Abstract: Apparatus and method for merging sheet streams conveyed in side-by-side streams in a conveying direction into a single stream. An infeed conveyor conveys at least two sheet streams side-by side in a direction toward a merger. The merger separates and separately conveys the sheet streams to a merge location. The sheet streams are transported at different accelerations or speeds, such that each article of one of the sheet streams is directed into a gap between the articles of the other sheet stream in order to produce a single, merged sheet stream traveling at an accelerated outfeed speed for further processing.

Abstract: A system, method, device, and/or computer program product for remotely managing a plurality of remote mail processing devices. The system comprises receiving means for receiving operation related information from each of said plurality of remote mail processing devices. The system also includes monitoring means for remotely monitoring operation related information from each of said plurality of remote mail processing devices. Features of the present invention include the ability to create threshold settings for separate mail processing devices and individual jobs running on the separate mail processing devices. Violations of the threshold settings will result in an alarm indicating deviation from pre-set job goals. A user also has the ability to remotely create, maintain, and communicate valid mail processing device operator lists for specified mail processing devices.

Abstract: A smudge-free sheet material handling apparatus and method are disclosed. The device moves sheet material by only pushing on the edges of the sheet material. Since there is no toner or ink at these locations, the sheet material can be fed without risk of smudging the toner material on the sheet surfaces. Furthermore, since no high friction parts come into relative contact/movement with the surfaces of the sheet material, smudging is even further reduced.

Abstract: Systems, methods, and computer program products for managing a plurality of mail processing devices are provided. A mail insertion device is represented on a computer display as an interactive icon. Visible indicia is associated with each icon for displaying in real time operational status information about the mail inserting machine represented by the icon. The indicia changes appearance in response to a change in the operation related information received from the respective mail insertion machine. Each interactive icon is responsive to user actions for displaying selective operation related information about a respective mail insertion device.

Abstract: A stager interface apparatus and method for staging two-up printed material are disclosed. The stager interface apparatus and method, in the form of a cutter stager, by independently holding each piece of printed material, allow side-by-side printed material to be released downstream either simultaneously or sequentially dependent upon downstream requirements.

Abstract: A document transporting system for conveying documents along a transport path in a first direction from a document infeed station to a document processing station, certain of such documents being advanced along the transport path from the infeed station with an improper facing orientation. A plurality of document re-orienting devices are disposed adjacent the transport path between the infeed station and the document processing station. Each of the document re-orienting devices are adapted to receive an improperly oriented document, to reverse the orientation of the previously improperly oriented document, and to transport the correctly oriented document back onto the document transport path. Control elements operatively associated with each of the plurality of document re-orienting devices deliver improperly oriented documents into a pre-selected empty re-orienting device.

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 of synchronizing entry of a mailpiece from a mail feeder into a designated mailpiece location of a mail sorting conveyor. The method includes the steps of establishing a symmetric speed versus time profile around a send signal. In a first case, when the mailpiece stops before receiving the send signal, the method further includes following the speed versus time profile to accelerate to a merge speed for merging the mailpiece with the designated mail location of the sorting conveyor. In a second case, when the send signal arrives before the mailpiece reaches the stop position, holding the mailpiece at a constant speed across the speed versus time profile until the position of the mailpiece intersects an opposing side of the speed versus time profile and then following the speed versus time profile to accelerate the mailpiece to a merge speed for merging the mailpiece within the designated mail location of the sorting conveyor.

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 method of producing at least one control signal data look-up table for a mail insertion machine having a 360 degree cycle of operation and capable of variable operating speeds within a given cycle. The mail insertion machine possesses predetermined electro-mechanical lag times for extending and retracting mechanical components. The method entails creating a baseline control signal data look-up table for a first operating speed based upon pre-determined electro-mechanical lag times. The look-up table comprises a start angle and a stop angle within the 360 degree cycle of operation. The start and stop angles are then compensated for a second operating speed based upon the pre-determined electro-mechanical lag times for extending and retracting mechanical components and the first operating speed. A second control signal data look-up table is then created by writing the compensated start and stop angles that correspond to the second operating speed into the second control signal data look-up table.

