Abstract: A method and system for dynamically adjusting the placement of internal content material to optimally position the content material relative to a wrapped enclosure, and obviate the requirement to out-sort the assembled envelope. Upon assembly, a detection system visually images each envelope in predetermined regions of interest (ROIs). A controller captures the image data for comparison with a set of predefined position data and issues a feedback signal indicative of a directional change which drives an error signal to zero. The correction signal is used by the phase nip roller assembly to adaptively adjust the position of the content material by incrementally adjusting, advancing or retarding, the phase-nip roller assembly, i.e., forward or aft. A predefined number of envelopes is selected to acquire a running average of the image data.

Abstract: A method and system for identifying and detecting improperly wrapped envelopes for use in a mailpiece fabrication system. The method/system visually images each envelope in predetermined regions of interest (ROIs) to determine the spatial relationship between the internal content material and one or more points of reference indicative of the internal bounds of a sealing adhesive. By examining the spatial relationship, a determination is made regarding the proximity of the internal content material and the sealing adhesive. If the distance, or spatial separation, therebetween is below a threshold value, then an assumption is made that the content material and sealing adhesive are contiguous and that the envelope has been improperly sealed, i.e., with the content material interposing or otherwise inhibiting the proper closure of the wrapped envelope.

Abstract: A system for handling tape dispensers to be used by parcel preparation workers. Identification markings on the parcels are scanned. The identification markings are matched with corresponding different kinds of packaging tape. A tape dispenser receptacle holds a plurality of tape dispensers in respective cradles. Each of the cradles has an associated display indicator that is activated based on the type of packaging tape determined by the scanner and the processor.

Abstract: A system for handling tape dispensers to be used by parcel preparation workers. Identification markings on the parcels are scanned. The identification markings are matched with corresponding different kinds of packaging tape. A tape dispenser receptacle holds a plurality of tape dispensers in respective cradles. Each of the cradles has an associated display indicator that is activated based on the type of packaging tape determined by the scanner and the processor.

Abstract: A method and apparatus are for decelerating a sheet of paper in a paper-cutting system. The sheet of paper is cut using a cutter, and the sheet is then accepted into a take-away nip. The take-away nip is operated at an initial rate in order to move the sheet of paper away from the cutter at an initial speed. The take-away nip is then operated at a rate decreasing to a final rate, in order to decelerate the sheet of paper to a final speed by the time the sheet of paper exits the take-away nip. The take-away nip is subsequently operated at the initial rate again, prior to accepting another sheet of paper at the initial speed.

Abstract: A method for producing a continuous web of printed material for use in creating mailpieces. The continuous web has a width and a length, the length comprised of a series of attached sheets. The series of attached sheets are comprising envelope sheets and rectangular content pages. The content pages are rectangular in shape and may be oriented relative to the envelope sheets in a number of different configurations. In some configurations, two sets of content pages and/or envelope sheets can be printed across the width of the web. Sheets for forming business return envelopes may be printed in series with the content pages and envelope sheets. BREs may include individualized return addresses. A control code may be printed on one or more of the sheets for a given mailpiece, providing information for controlling assembly of the mailpiece.

Abstract: A method and system for dynamically adjusting the placement of internal content material to optimally position the content material relative to a wrapped enclosure, and obviate the requirement to out-sort the assembled envelope. Upon assembly, a detection system visually images each envelope in predetermined regions of interest (ROIs). A controller captures the image data for comparison with a set of predefined position data and issues a feedback signal indicative of a directional change which drives an error signal to zero. The correction signal is used by the phase nip roller assembly to adaptively adjust the position of the content material by incrementally adjusting, advancing or retarding, the phase-nip roller assembly, i.e., forward or aft. A predefined number of envelopes is selected to acquire a running average of the image data.

Abstract: A method and system for identifying and detecting improperly wrapped envelopes for use in a mailpiece fabrication system. The method/system visually images each envelope in predetermined regions of interest (ROIs) to determine the spatial relationship between the internal content material and one or more points of reference indicative of the internal bounds of a sealing adhesive. By examining the spatial relationship, a determination is made regarding the proximity of the internal content material and the sealing adhesive. If the distance, or spatial separation, therebetween is below a threshold value, then an assumption is made that the content material and sealing adhesive are contiguous and that the envelope has been improperly sealed, i.e., with the content material interposing or otherwise inhibiting the proper closure of the wrapped envelope.

Abstract: A system and method for skew correction of a mailpiece includes moving the mailpiece along a path of travel in a first orientation toward a first drive roller and a second drive roller. Control of the mailpiece is established in the first orientation by the drive rollers. A first skew correction of the mailpiece is implemented by employing the first drive roller and the second drive roller to align the mailpiece with respect to the path of travel. The first drive roller and the second drive roller may be employed to change the orientation of the stopped mailpiece from the first orientation to a second orientation with respect to the path of travel. A second skew correction may be implemented by employing the first drive roller and the second drive roller to align the mailpiece in the second orientation with respect to the path of travel.

