paper web into individual two-up sheets. In order to separate the two-up sheets into one-up sheets, a stacking module is located downstream in the path of travel from the separating module and is configured to receive the two-up sheets, stack the two-up sheets and individually feed one-up sheets from the stack.

Abstract: A breakaway pusher for a timing belt used as part of a mailing machine. A split lug, having two halves, each with a hole, is affixed to the timing belt. A torsion spring having two legs and an eye, with one leg bonded to a surface of a pusher, is inserted between the two halves of the split lug, with the eye of the torsion spring aligned with the holes in the halves of the split lug. A pin is press fit into the holes of the two halves of the split lug, and pierces the eye of the torsion spring.

Abstract: A method is disclosed for processing a collation in a folding station (100) having a folding roller assembly (106, 108, 110, 112), a first fold plate assembly (102) and a second fold plate assembly (104) downstream of the folding roller assembly and the first fold plate assembly. The second fold plate assembly includes a stop member (126) movable at least between a distal position away from the folding roller assembly and a proximal position in proximity to the folding roller assembly. A portion of the collation is first conveyed into the first fold plate assembly (102) and the collation is then conveyed from the first fold plate assembly, through the folding roller assembly, and into the second fold plate assembly. Once in the second folding plate assembly the collation abuts against the stop member, whereafter the stop member (126) is moved from its distal position to its proximal position so as to cause the collation to convey out of the second fold plate assembly (104).

Abstract: A method and system for tracking manually repaired mailpieces and the like. Control documents are produced by a data processing system and transported to an inserter system. The inserter system inputs the control documents and assembles mailpieces in accordance with mailpiece records identified by coded information on the documents. If a damaged mailpiece is manually repaired an operator scans the coded information from the damaged mailpiece. A data processing system accesses the mailpiece record in accordance with the scanned information and updates the corresponding mailpiece record to reflect manual repair of the document.

Abstract: A method is provided for establishing mutual authentication and secure communications between an microprocessor-based transaction evidencing device and a microprocessor-based server coupled thereto. A session key KS is generated at the transaction evidencing device and encrypted with a first key K1 to form a first message. The first message is sent to the server and decrypted using a second key K2. In response to the first message a second message is generated at the server and encrypted using the session key KS. The encrypted second message is sent to the transaction evidencing device and decrypted using the session key KS. A response to the second message is generated at the transaction evidencing device and is signed using a third key K3. The signed response is encrypted with the session key KS and transmitted to the server. The encrypted signed response is decrypted using the session key KS and the signature is verified using a fourth key k4.

Abstract: A sheet feeder for feeding sheets from a sheet stack, having a feed deck for supporting the sheet stack and a pair of spaced apart parallel guide rails on the feed deck for receiving the sheet stack between the guide rails. A sheet feeding assembly is mounted in proximity to a sheet feeding end of the feed deck and is operative to feed individual lowermost sheets from the sheet stack, the sheet feeding assembly including a continuously rotating feed drum having an inner and outer circumference and a plurality of suction openings and a vacuum assembly received in the inner circumference of the feed drum and having at least one rotating cylinder coupled to a vacuum source and movable between an actuated position for drawing air downward through the portion of the feed drum extending above the planar surface of the feed deck and a default position preventing the drawing of air through the feed drum when a vacuum is applied to the at least one rotating cylinder.

Abstract: The present invention provides an apparatus and method for receiving at least one sheet from a first upstream direction and feeding the at least one sheet in either a second mainstream direction or a third disposal direction. Conventionally, this invention may be used to reorient a sheet, or an accumulation of sheets, from landscape to portrait or vice versa, and to dispose of an incorrect accumulation of sheets into an out-sort station.

Abstract: A collating device that collates one or more sheets of paper into a sheet collation that includes an input end that receives individual sheets and an output end through which passes the sheet collation. A plurality of sheet paths are provided each providing a sheet path between the input end and the output end. Each sheet path includes a switching mechanism located in proximity to the input end that is operative to selectively direct a sheet received in the input end to the associated sheet path and a drive mechanism operative to vary the speed at which a sheet is conveying in the sheet path associated with the drive mechanism to effectuate a common collation with other sheets being conveyed through other sheet paths.

Abstract: An apparatus for changing the direction of travel of a flat article being conveyed seriatim along a paper path without changing the orientation of the flat article with respect to a first direction of travel. The apparatus includes a deck having an upstream end for receiving a flat article being conveyed along a paper path in a first direction and a registration wall upstanding on the deck and spaced from the upstream end, the registration wall having a longitudinal axis defining a second direction that is substantially orthogonal to the first direction. A drive assembly is operatively coupled to the deck in proximity to the registration wall and is operative to seize a first leading edge of a flat article traveling in the first direction on the deck and convey the flat article in the second direction such that the leading edge of the flat article abuts against the registration wall.

Abstract: A separator assembly operative to separate and feed individual documents from a storage tray of an inset feeder apparatus. The separator assembly including an adjustment assembly configured to adjustably position the separator roller relative to the separator stone. The separator assembly further includes a leverage assembly configured to raise the separator roller from an adjusted position to a height suitable for clearing a paper jam and to return the separator roller to the adjusted position relative to the separator stone. The leverage assembly and adjustment assembly both having respective operator actuated mechanisms positioned atop one of the first and second side portions of the feeder apparatus.

