Abstract: A high speed apparatus and method for reorienting and assembling individual ones of flat articles, such as envelopes, into horizontal rows of articles which are vertically oriented, on edge, and stacked in facing relation. Envelopes are delivered horizontally and seriatim, to an article rotation assembly. The rotation assembly reorients the envelopes into a vertical, on-edge orientation, and feeds them individually to a helical drive assembly. The drive assembly includes a pair of parallel, counter-rotating, helical screws, mounted on a pivotally suspended sub-frame. The screws transport the envelopes in spaced relation to an accumulating conveyor. The conveyor has movable brace plate, transversely positioned over a pair of conveyor belts. A roller on one end of the plate rests upon one of the belts. Successive envelopes are delivered to and stacked against the brace plate. As the pressure increases, the sub-frame pivots away from the plate until a predetermined limit is reached.

Abstract: In a mail inserter machine including at least one subassembly with a component driven in reciprocating fashion, an apparatus for inserting a sheet into an envelope. The apparatus comprises a movable gripper jaw assembly, an envelope vacuum cup assembly, an envelope opener assembly including a nozzle in communication with a gaseous fluid supply source, and an insertion assembly. An electrical control circuit is adapted to issue electrical control signals to the respective assemblies, in such manner that the occurrence and duration of the control signals determine relative periods of operation of the assemblies during a cycle of operation of the apparatus and over a range of speeds of the apparatus.

Abstract: In a mail inserter having a 360 degree operational cycle and a plurality of subassemblies, a computer issues a plurality of electrical control signals having predetermined rotational positions and durations within the operational cycle at a given inserter speed. Solenoids, actuators and other driving devices are responsive to the control signals to determine the operation of the subassemblies. A device measures the operation speed of the inserter, and the computer adjusts the rotational position of each control signal within the operational cycle according to the inserter speed.

Abstract: An apparatus and method for computerized control of a "Phillipsburg-type" mail insertion machine. The mechanical timing and drive mechanisms of the prior art inserter are replaced with a programmable computer, solenoid valves, and pneumatic cylinders, or other suitable drivers. The computer's software includes a plurality of programmed look-up tables. An operational delay look-up table includes electro-mechanical lag times for the pneumatically driven stations/sub-assemblies of the inserter. Also provided are look-up speed tables, which include start and stop angles for actuation of each of the pneumatic cylinders. A first look-up speed table includes actuation data appropriate for operation of the machine within a relatively slow range of speeds. Four additional look-up speed tables provide correct actuation data for successively higher speed groups, up to 10,000 insertion cycles per hour.

Abstract: A method of producing at least one control signal data look-up table for a mail insertion machine having a 360 degree cycle of operation and capable of variable operating speeds within a given cycle. The mail insertion machine possesses predetermined electro-mechanical lag times for extending and retracting mechanical components. The method entails creating a baseline control signal data look-up table for a first operating speed based upon pre-determined electro-mechanical lag times. The look-up table comprises a start angle and a stop angle within the 360 degree cycle of operation. The start and stop angles are then compensated for a second operating speed based upon the pre-determined electro-mechanical lag times for extending and retracting mechanical components and the first operating speed. A second control signal data look-up table is then created by writing the compensated start and stop angles that correspond to the second operating speed into the second control signal data look-up table.

Abstract: An apparatus and method for computerized control of a "Phillipsburg-type" mail insertion machine. The mechanical timing and drive mechanisms of the prior art inserter are replaced with a programmable computer, solenoid valves, and pneumatic cylinders, or other suitable drivers. The computer's software includes a plurality of programmed look-up tables. An operational delay look-up table includes electro-mechanical lag times for the pneumatically driven stations/sub-assemblies of the inserter. Also provided are look-up speed tables, which include start and stop angles for actuation of each of the pneumatic cylinders. A first look-up speed table includes actuation data appropriate for operation of the machine within a relatively slow range of speeds. Four additional look-up speed tables provide correct actuation data for successively higher speed groups, up to 10,000 insertion cycles per hour.

Abstract: An apparatus and method for singulating sheets from a stack of sheets and transporting individual ones of them to a conveyor. A picker arm is mounted at its upper end to a rotatable shaft, for reciprocating movement between first and second positions. A lower end of the arm includes a foot and a movable gripper jaw. When the arm is rotated into the first position, it grasps a segregated sheet. As the arm reverses direction and rotates toward the second position, it draws the sheet away from the stack. A sensor, provided within the foot, produces an electrical signal corresponding to the thickness of the sheet. The digital output signal is compared to a reference, or calibration value stored in a computer. If the output signal falls unacceptably outside the reference value, a signal is stored to effect later outsorting. Just before the arm reaches the second position, the jaw is opened, dropping the sheet upon the conveyor.