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: An item transport system includes an input transport for receiving items along a first transport path, an angle transport for conveying the items along a second transport path disposed at an angle with respect to the first transport path, an alignment transport for conveying the items along a third transport path disposed at approximately 90 degrees to the first transport path, and an alignment surface for engaging the items while the items are conveyed in the alignment transport. The alignment transport may include an alignment nip comprising a driven element and an idler element for engaging opposing surfaces of the items, a manifold, a source providing pressurized gas to the manifold, and an orifice in the manifold proximate to the third transport path, wherein the idler element is disposed in the orifice.

Abstract: An item handling system includes a transport system defining a transport plane, a printer assembly defining a printer plane, and a printer alignment system supporting the printer assembly. The printer alignment system includes a plurality of drive elements configured to move the printer assembly. A method of aligning a printer in the item handling system includes moving the printer assembly to a limit position of the printer alignment system distal from the transport system using the drive elements, moving the printer assembly to a limit position of the printer alignment system proximate to the transport system using the drive elements, and driving each of the drive elements at a respective predetermined level to place the printer plane in a substantially parallel orientation with respect to the transport plane.

Abstract: A method for creating mailpieces from a single web of printed material. The web of printed material includes printed matter to be used on envelopes, and other printed matter to be used on mail content to be included in the envelopes. The method starts with cutting consecutive sections of the web into separated sheets. Some of the separated sheets are envelope sheets including envelope printed matter, and some of the sheets are mail content sheets including mail content printed matter. The method includes cutting variable sized sheets depending on whether a sheet is a mail content sheet, or an envelope sheet. The method further includes cutting variable sized envelope sheets depending on the size of the mailpieces.

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 system for controlling friction forces acting on a mailpiece in a mailpiece insertion module. The system includes, a backstop assembly for arresting the motion of the envelope when disposed in a first positon and permitting conveyance along the feed path when disposed in a second position, an actuator operative to position the backstop assembly into the first and second positions and consuming energy to maintain the backstop assembly in the first position, a sensor for acquirinq data indicative of the magnitude of energy consumed by the actuator; a means for developing a pressure differential across the envelope to urge the envelope into frictional engagement with a plurality of drive belts and for developing friction forces along a mating interface, and a system controller, for varying the magnitude of the pressure differential and the friction forces developed along the mating interface of the envelope.

Abstract: A system for controlling friction forces acting on a mailpiece in a mailpiece insertion module. The system includes a backstop assembly for arresting the motion of the envelope when disposed in a first position and permitting conveyance along the feed path when disposed in a second position, an actuator operative to position the backstop assembly into the first and second positions and consuming energy to maintain the backstop assembly in the first position, a sensor for acquiring data indicative of the magnitude of energy consumed by the actuator; a means for developing a pressure differential across the envelope to urge the envelope into frictional engagement with a plurality of drive belts and for developing friction forces along a mating interface, and a system controller, for varying the magnitude of the pressure differential and the friction forces developed along the mating interface of the envelope.

Abstract: A method for tuning operation of servo motors includes selecting a plurality of discrete positions in a guillotine blade cycle for which to determine tuning coefficients, determining tuning coefficients at the discrete positions, interpolating tuning coefficients for positions between the discrete positions, and applying the determined and the interpolated tuning coefficients to the servo motor. The servo motors may be used in connection with a guillotine cutter for separating individual sheets from a continuous web. The guillotine cutter blade may be driven by a servo motor to cyclically lower and raise to transversely cut the web transported below the cutter blade.

Abstract: A printing assembly includes a transport system configured to transport items on a transport path and a printer rotatably disposed on a support. The printer includes a plurality of printing elements disposed sequentially along the transport path. A method of calibrating the printing assembly includes aligning a first reference associated with the printer with a second reference associated with the support, transporting an item on the transport path, printing a pattern on the item using a first printing element and a second printing element, determining a correction value from the pattern, and rotating the printer relative to the support in an amount corresponding to the correction value to substantially align the printing elements with the transport path.

Abstract: A system for controlling friction forces acting on a mailpiece in a mailpiece insertion module.

Abstract: A method of detecting mailpiece thickness includes detecting a leading edge of the mailpiece, moving a detecting roller downwardly over a first predetermined period of time from a first position to a second position where it contacts the mailpiece, increasing a compressive force applied by the detecting roller to the mailpiece from an initial force to a predetermined measurement force over a second predetermined period of time, and applying the measurement force to the mailpiece for a third predetermined period of time. The method further includes applying the measurement force to the mailpiece for a fourth predetermined period of time and making a number of thickness measurements of the mailpiece based on a position of the detecting roller, and determining the thickness of the mailpiece based on the number of thickness measurements.