Abstract: System and method for monitoring grouped resources. A system and method of monitoring resource units in a stack is provided. The system and method includes providing a group of resource units and determining a thickness of one or more of the resource units. The system and method also includes indicating when the group of resource units reaches a predetermined size after one or more of the resource units has been moved from the group.

Abstract: A jam detector in an inserting station of an inserter comprises horizontal and vertical photosensors and therewith associated retroreflective targets; the horizontal sensors have a light beam directed across and above an envelope positioned in the inserting station, and the vertical sensors have a pair of vertical light beams directed toward opening fingers while the fingers are positioned in the inserting station for holding envelopes open. The jam detector detects jam malfunctions during the inserting cycle by sensing interruption of the horizontal beam and uninterrupted retroreflection of the vertical beams.

Abstract: A turnover module for turning over envelopes comprises a plurality of pulleys and disposed thereabout a driven endless belt in the general shape of a flattened figure `8`. The belt includes a crossover region and a first and a second reach extending therethrough. The reaches contact one another resiliently along length portions thereof while crossing over and twisting about one another. Envelopes are received in a first orientation at an entry end of the reaches; nipped between the reaches; transported thereby through the crossover region while being turned over by virtue of the twist of the reaches about one another; and, delivered from the turnover module in a second orientation.

Abstract: In an inserter, a skew and misalignment detector for measuring skew misalignment of inserts that are conveyed on and along a conveyor comprises a plurality of photosensors disposed above the insert-conveying path in transverse relation thereto and a plurality of retroreflective targets disposed beneath the insert-conveying path in transverse relation thereto and directed toward the photosensors. Inserts obstruct the targets while being conveyed thereover. The photosensor signals are sampled in synchronism with the insert-conveying motion. The obtained signals are evaluated in relation to pre-established skew rejection threshold criteria in dependence on insert conveying speed. Inserts are diverted when the skew detector arrangement provides measures of skew and misalignment of inserts that exceed rejection threshold criteria.

Abstract: An inserter with collation tracking comprises a programmable computer, means for tracking handled items including individual tracking and collation tracking, sensing means for sensing individual items in different locations, as well as for sensing defective, multiple or missing items, corrective action means, and, means for updating tracking information in correspondence with corrective action taken. The inserter performs corrective action in the form of the rejection and diversion of defective items. Further, the inserter provides for complementarily associating envelopes with particular inserts intended for insertion thereinto, for collation tracking of such complementarily-associated items, and for the diversion of such associated items if at least one of the associated items has been stigmatized as defective.

Abstract: An inserter station for inserting inserts into envelopes comprises an insert conveyor for conveying inserts to an inserting location, a gripper drum for delivering envelopes to the inserting location, vacuum means for holding bottom surfaces of envelopes, suction cups for lifting top sides and opening envelopes, and an insert pusher for pushing inserts into opened envelopes. The insert pusher moves along a noose-shaped path in a vertical plane. The path has a horizontal, forwardly-directed portion along which the pusher moves to engage and push inserts into evelopes. The path has a retracting portion that curves downwardly and backwardly out of the way of envelopes and inserts being provided to the inserting location. In operation, an envelope is delivered to the inserting location and has its bottom surface held by vacuum applied thereto. The top side of the envelope is lifted by suction cups so that the envelope is opened to receive inserts.

Abstract: An envelope flap opener comprises a revolving gripper drum for conveying envelopes thereupon in flap-up orientation with flap edge trailing and a revolving rotor disposed vicinally to the gripper drum, the rotor having at least one sucker cup extending from its periphery. Vacuum is valved to the sucker cup at a time when an envelope is conveyed upon the gripper drum past the rotor, the sucker cup grabs and opens the envelope flap, and subsequently the flap is released. Prior to release of the flap, a plow device intercepts the flap and further unfolds it. The plow device includes a photo-sensor for checking of proper flap opening and for detecting missing envelopes.

Abstract: A feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of inserts comprises: a gripper drum disc for transporting the inserts upon its periphery; a detector caliper assembly including a pivotable arm having a follower roller borne at one end and a magnet mounted at the other end, the arm being spring loaded with the follower roller against the periphery of the gripper drum disc; and, a stationary Hall sensor to measure relative displacement between the sensor and the magnet. As an insert is transported upon the periphery of the gripper drum disc, the insert is interposed between the periphery and the follower roller and the Hall sensor senses the consequent magnet displacement as a measure of the thickness of the insert. In one embodiment, an adjustable anvil having a peripheral surface is mounted on a face of the gripper drum disc. The anvil is pre-adjusted so that its peripheral surface is disposed at a constant radius from the axis of rotation of the disc.

Abstract: An in-line rotary inserter device comprises an envelope feed station (30) and insert feeding modules (20,22,24,26), an inserting station (32), a sealing and stacking assembly (38,40,42), and various diverters (33,36,56). The envelope feed station (30) withdraws envelopes from a hopper-held envelope stack )66,94) and conveys them to the inserting station (32). Each insert feeding module comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor (34). The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station (32). Diverter stations for diversion of envelopes and inserts in various locations along their feed paths are provided for normal operational purposes and for rectification of sensed fault conditions. Subsequently to inserting, insert-filled envelopes are conveyed from the inserting station (32), are sealed, turned, stacked, and processed through operations that are customary in preparation of mailable items.

Abstract: An in-line inserter device comprises envelope and insert feeding assemblies, an envelope inserting station assembly, a sealing and stacking assembly, and various diverter stations. The envelope feeding assembly withdraws envelopes from a hopper-held envelope stack and conveys them to the inserting station. Each modular insert feeding assembly comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor. The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station. Diverter stations are disposed ahead of the envelope inserting station for diversion of envelopes and inserts and ahead of the inserted envelope stacking assembly to divert inserted envelopes, for normal operational purposes and for rectification of sensed faults by rejection and extraction of processed faulty items.