Abstract: Disclosed herein is an envelope opening apparatus, preferably for use in an inserter (210). The envelope opening apparatus comprises means (54) for locating an envelope, having rear and front panels (116, 118) and a flap (64) hinged to the front panel, in a waiting position with its flap in an open position in substantially the same plane as its front panel, and means (60, 62, 68, 70) operable for forming a step-like deformation in the flap, so as to cause the rear panel (116) to separate from the front panel (118).

Abstract: An inserter is disclosed having an insertion station and a feeding mechanism for feeding an envelope to the insertion station with the bottom edge of the envelope leading and the envelope flap in an open position and trailing, envelope opening mechanism at the insertion station and sheet feeding mechanism. A sensor detects the leading edge of the envelope as it is fed to the insertion station and, in response, causes the envelope opening mechanism to open the envelope after its arrival at the insertion station. The sensor also detects whether the envelope flap, when the envelope is waiting at the insertion station, is not in its open position and, when this is the case, it terminates operation of the envelope feeding mechanism and sheet feeding mechanism for the next envelope and sheet.

Abstract: A sheet feeder for feeding sheets from a sheet stack, having a feed deck for supporting the sheet stack and a pair of spaced apart parallel guide rails on the feed deck for receiving the sheet stack between the guide rails. A sheet feeding assembly is mounted in proximity to a sheet feeding end of the feed deck and is operative to feed individual lowermost sheets from the sheet stack, the sheet feeding assembly including a continuously rotating feed drum having an inner and outer circumference and a plurality of suction openings and a vacuum assembly received in the inner circumference of the feed drum and having at least one rotating cylinder coupled to a vacuum source and movable between an actuated position for drawing air downward through the portion of the feed drum extending above the planar surface of the feed deck and a default position preventing the drawing of air through the feed drum when a vacuum is applied to the at least one rotating cylinder.

Abstract: A method of selectively printing a Postnet barcode on an envelope which includes conveying an address bearing document from an input module along a chassis from an upstream location to a downstream location. Also including scanning the document at the input module to determine whether or not a Postnet barcode is to be printed on the envelope and printing a Postnet barcode with a printer on the envelope if the scanning process indicates that the document contains data which is valid based on a selected configuration. Further including, changing the font of the printer to print a blank string, if the scanning process indicates that the document contains data which is not valid based on selected configuration.

Abstract: A rotatable insertion horn for opening an envelope prior to insertion of documents into the envelope. The insertion horn includes a planar bottom plate having an upstream end, a downstream end and first and second side portions. A side wall is provided that extends upward from the first side portion of the planar bottom plate. The side wall has a downstream end adjacent to the downstream end of the planar bottom plate and an upstream end adjacent to the upstream end of the planar bottom plate wherein a portion of the planar bottom plate extends downstream from the downstream end of the side wall. A top planar plate is provided that extends from the top of the side wall and towards the second side of the bottom plate wherein the top plate is superposed and substantially parallel to the bottom plate.

Abstract: A method and apparatus for controlling an insertion device includes the steps of providing sensors for providing respective signals in accordance with selected events associated with the operations and providing a plurality of motor profiles for operation of motors associated with the operations. Respective motors associated with respective operations of the apparatus are driven in correspondence with selected ones of said plurality of motor profiles for controlling driving of said motors in response to receiving the event signals from the sensors and other modules of the control program. In the event of out of tolerance conditions the envelope can be diverted and another substituted without having to shut down and restart the system at a known place.

Abstract: A separator assembly operative to separate and feed individual documents from a storage tray of an inset feeder apparatus. The separator assembly including an adjustment assembly configured to adjustably position the separator roller relative to the separator stone. The separator assembly further includes a leverage assembly configured to raise the separator roller from an adjusted position to a height suitable for clearing a paper jam and to return the separator roller to the adjusted position relative to the separator stone. The leverage assembly and adjustment assembly both having respective operator actuated mechanisms positioned atop one of the first and second side portions of the feeder apparatus.

Abstract: The present invention provides a sorter preferably for an inserting system for sorting mailpieces into one of at least two sorting bins, the sorter having a transport device for conveying the mailpieces along a transport path. Each sorting bin includes a bending mechanism for bending the tail edge portion of a mailpiece and a final stacking roller for unbending the tail edge portion of the mailpiece such that the tail edge portion of the mailpiece is diverted into the sorting bin and away from the transport device without the occurrence of jamming of the mailpiece in the entry portion of the sorting bin.

Abstract: The present invention provides a sorter for sorting mailpieces into one of at least two sorting bins, the sorter having a transport device for conveying the mailpieces along a transport path. Each sorting bin includes a drive nip located in close proximity to a gate assembly for conveying a mailpiece away from the transport path and into the sorting. Each sorting bin further includes a stacking belt assembly spaced away from the drive nip and having a first end positioned at an acute angle relative to the drive nip and second end positioned adjacent a registration wall.