Abstract: In a mail inserter machine including at least one subassembly with a component driven in reciprocating fashion, an apparatus for inserting a sheet into an envelope. The apparatus comprises a movable gripper jaw assembly, an envelope vacuum cup assembly, an envelope opener assembly including a nozzle in communication with a gaseous fluid supply source, and an insertion assembly. An electrical control circuit is adapted to issue electrical control signals to the respective assemblies, in such manner that the occurrence and duration of the control signals determine relative periods of operation of the assemblies during a cycle of operation of the apparatus and over a range of speeds of the apparatus.

Abstract: In a mail inserter having a 360 degree operational cycle and a plurality of subassemblies, a computer issues a plurality of electrical control signals having predetermined rotational positions and durations within the operational cycle at a given inserter speed. Solenoids, actuators and other driving devices are responsive to the control signals to determine the operation of the subassemblies. A device measures the operation speed of the inserter, and the computer adjusts the rotational position of each control signal within the operational cycle according to the inserter speed.

Abstract: An apparatus and method for computerized control of a "Phillipsburg-type" mail insertion machine. The mechanical timing and drive mechanisms of the prior art inserter are replaced with a programmable computer, solenoid valves, and pneumatic cylinders, or other suitable drivers. The computer's software includes a plurality of programmed look-up tables. An operational delay look-up table includes electro-mechanical lag times for the pneumatically driven stations/sub-assemblies of the inserter. Also provided are look-up speed tables, which include start and stop angles for actuation of each of the pneumatic cylinders. A first look-up speed table includes actuation data appropriate for operation of the machine within a relatively slow range of speeds. Four additional look-up speed tables provide correct actuation data for successively higher speed groups, up to 10,000 insertion cycles per hour.

Abstract: A sheet processing apparatus and method for selectively inverting, staging and selectively advancing or diverting sheet material along a predetermined conveying path. The apparatus has a pair of support plates with space between the plates for passage of sheet material and a nip roller mechanism operatively connected to the support plates for advancing the sheet material. A rotation mechanism selectively simultaneously rotates the support plates as sheet material is positioned between the plates. The rotation mechanism selectively inverts the sheet material and positions the sheet material for advancement by the nip rollers from between the support plates along the predetermined conveying path.

Abstract: A collector apparatus and method are provided for collecting sheet articles and advancing collected sheet articles therefrom. The collector apparatus includes a collector plate having a surface for receiving one or more sheet articles thereon to collect the sheet articles. At least one stop bracket is movable through an opening defined through the collector plate to provide a stop for collected sheet articles and to allow collected sheet articles to be further advanced from their collection position. At least one upper idler drop roller is spacedly positioned above and movable toward the collector plate surface.

Abstract: A document collector, stager and diverter apparatus and method are provided for processing sheet articles through a first and second stage. The first stage is adapted for receiving sheet articles advanced thereto and collected therein and includes a first transport mechanism being operative for selectively diverting collected sheet articles in a divert direction opposite to the conveying direction of the sheet articles. Alternately, the first transport mechanism is operative for selectively advancing the collected sheet articles from the first stage to the second stage. In the second stage, sheet articles can be independently processed and held until a predetermined time when they can be advanced from the second stage by a second transport mechanism. The first and second transport mechanisms each preferably includes plastic chains each with plastic lugs thereon. The chains of the first and second transport mechanisms are simultaneously rotatably movable by a motor and gears or pulleys associated therewith.

Abstract: A high-capacity collector apparatus and method are provided for collecting sheet articles and advancing collected sheet articles. The collector apparatus includes a stage for collecting a stack of sheet articles advanced thereto wherein the stage is adjustable to accommodate sheet articles of various dimensions or sizes. Pusher/stop members are provided and are operable to stop sheet articles collected in a stack in the stage and to subsequently push the stack of sheet articles from the stage. The pusher/stop members are preferably lug members fixedly attached to a plurality of belts with each belt having one lug member fixedly attached thereto.In a preferred embodiment, the collector apparatus comprises two pairs of independently controlled movable belts each having one lug member attached thereto.

Abstract: The present invention provides a novel extension apparatus and method for providing a selectively adjustable conveying path for sheet articles between sheet processing apparatuses. The extension apparatus includes a base bracket with a pair of rotatably movable spring-loaded bracket arms attached to a shaft extending therethrough. A pair of bracket arm rollers are attached to each of the bracket arms. An extension plate is positioned above and slidably movable on the base bracket, and a pair of rotatable extension rollers are rotatably attached to a shaft extending through the extension plate such that slidable movement of the extension plate simultaneously and identically moves the extension rollers. A pair of rear rollers are utilized and are operatively aligned with an extension roller and a pair of the bracket arm rollers.

Abstract: An apparatus and method for computerized control of a "Phillipsburg-type" mail insertion machine. The mechanical timing and drive mechanisms of the prior art inserter are replaced with a programmable computer, solenoid valves, and pneumatic cylinders, or other suitable drivers. The computer's software includes a plurality of programmed look-up tables. An operational delay look-up table includes electro-mechanical lag times for the pneumatically driven stations/sub-assemblies of the inserter. Also provided are look-up speed tables, which include start and stop angles for actuation of each of the pneumatic cylinders. A first look-up speed table includes actuation data appropriate for operation of the machine within a relatively slow range of speeds. Four additional look-up speed tables provide correct actuation data for successively higher speed groups, up to 10,000 insertion cycles per hour.

Abstract: A guide apparatus and method are provided for selectively guiding sheet articles into a first, second or third conveying path. In a preferred embodiment, the first and second conveying paths are the upper and lower conveying paths, respectively, of a dual-deck accumulator and the third conveying path is a divert path. The guide apparatus includes a guide member having a pair of spaced-apart divert plates which are elongated and parallel so as to define a slot therebetween for passage of sheet articles therethrough. The divert plates are fixedly positioned with respect to one another and selectively pivotal in a first position for guiding sheet articles into a first conveying path, a second position for guiding sheet articles into a second conveying path and a third position for guiding sheet articles into a third conveying path.

Abstract: An accumulator apparatus and method are provided for accumulating sheet articles. The accumulator apparatus includes an upper belt system and lower belt system operative for advancing sheet articles in seriatim manner therebetween. Guide rollers are provided at the entrance of the sheet articles between the upper and lower belt systems for guiding the sheet articles therebetween without pinching. Nip rollers are provided downstream from the entry guide rollers for pulling sheet articles into the accumulator apparatus between the guide rollers and the nip rollers. A ramp system operative for deflecting advancing sheet articles is provided downstream from the nip rollers. Sheet articles deflected by the ramp assembly can then be accumulated in an accumulation location where the lower belt system is maintained in a spaced-apart position below the accumulation location such that the lower belt system cannot contact or mark sheet articles accumulated therein.

Abstract: An impact pulley apparatus and method are provided for use with a high-speed media processing apparatus by driven attachment to the rotatable shaft of a motor associated therewith to absorb impact energy caused by the high-speed media processing apparatus encountering media to be conveyed. The impact pulley apparatus includes a base plate for mounting on the rotatable shaft such that rotation of the shaft causes identical and simultaneous rotation of the base plate. A pulley member is operatively connected to the base plate by biasing members which are springs in the preferred embodiment such that the pulley member is substantially identically rotatable with rotation of the base plate in one direction in a non-actuated position until an amount of impact energy is encountered by the pulley member sufficient for the pulley member to biasedly rotate in the same direction less than the base plate in an actuated position of the impact pulley apparatus in order to absorb the impact energy.