Abstract: An apparatus for preparing a collation of sheets for folding operations. The system includes a registration device including multiple registration stations and a conveyance device for transporting the collation to one of the registration stations. Each registration station is adapted to register the edges of the collation based upon a desired edge geometry. A processor determines the fold configuration of the collation and determines the edge geometry thereof based upon the fold configuration of the collation. The processor selects one of the registration stations based upon the fold configuration and then controls the conveyance device to transport the collation to the selected registration station. The registration station selected may also be based upon the thickness of the collation and a desired location for binding the collation.

Abstract: A system for preparing a collation of sheets for a subsequent folding operation wherein edges of the collation are aligned to eliminate the need for additional trimming operations. The system comprises: a cutting device operative to cut each sheet of the collation based upon a length dimension of each of the inner and outer sheets, an accumulating device operative to stack the sheets to form the collation, a registration device operative to register at least one edge of the collation, a conveyance device for transporting the sheet material along a feed path to the cutting, accumulating and registration devices, and a processor operatively coupled to, and controlling, the cutting, accumulating, registration and conveyance devices.

Abstract: An apparatus for preparing a collation of sheets for folding operations. The system includes a registration device including multiple registration stations and a conveyance device for transporting the collation to one of the registration stations. Each registration station is adapted to register the edges of the collation based upon a desired edge geometry. A processor determines the fold configuration of the collation and determines the edge geometry thereof based upon the fold configuration of the collation. The processor selects one of the registration stations based upon the fold configuration and then controls the conveyance device to transport the collation to the selected registration station. The registration station selected may also be based upon the thickness of the collation and a desired location for binding the collation.

Abstract: A system for preparing a collation of sheets for a subsequent folding operation wherein edges of the collation are aligned to eliminate the need for additional trimming operations. The system comprises: a cutting device operative to cut each sheet of the collation based upon a length dimension of each of the inner and outer sheets, an accumulating device operative to stack the sheets to form the collation, a registration device operative to register at least one edge of the collation, a conveyance device for transporting the sheet material along a feed path to the cutting, accumulating and registration devices, and a processor operatively coupled to, and controlling, the cutting, accumulating, registration and conveyance devices.

Abstract: A system is provided for aligning multi-sheet collations including a conveyance system having a transport deck for supporting and conveying the multi-sheet collation along a feed path. The system includes a first pair of registration members disposed orthogonal to the feed path and defining a processing station along the feed path. The registration members further define registration surfaces which are repositionable from an active position above the transport deck to an idle position below the transport deck. A first displacement mechanism raises and lowers the registration members into and out of the active and idle positions, and oscillates at least one of the registration surfaces forward and aft in a direction parallel to the feed path when the registration member is in its active position.

Abstract: A system for binding variable thickness multi-sheet collations includes first and second processing stations including a stitcher and stapler, respectively and a means for determining the thickness of a multi-sheet collation. A processor is responsive to a thickness value signal and selects one of the first and second processing stations to bind the multi-sheet collation. A conveyance system then transports the multi-sheet collation to the selected one of the first and second processing stations. A method includes the steps of: stacking sheet material to produce a multi-sheet collation, determining the thickness of the multi-sheet collation, and selecting an apparatus to bind the multi-sheet collation from one of at least two binding apparatus based upon the thickness of the multi-sheet collation. The multi-sheet collation is then conveyed along a feed path to a selected one of the binding apparatus.

Abstract: A stitcher for binding variable thickness collations including a means for determining the thickness of a multi-sheet collation, a stitch head operative to drive a stitch through the multi-sheet collation, an anvil operative to clinch the stitch to bind the sheets of the collation and a plurality of actuators operative to displace forming elements of the stitch head to form the stitch, position the stitch head and anvil against opposite surfaces of the multi-sheet collation, drive the stitch through the collation and clinch the ends of the stitch. A processor, responsive to the thickness value signal, controls the actuators to form the stitch and bind the collation.

