Abstract: A system for conveying mailpieces along a conveyance path and singulating a mailpiece from a stack of mailpieces along the conveyance path. The system includes a first conveyance for conveying mailpieces at a variable velocity and a second conveyance, downstream of the first conveyance, for conveying mailpieces at a constant velocity along the conveyance path. A series of optical sensors extends from the first to the second conveyance and is operative to issue a gap signal indicative of the relative spacing between sequential mailpieces along the conveyance path. A processor is responsive to the gap signal and is operative to control the first conveyance to decrease the relative spacing between sequential mailpieces when the gap signal exceeds a threshold value.

Abstract: A system for conveying mailpieces along a feed path includes a plurality of conveyances. A first conveyance is operative to convey mailpieces along the feed path and includes a singulating and drive belt. The singulating and drive belts define a throat for singulating a mailpiece from the stack of mailpieces. A second conveyance accepts mailpieces from the first conveyance and conveys singulated mailpiece downstream of the first conveyance. The system further includes a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path. Additionally, the system includes a means, responsive to the gap signal, for developing a variable opposing force between the singulating and drive belts to optimize singulation of mailpieces along the feed path.

Abstract: A system for singulating mailpieces including a first conveyance including a pair of opposing belts for singulating a mailpiece from a stack of mailpieces. The system includes an actuation mechanism operative to apply a force pulse through one of the belts to momentary separate mailpieces of the stack and augment singulation of the mailpiece from the stack by the first conveyance.

Abstract: A system for conveying mailpieces along a feed path including first and second conveyances. A first conveyance is operative to convey mailpieces along the feed path and includes a singulating and drive belt. The singulating and drive belts define a throat or singulating a mailpiece from the stack of mailpieces. A second conveyance accepts mailpieces from the first conveyance and conveys singulated mailpiece downstream of the first conveyance. The system further includes a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path. Additionally, the system includes a means to vary the velocity of the drive belt based upon the location of the gap signal along the series of sensors.

Abstract: A system for singulating mailpieces including a first conveyance including a pair of opposing belts for singulating a mailpiece from a stack of mailpieces. The system includes an actuation mechanism operative to apply a force pulse through one of the belts to momentary separate mailpieces of the stack and augment singulation of the mailpiece from the stack by the first conveyance.

Abstract: A system for conveying mailpieces along a conveyance path and singulating a mailpiece from a stack of mailpieces along the conveyance path. The system includes a first conveyance for conveying mailpieces at a variable velocity and a second conveyance, downstream of the first conveyance, for conveying mailpieces at a constant velocity along the conveyance path. A series of optical sensors extends from the first to the second conveyance and is operative to issue a gap signal indicative of the relative spacing between sequential mailpieces along the conveyance path. A processor is responsive to the gap signal and is operative to control the first conveyance to decrease the relative spacing between sequential mailpieces when the gap signal exceeds a threshold value.

Abstract: A system for conveying mailpieces along a feed path including first and second conveyances. A first conveyance is operative to convey mailpieces along the feed path and includes a singulating and drive belt. The singulating and drive belts define a throat or singulating a mailpiece from the stack of mailpieces. A second conveyance accepts mailpieces from the first conveyance and conveys singulated mailpiece downstream of the first conveyance. The system further includes a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path. Additionally, the system includes a means to vary the velocity of the drive belt based upon the location of the gap signal along the series of sensors.

Abstract: A system for conveying mailpieces along a feed path includes a plurality of conveyances. A first conveyance is operative to convey mailpieces along the feed path and includes a singulating and drive belt. The singulating and drive belts define a throat for singulating a mailpiece from the stack of mailpieces. A second conveyance accepts mailpieces from the first conveyance and conveys singulated mailpiece downstream of the first conveyance. The system further includes a series of sensors extending from the first to the second conveyance for issuing a gap signal indicative of the relative spacing between sequential mailpieces along the feed path. Additionally, the system includes a means, responsive to the gap signal, for developing a variable opposing force between the singulating and drive belts to optimize singulation of mailpieces along the feed path.

Abstract: A method of measuring a thickness of a sheet being conveyed on a transport path includes rotating a substantially cylindrical reference surface disposed in the transport path and engaging a probe with the reference surface to determine a runout value for each of a set of positions along a circumference of the reference surface. The method further includes conveying the sheet on the transport path so that the sheet contacts the reference surface at one position of the set, engaging the probe with the sheet at the one position to determine a measured sheet thickness value, and adjusting the measured sheet thickness value based on the runout value for the one position to obtain an actual sheet thickness value.

Abstract: A method of singulating overlapping items includes receiving the overlapping items in a singulation device, the device including a first transport element configured for rotation in a first direction and a second transport element in opposing relation to the first transport element, wherein the second transport element is configured for rotation in a second direction opposite to the first direction. The method further includes rotating the first transport element at a first transport speed, rotating the second transport element at a second transport speed substantially equal to the first transport speed, conveying the overlapping items between the transport elements along a transport path, decreasing the second transport speed to singulate the overlapping items, decreasing the first transport speed to reduce a speed of a lead item, and transporting the lead item away from the singulation device.

Abstract: A method of measuring a thickness of a sheet being conveyed on a transport path includes rotating a substantially cylindrical reference surface disposed in the transport path and engaging a probe with the reference surface to determine a runout value for each of a set of positions along a circumference of the reference surface. The method further includes conveying the sheet on the transport path so that the sheet contacts the reference surface at one position of the set, engaging the probe with the sheet at the one position to determine a measured sheet thickness value, and adjusting the measured sheet thickness value based on the runout value for the one position to obtain an actual sheet thickness value.