Abstract: An in-feed magazine apparatus for loading documents includes a magazine feed ramp having one or more document conveyor belts disposed along a bottom surface, the belts being arranged to engage the bottom boundary of the documents. The conveyor belts are configured to effect forward movement of the stack of documents toward a document shingler mechanism along a linear axis defined by forward movement of the conveyor belts. Also included is a backing plate having a lower portion disposed proximal to the conveyor belt, an upper portion disposed vertically upward from the lower portion, and a generally planar face parallel to the plane defined by the face of the documents. An upper and lower sensor sense contact with the front end of the stack of documents while a controller operatively coupled to the upper and the lower sensors determines when the front end of the stack of documents lies in a plane substantially parallel to the face of the backing plate.

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 system for applying linerless labels to mailing items includes a label feeder for feeding a continuous length web of linerless label material from a supply roll through a loop path to a label applying station juxtaposed to the path traversed by mailing items conveyed on edge in sequential fashion by a belt conveyor. The label material passes through a web guide and advance assembly to a cutter station operative to sever the label material transversely and create labels of desired height. A paddle member is operative to engage and hold each successive label as it is being severed from the label material web generally simultaneously to adhere the adhesive side of the label against a mailing items passing through the label applying station. The various operating functions of the linerless label applying system may be coordinated by conventional control logic.

Abstract: A document accumulator comprising for high-speed document assembly includes first and second pulleys, a first outer belt extending between the first and second pulleys for contacting and transporting a document, a second outer belt extending between the first and second pulleys, and extending generally parallel to and horizontally displaced from the first outer belt, for contacting and transporting a document, and an inner belt generally parallel to and horizontally displaced from both the first and second outer belts such that it lies between the first and second outer belts. A first side guide has a first vertical surface adjacent to a horizontal reach of the first outer belt, and a second side guide has a second vertical surface adjacent to a horizontal reach of the second outer belt. A belt-dampening table having a horizontal surface adjacent to a horizontal reach of the inner belt is provided for dampening oscillations of the inner belts which occur at high speeds.

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 method and apparatus for document surveillance along a transport path in a mail sorting machine includes using a plurality of sequentially positioned photocells affixed along the transport path to detect document separation and jamming events through the application of assigned document identification and message transfer schemes whereby one sensor detects an edge of the document and transfers the document identifier and a shaft encoder count to the next sensor along the transport path in the form of a message. A message queue for each sensor is maintained to detect improper document leading edge and trailing edge conditions. A series of surveillance modules operates on a multi-tasking basis through a primary master processor.

Abstract: The apparatus is used to remove a generally rectangular container from an unloading device that places the container in a predetermined position. The container has a bottom surface, upstanding sidewalls and forward and rear endwalls. The apparatus includes a base portion for supporting the apparatus and a container removing arm pivotally attached to the base portion configured to releasably engage the container and remove the container from the unloading device. Also included are container engaging clamps operatively connected to the container removing arm arranged to contact and releasably engage at least one of the bottom surface, the upstanding sidewalls, the forward endwall, and the rear endwall of the container. A powered assembly pivotally displaces the container removing arm when the clamps releasably engage the container. A controller is operatively coupled to the powered assembly to selectively control forward and backward pivoting of the arm.

Abstract: A diverter apparatus and method are provided for high-speed media processing for diverting media such as envelopes or envelope inserts including folded sheets of paper from a conveying path and in a divert direction substantially opposite to the direction of the conveying path. In the preferred embodiment, the diverter apparatus includes a rotation member such as a belt which can be moved in opposite directions and which includes a plurality of push members thereon for engaging and conveying media. A closed-loop servomotor or a step motor can be utilized to drive the belt. In an advance mode, the belt rotates so that at least one push member causes media to be conveyed in the direction of the conveying path. In a divert mode, rotation of the belt is reversed so that at least one push member diverts and conveys media in a divert direction opposite to the direction of the conveying path. Diverted media is advanced to a divert chute through which it can pass to a collecting bin.

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.