Abstract: A document handling apparatus includes a document transport buffering apparatus including drive belts and aligner belts. Each of the drive belts has a general continuous loop shape. The aligner belts are intermixed with the drive belts. Each of the aligner belts has a general continuous loop shape and a projection extending in a general cantilever fashion from the aligner belt. A first drive system is adapted to rotate the drive belts. A second drive system is adapted to rotate the aligner belts individually. The first and second drive systems are adapted to rotate the drive belts and the aligner belts such that a plurality of spaced stacks of documents are transported by the drive belts with one of the projections at a leading edge of each of the stacks and another one of the projections at a trailing edge of each of the stacks.

Abstract: A document handling apparatus includes a document transport buffering apparatus including drive belts and aligner belts. Each of the drive belts has a general continuous loop shape. The aligner belts are intermixed with the drive belts. Each of the aligner belts has a general continuous loop shape and a projection extending in a general cantilever fashion from the aligner belt. A first drive system is adapted to rotate the drive belts. A second drive system is adapted to rotate the aligner belts individually. The first and second drive systems are adapted to rotate the drive belts and the aligner belts such that a plurality of spaced stacks of documents are transported by the drive belts with one of the projections at a leading edge of each of the stacks and another one of the projections at a trailing edge of each of the stacks.

Abstract: A stitcher for binding variable thickness collations including a means for determining the thickness of a multi-sheet collation, a stitch head operative to drive a stitch through the multi-sheet collation, an anvil operative to clinch the stitch to bind the sheets of the collation and a plurality of actuators operative to displace forming elements of the stitch head to form the stitch, position the stitch head and anvil against opposite surfaces of the multi-sheet collation, drive the stitch through the collation and clinch the ends of the stitch. A processor, responsive to the thickness value signal, controls the actuators to form the stitch and bind the collation.

Abstract: A system for binding variable thickness multi-sheet collations includes first and second processing stations including a stitcher and stapler, respectively and a means for determining the thickness of a multi-sheet collation. A processor is responsive to a thickness value signal and selects one of the first and second processing stations to bind the multi-sheet collation. A conveyance system then transports the multi-sheet collation to the selected one of the first and second processing stations. A method includes the steps of: stacking sheet material to produce a multi-sheet collation, determining the thickness of the multi-sheet collation, and selecting an apparatus to bind the multi-sheet collation from one of at least two binding apparatus based upon the thickness of the multi-sheet collation. The multi-sheet collation is then conveyed along a feed path to a selected one of the binding apparatus.

Abstract: A system is provided for aligning multi-sheet collations including a conveyance system having a transport deck for supporting and conveying the multi-sheet collation along a feed path. The system includes a first pair of registration members disposed orthogonal to the feed path and defining a processing station along the feed path. The registration members further define registration surfaces which are repositionable from an active position above the transport deck to an idle position below the transport deck. A first displacement mechanism raises and lowers the registration members into and out of the active and idle positions, and oscillates at least one of the registration surfaces forward and aft in a direction parallel to the feed path when the registration member is in its active position.

Abstract: An inserting system is provided for securing an envelope having a window. The system includes a deck slidably supporting the envelope, where the deck defines an insertion area, and a securing mechanism in the insertion area securing the envelope in an insertion location during insertion of a collation. The securing mechanism includes a first securing element selectively securing a first portion of the envelope between the window and an open edge of the envelope and a second securing element selectively securing a second portion of the envelope between the window and a closed edge of the envelope. The inserting system may also include a deflection element disposed on the deck between the first securing element and the second securing element, wherein the deflection element guides the collation away from an edge of the window.

Abstract: A roller assembly for conveying stacked sheet material along a feed path. The roller assembly includes a first roller adapted for rotation within a housing, a second roller pivotally mounting about an axis to the housing and opposing the first roller to define a roller nip, a spring biasing mechanism operative to bias the second roller about the pivot axis toward the first roller to effect optimum frictional engagement of the roller nip with the face surfaces of the stacked sheet material and a transmission assembly operative to (i) transfer rotational motion of the first roller to the second roller, (ii) drive the first and second rollers in opposing directions to convey the stacked sheet material along the feed path, and (iii) facilitate pivot motion of the second roller about the pivot axis to vary the spacing of the roller nip and accommodate stacks of sheet material which vary in thickness.

