Abstract: A registration device for a mail processing system having wide print nozzle arrays that reduces problems associated with printing on variable thickness media. A thin wire, held by guides, is strung across the print nozzle openings in the registration plate to support and guide the top (print) surface of a mail piece and to prevent the mail piece from protruding into the openings. The guides are positioned such that the wire passes between zones where there are no print nozzles located. A tensioning device is provided to adjust the tension of the wire to ensure the wire maintains its position within the openings. The wire acts as a guide to maintain the optimal gap between the mail piece top surface and the print nozzles.

Abstract: A registration device for a mail processing system having wide print nozzle arrays that reduces problems associated with printing on variable thickness media. A thin wire, held by guides, is strung across the print nozzle openings in the registration plate to support and guide the top (print) surface of a mail piece and to prevent the mail piece from protruding into the openings. The guides are positioned such that the wire passes between zones where there are no print nozzles located. A tensioning device is provided to adjust the tension of the wire to ensure the wire maintains its position within the openings. The wire acts as a guide to maintain the optimal gap between the mail piece top surface and the print nozzles.

Abstract: A calibration procedure is carried out for determining the displacement distance from a reference point to the center of the blade in a web cutter in a mail inserter. A photosensor is placed near the paper plane of the web cutter to sense a web edge at the reference point downstream or upstream from the blade. At the start of the calibration procedure, the blade is caused to cut the web for providing a web edge. The web edge is moved in a backward and forward motion over the photosensor a few times for determining the theoretical center position of the photosensor relative to the position where the web is cut by the blade. By taking into account the chip-out width, the displacement distance from the center of the photosensor to the center of the chip out blade can be determined.

Abstract: A calibration procedure is carried out for determining the displacement distance from a reference point to the center of the blade in a web cutter in a mail inserter. A photosensor is placed near the paper plane of the web cutter to sense a web edge at the reference point downstream or upstream from the blade. At the start of the calibration procedure, the blade is caused to cut the web for providing a web edge. The web edge is moved in a backward and forward motion over the photosensor a few times for determining the theoretical center position of the photosensor relative to the position where the web is cut by the blade. By taking into account the chip-out width, the displacement distance from the center of the photosensor to the center of the chip out blade can be determined.

Abstract: An apparatus and method are disclosed for preventing components in an inserter machine from causing the inserter machine to stop or function less than optimally due to lack of proper attention from an operator. Accordingly, various component conditions are categorized based upon two or more levels of urgency, and each component having such a condition signals the category of urgency to an operator.

Abstract: A buckle chute folder for folding one or more sheets of paper, including a buckle chute and a pair of folding rollers situated downstream of the buckle chute. Each of the folding rollers has a plurality of circumferential grooves extending perpendicular to the axis of the roller, and the grooves of one roller are offset with respect to the grooves of the other roller.