Abstract: An apparatus for weighing mail pieces being advanced across a transport path including a weighing module having load cells, an in-feed drive module and a takeaway module. The scale platform is mounted independently of the in-feed drive module and the takeaway module, and the scale platform comprises an uninterrupted mail piece support surface. A control system is provided that acquires a mail piece weight signal when the lead edge of a mail piece reaches a sensor at the exit of the weighing module. Sensors also calculate the velocity of a mail piece as it leaves the weighing module, whereby speed of each mail piece is accelerated to its original speed and position in the mail transport path. Mail weighing throughput rates of up to 10 mail pieces per second are achieved.

Abstract: The present invention relates to an apparatus for collating a plurality of separate groups or bundles of similar flats mailpieces arranged in a predetermined delivery point sequence, each mailpiece imprinted with a distinct delivery point or address indicia, to produce a single stream of mailpieces in new groups, where each new group comprises a plurality of mailpieces all addressed to a distinct delivery point. The apparatus comprises a plurality of feed units, each unit configured to process a quantity of similar mailpieces, each with a distinct delivery point indicia on the face of the mailpiece, and to deposit each mailpiece in a distinct pocket on a collation conveyor which traverses all of the plurality of feed units. Each pocket will ultimately contain different mail pieces, all addressed to the same delivery point Multiple new groups of mailpieces are then automatically placed in containers in a sequence corresponding to a predetermined delivery route.

Abstract: A method and apparatus is disclosed for combining multiple small stacks of flats mailpieces into a single large stack of mailpieces and then transferring the large stack to a standard flats mail tray, all while maintaining the sequence order of the mail in the accumulated stack. The apparatus is comprised of three primary subsystems: a bridge conveyor, a stack accumulator, and an output tray station. The bridge conveyor carries mailpieces from the exit conveyor of a mail processing machine such as a collator, to the stack accumulator. The stack accumulator combines small stacks of mailpieces into large stacks in a desired sequence. The output tray station provides support for an empty tray as the accumulated mail stack is transferred to the tray, and then releases the filled tray in a controlled manner.

Abstract: An apparatus and method to individually weigh continuously fed mail pieces wherein each mail piece is configured in a vertical orientation and fed through the weighing system in seriatim. The apparatus contains a scale transport assembly for transporting mail pieces seriatim, a mail piece channel pathway assembly for maintaining the vertical orientation of individual mail pieces, a load cell assembly for measuring the mail piece weight, an x-y table assembly for allowing position adjustments of the weighing system, data collection circuitry, and a support module. The apparatus can be used in conjunction with bulk mail processing systems or it can be used independently.

Abstract: The invention is directed to an automatic mail tray loading device that is adapted to receive envelopes from an inserting machine or from other mail-processing systems and place them in mail trays. The device has a two-stage envelope buffer, which buffers the envelopes into a shingled array before depositing them into the mail tray. The first stage buffers the envelopes during purging of the second stage and the second stage buffers the mail during a tray change. The mail trays are held on a tray conveyor, at an inclination that ensures proper loading of the tray and reliable transfer of envelopes from the tray. The tray conveyor incrementally moves the envelope tray downward until the tray is full of envelopes. A new, empty tray is then moved into position and the filled tray is moved laterally to the tray offload station. The system comprises an envelope conveyor, a tray conveyor, a lateral tray transfer mechanism and an auxiliary buffer.

Abstract: The present invention relates to an apparatus for collating a plurality of separate groups or bundles of similar flats mailpieces arranged in a predetermined delivery point sequence, each mailpiece imprinted with a distinct delivery point or address indicia, to produce a single stream of mailpieces in new groups, where each new group comprises a plurality of mailpieces all addressed to a distinct delivery point. The apparatus comprises a plurality of feed units, each unit configured to process a quantity of similar mailpieces, each with a distinct delivery point indicia on the face of the mailpiece, and to deposit each mailpiece in a distinct pocket on a collation conveyor which traverses all of the plurality of feed units. Each pocket will ultimately contain different mail pieces, all addressed to the same delivery point Multiple new groups of mailpieces are then automatically placed in containers in a sequence corresponding to a predetermined delivery route.

Abstract: The present invention relates to an apparatus for collating a plurality of separate groups or bundles of similar flats mailpieces arranged in a predetermined delivery point sequence, each mailpiece imprinted with a distinct delivery point or address indicia, to produce a single stream of mailpieces in new groups, where each new group comprises a plurality of mailpieces all addressed to a distinct delivery point. The apparatus comprises a plurality of feed units, each unit configured to process a quantity of similar mailpieces, each with a distinct delivery point indicia on the face of the mailpiece, and to deposit each mailpiece in a distinct pocket on a collation conveyor which traverses all of the plurality of feed units. Each pocket will ultimately contain different mail pieces, all addressed to the same delivery point. Multiple new groups of mailpieces are then automatically placed in containers in a sequence corresponding to a predetermined delivery route.

Abstract: An apparatus and method to individually weigh continuously fed mail pieces wherein each mail piece is configured in a vertical orientation and fed through the weighing system in seriatim. The apparatus contains a scale transport assembly for transporting mail pieces seriatim, a mail piece channel pathway assembly for maintaining the vertical orientation of individual mail pieces, a load cell assembly for measuring the mail piece weight, an x-y table assembly for allowing position adjustments of the weighing system, data collection circuitry, and a support module. The apparatus can be used in conjunction with bulk mail processing systems or it can be used independently.

