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 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: 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 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: 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: 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.

Abstract: A multi-pass sorting machine includes a housing or 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 feeder first transporting mechanisms, a singulating device, an accelerating mechanism, second transporting mechanisms, a bar code reader and associated electronic and computer equipment, a plurality of first sorting devices in the form of diverting vanes, an equal number of first pass stacker buffers, 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.

Abstract: A speed optimization circuit (140) is employed by an insertion machine to result in a greater actual throughput of successfully enveloped sets of documents. The speed optimization circuit (140) includes a microcontroller (142) which determines whether the machine cycling speed should be changed and which generates a signal for application to a speed adjustment servomechanism (136) for automatically changing the machine cycling speed in accordance with the determination.

Abstract: A speed optimization circuit (140) is employed by an insertion machine to result in a greater actual throughput of successfully enveloped sets of documents. The speed optimization circuit (140) includes a microcontroller (142) which determines whether the machine cycling speed should be changed and which generates a signal for application to a speed adjustment servomechanism (136) for automatically changing the machine cycling speed in accordance with the determination.

Abstract: Apparatus for stacking a plurality of documents on one edge thereof in vertically disposed position which comprises a movable stacker carriage adapted for movement between a forward and a rear position. An upper stacking screw worm rotatable about a horizontal axis is rigidly attached to the movable stacker carriage and functions to move documents laterally away from the carriage and into stacked relationship. At least one lower stacking screw worm and preferably two lower stacking screw worms rotatable about horizontal axes are rigidly attached to the movable stacker carriage and function to move documents laterally away from the carriage and into stacked relationship. The upper and lower stacking screw worms are rotatable. The stacking apparatus is adapted for use with a device for delivering single documents thereto and the stacking apparatus can be used with a movable transport element such as a conveyor for transporting stacked documents.

Abstract: Apparatus and method for automatically preparing large mailings in which one or more documents are nested within the fold of a letter sheet prior to insertion into an outer envelope. One or more unfolded letter sheets are transported to a folding operation involving a clamp assembly and a roller folding assembly which is movable into engagement with the clamp assembly. After folding and prior to stuffing into an envelope, one or more inserts can be inserted within the folded letter sheet.

Abstract: Method and apparatus for detecting article engagement errors and for calibrating engagement error detection apparatus associated with a plurality of gripper arms (16) of an insertion machine (10). Gripper arms (16) at each of a plurality of insert stations S comprise a first jaw member (24) and a second jaw member (26) which selectively engage articles therebetween. Field-generating means (420) is mounted on one jaw member while a Hall Effect sensor (400) is connected on the other jaw member. The sensed flux density of the generated field is a function of the relative displacement of the first and second jaw members (24,26). A signal generated by the sensor (400) operated in a slide-by mode is related to the separation of the first jaw member (24) and second jaw member (26). If the sensor-generated signal is within predetermined limits of a stored reference signal a proper number of articles are engaged between the first and second jaw members (24,26).

Abstract: An electromechanical automated document encoding apparatus is releasably constructed of modular components for accepting and transporting batch documents from either the left or the right. The apparatus is further capable of printing on a first side of a document or an opposite facing second side. A print module includes two parallel document receiving tracks, and a rotatable print head which moves responsive to movement of a table mounting the two document receiving tracks. The print head has two positions, and is capable of printing either on the front or rear of the document. Neither reversing print modes nor feeding batches of documents of different or varying thicknesses require realigning or repositioning of the printing head. Document sensors are an integral part of an adaptive control system optimizing apparatus productivity.

Abstract: A gripper arm includes jaw members (24,26) between which articles are engaged and from which engaged articles are released in precise placement upon a transport means. Jaw (26) is actuated by solenoid actuating means (28) acting through linkage means (30) to perform the engagement and release operations. The activation of the solenoid actuating means (28) is controlled to be dependent upon the operating speed of a machine in conjunction with which the gripper arm is used. The solenoid actuating means (28) is assisted by biasing means (122) which is preloaded to facilitate the application of a desired holding force on articles engaged between the jaw members (24,26). The jaw member (24) has a piece (162) of high coefficient of friction material embedded in a surface oriented to contact articles engaged between the jaws (24, 26).

Abstract: A device for feeding envelopes from a hopper to an envelope reading station upon demand. A pair of drive rollers are mounted on a first drive shaft by means of a one-way clutch which allows the rollers to rotate only in a feeding direction. Mounted below the drive rollers are a pair of driven rollers which have a brake applying a force to them counter to the feeding direction. The braking force minimizes the possibility of feeding two documents at the same time. A second substantially identical set of rollers are mounted downstream of the first set of rollers. Upon demand envelopes are fed through the feeder and retained in the nip of the second set of rollers with a portion of the envelope extending into an envelope reading area. An operator reads address indicia from the envelope and keys it into envelope processing apparatus.

Abstract: A device for feeding envelopes from a hopper to an envelope processing station. Driving and driven rollers feed the envelopes one at a time from the hopper. The rollers define a nip through which the envelopes are fed. A unique "U" shaped spring forces the driven roller to contact the driving roller causing the driven roller to oscillate when no envelopes are fed. The oscillation helps envelope feeding by pulling and separating the lead envelope from the stack.