Abstract: A roller assembly for conveying stacked sheet material along a feed path. The roller assembly includes a first roller adapted for rotation within a housing, a second roller pivotally mounting about an axis to the housing and opposing the first roller to define a roller nip, a spring biasing mechanism operative to bias the second roller about the pivot axis toward the first roller to effect optimum frictional engagement of the roller nip with the face surfaces of the stacked sheet material and a transmission assembly operative to (i) transfer rotational motion of the first roller to the second roller, (ii) drive the first and second rollers in opposing directions to convey the stacked sheet material along the feed path, and (iii) facilitate pivot motion of the second roller about the pivot axis to vary the spacing of the roller nip and accommodate stacks of sheet material which vary in thickness.

Abstract: A reconfigurable transport system includes a transport device for receiving items in a first orientation in one of a first portion and a second portion and releasing the items from the other of the first portion and the second portion. The transport device includes rotating transport elements in opposing relation. Items received between the transport elements are conveyed along a transport axis. The transport system further includes a positioning device for selectively moving the second portion between a first position in which the transport device maintains the items in the first orientation, and a second position in which the transport device rotates the items substantially about the transport axis to a second orientation.

Abstract: A collation control mechanism is used to transfer a collation from a dual accumulator to an exit nip of a collation machine. The collation control mechanism has a middle drum and two side rollers to form an upper nip and a lower nip. The drum is caused to rotate alternately in a clockwise direction and in a counter-clockwise direction for transferring a collation from the upper bay and the lower bay, respectively, to the exit nip. A motor is used to drive the drum in both the clockwise and counter-clockwise direction. A coupling mechanism including two sets of one-way clutches is used to engage the motor to the upper and lower rollers of the exit nip so that the upper roller is caused to rotate only in the counter-clockwise direction while the lower roller is cause to rotate only in the clockwise direction.

Abstract: A transport and alignment system is provided for handling stacked sheet material on a support deck including first and second belts each having a portion thereof disposed parallel to the support deck. Each of the belts includes a plurality of spaced-apart fingers which engage the edges of the stacked sheet material and define a pocket therebetween. The transport and alignment system further includes a drive mechanism for independently driving the first and second belts to effect concurrent and relative motion of the fingers. Concurrent motion of the fingers transports the stacked sheet material along the support deck while relative motion of the fingers opposed edges of the stacked sheets of material. The transport and alignment system is described in the context of a stitcher and chassis module of a mailpiece inserter.

Abstract: An inserting system is provided for securing an envelope having a window. The system includes a deck slidably supporting the envelope, where the deck defines an insertion area, and a securing mechanism in the insertion area securing the envelope in an insertion location during insertion of a collation. The securing mechanism includes a first securing element selectively securing a first portion of the envelope between the window and an open edge of the envelope and a second securing element selectively securing a second portion of the envelope between the window and a closed edge of the envelope. The inserting system may also include a deflection element disposed on the deck between the first securing element and the second securing element, wherein the deflection element guides the collation away from an edge of the window.

Abstract: A stitcher system includes a stitcher mechanism for stitching collations of documents and adapted to form stitches from a conductive wire moved into the stitcher mechanism. A non-conductive spool is mounted for rotation on a spindle. A conductive wire is wound on the non-conductive spool. The conductive wire has a tail end adjacent to the non-conductive spool and a lead end remote from the spool. The spool rotates when the conductive wire is moved into the stitcher mechanism to provide conductive wire to be used by the stitcher mechanism to form stitches. A sensing circuit is provided with a circuit path that includes the conductive wire wrapped on the non-conductive spool and a conductive member mounted to engage the wire. The sensing circuit path becomes open when the conductive wire is not wrapped on the non-conductive spool to thereby detect an out of wire condition.