Abstract: A method of measuring a thickness of mailpieces includes calculating, for each mailpiece comprising a unique collation, an estimated mailpiece thickness value, including combining a measured envelope thickness value, a measured insert thickness value for each insert associated with the mailpiece, and a theoretical document thickness value for an input document associated with the mailpiece. The method further includes assembling the mailpiece, obtaining a measured mailpiece thickness value for the mailpiece, and comparing the measured mailpiece thickness value with the estimated mailpiece thickness value.

Abstract: A method of singulating overlapping items includes receiving the overlapping items in a singulation device, the device including a first transport element configured for rotation in a first direction and a second transport element in opposing relation to the first transport element, wherein the second transport element is configured for rotation in a second direction opposite to the first direction. The method further includes rotating the first transport element at a first transport speed, rotating the second transport element at a second transport speed substantially equal to the first transport speed, conveying the overlapping items between the transport elements along a transport path, decreasing the second transport speed to singulate the overlapping items, decreasing the first transport speed to reduce a speed of a lead item, and transporting the lead item away from the singulation device.

Abstract: A method of transporting items includes receiving a group of one or more items in a singulation device, implementing a singulation routine, measuring a speed of a first portion of the group, measuring a speed of a second portion of the group, and comparing the speed of the first portion with the speed of the second portion. The method may further include continuing the singulation routine where the speed of the first portion is not equal to the speed of the second portion, and terminating the singulation routine where the speed of the first portion is equal to the speed of the second portion. The method may also include transporting a lead item away from the singulation device. The singulation device may include opposing transport elements.

Abstract: A method of transporting items includes receiving a group of one or more items in a singulation device, implementing a singulation routine, measuring a speed of a first portion of the group, measuring a speed of a second portion of the group, and comparing the speed of the first portion with the speed of the second portion. The method may further include continuing the singulation routine where the speed of the first portion is not equal to the speed of the second portion, and terminating the singulation routine where the speed of the first portion is equal to the speed of the second portion. The method may also include transporting a lead item away from the singulation device. The singulation device may include opposing transport elements.

Abstract: A system and a method to control the motion of envelopes within a postage printing module to accommodate the use of slower print techniques and to achieve continuous high speed throughput in a mail processing system. At least two print heads in series are utilized to ensure continuous printing operation, even when a print head must be taken out of service for maintenance, or fails. Depending on which print head is in used, different sets of transport elements in the print module are used to affectuate the motion profile appropriate for the print head that is in operation. Based on the status of the print heads, a controller selectively groups different individual transport elements together to act in unison for the motion control. Print heads may be geared to operate in synchronism with the motion of the print transport.

Abstract: An enclosure feeder system (500) and corresponding method for use in combining collations in a sequence of collations with a given number of respective corresponding specific enclosures, the enclosures for each successive collation ordinarily being separator by a divider indicator, the enclosure feeder system (500) including: an enclosure feeder (210) for feeding the enclosures, and a supervisory controller (300) for providing to the enclosure feeder (210) a dynamic over-count number, corresponding to a specific collation, equal to one more than the expected number of enclosures for the collation, with the enclosure feeder (210) implemented so as to continue feeding enclosures for a collation until either encountering a divider indicator or until the number of enclosures actually fed is equal to the expected number of enclosures for the collation.

Abstract: An enclosure feeder system (500) and corresponding method for use in combining collations in a sequence of collations with a given number of respective corresponding specific enclosures, the enclosures for each successive collation ordinarily being separator by a divider indicator, the enclosure feeder system (500) including: an enclosure feeder (210) for feeding the enclosures, and a supervisory controller (300) for providing to the enclosure feeder (210) a dynamic over-count number, corresponding to a specific collation, equal to one more than the expected number of enclosures for the collation, with the enclosure feeder (210) implemented so as to continue feeding enclosures for a collation until either encountering a divider indicator or until the number of enclosures actually fed is equal to the expected number of enclosures for the collation.

Abstract: A control system for controlling a motor driving a separator roller of a collation-feeder stager assembly in an inserter system including one or more enclosure feeders, the collation-feeder stager assembly including a following roller assembly having a first and a second, following, set of rollers, the control system comprising: an edge sensor, disposed so as to have a line of sight suitable for sensing the arrival, between the first and second set of the following roller assembly, of a leading or trailing edge of a collation, and for providing signals indicating the arrival of the edge; and a controller, responsive to the signals indicating the arrival of the edge, for determining a motion control profile for the motor designed to maintain within a predetermined range a gap between collations based on having the controller decelerate the separator roller upon receiving a leading edge signal from the edge sensor.

Abstract: A method and corresponding system for assembling collation sets from a split web consisting of two webstreams, each providing a series of collations of connected sheets. The method includes the steps of: alternately selecting the two webstreams and from the selected webstream drawing a sheet to a cutting or bursting station; cutting or bursting the sheet to separate it from the webstream; conveying the sheet to an accumulating station where sheets are accumulated; monitoring the sheet for determining whether the sheet is a beginning or an end of a collation; and ejecting the sheets accumulated from the selected webstream based on the determining of whether the sheet is the beginning or the end of a collation.