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 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 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: 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 conveyer 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 conveyer 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 pivotal mail tray unloader for unloading a tray having mail pieces horizontally stacked therein includes a frame having an elongated, inclined support surface, a carriage slidably mounted to the frame, and a retaining member slidably mounted to the frame. The carriage includes first, second and third pivotal support members. The first support member pivots upwardly and forwardly from said support surface and carries the tray thereon. The second support member is also pivotal upwardly and forwardly and is positioned adjacent to and forward of the first support member. The second member receives the tray from the first support member. The third support member is mounted to the second support member forward thereof and is adapted to receive the mail pieces thereon. The third support member pivots forwardly to receive the mail pieces and subsequently, pivots rearwardly to reorient the mail in a generally vertical orientation.

Abstract: A buffered stacking system for selectively diverting horizontally disposed documents from a generally horizontal main conveying path, stacking the documents in a horizontal orientation and dropping the documents into replaceable receiving receptacles is provided. The system has a primary horizontal conveyor belt with a lower horizontal reach defining a horizontal primary conveying path. A plurality of sorting stations are located serially along and below the primary conveying path. Each of the sorting stations has at least one diverter arm disposed along the conveying path. The diverter arms are selectively movable from a generally horizontal position which allows passage of the documents along the conveying path to an inclined position to divert the document into the corresponding sorting station. The diverter arms divert the document in a downwardly inclined direction into a stacking station.

Abstract: A labeling assembly for applying labels carried on a substrate to a sequential series of moving documents is provided. The assembly transports the document in a generally vertical end on end orientation down a conveying path and peels the label from the substrate to position the peeled label in a generally vertical orientation. The labeling assembly also includes a paddle having a front surface with vacuum ports for attaching and releasably retaining the peeled label on the front surface. An actuating mechanism pivots the paddle to force an end of the retained label into contact with the document. Upon contact, the downstream end of the retained label adheres to the document and the label is pulled off the paddle. As the label is pulled off the paddle the contact between the end of the paddle presses the label against the document.

Abstract: A buffered stacking apparatus selectively diverts horizontally disposed documents from a main conveying path, then stacks and transports the documents to replaceable receiving receptacles. The apparatus has a primary horizontal conveyor belt with a lower reach defining a horizontal primary conveying path and at least one secondary conveyor belt having an upper reach which, when the secondary conveyor belt is in a horizontal position, is disposed in a lower juxtaposed relation to the lower reach of the primary conveying belt. The buffered stacking system also selectively effects pivotal movement of the secondary conveyor belt from the horizontal position to a second inclined position wherein the reach of the secondary belt is inclined to the lower reach of the primary conveyor belt. Documents being transported along the primary conveying path are diverted along the inclined reach when the secondary conveying belt is inclined.

Abstract: Apparatus for shingling a plurality of documents disposed in stacked relation so that the stack extends successively from a first end to a second end, and has at least one boundary defined by substantially coplanar marginal edges of the documents. The stack of documents is conveyed along a predetermined path during which one or more rotatable shingling members engage the coplanar marginal edges of the documents and impart velocity components of progressively increasing magnitude to the marginal edges in a manner to effect movement of the documents into a shingled array. In the preferred embodiments, the rotatable shingling member has a conical shingling surface traversed by the documents in tangential relation so that the velocity components imparted to the marginal edges of the documents lie in the planes of the documents and move them laterally in shingled relation to each other.

Abstract: An apparatus for separating and advancing documents includes a first assembly having movable belts for frictionally engaging and advancing one of the documents along a path, and a second assembly having stationary belts and retrogressingly moving a portion of an endless belt along the path to frictionally engage and halt the remainder of the documents. The retrogressional movement of the endless belt distributing wear experienced by the engaging and halting of documents over the length of the endless belt. The movable belts of the first assembly and the belts of the second assembly are disposed in relative juxtaposition whereby the one document is gripped between the first assembly and second assembly and advanced along the path under the influence of the first assembly.

Abstract: An Apparatus for separating and advancing documents includes a moving element for frictionally engaging and advancing one of the documents along a path, and a stationary element for frictionally engaging and halting the advance of the remainder of the documents. The moving element and the stationary element each include a plurality of belts and are disposed in relative juxtaposition whereby the one document is gripped between the moving element and the stationary element and advanced along the path under the influence of the moving element. The moving element and the stationary element contact the first and second surfaces, respectively, of the one document via the respective belts to provide a column strength to the one document over a substantial surface area of the document as the one document advances through the apparatus, thereby preventing portions of the one document from being crimped between the moving element and the stationary element.

Abstract: The multi-pass sorting machine of this disclosure includes a supporting structure which has the configuration of an A-Frame. The A-Frame structure has a slanting front side supporting several individually functional devices and a slanting back side supporting other individually functional devices. The devices of the front side include an input feeding means, a first transporting means, a singulating means, an accelerating means, a second transporting means, a bar code reader and associated electronic and computer means, a plurality of first sorting means in the form of diverting vanes, an equal number of first pass stacker buffer means, and a reversing member for transporting letters from the front side to the back side while at the same time retaining the same orientation of the letters to the planar surface as the letters go around the corner.