Abstract: A robotic surgical instrument includes a housing, a support plate disposed within the housing, and a shaft having a proximal end portion coupled to the support plate within the housing, a proximal segment, a distal segment, and an articulating portion interconnecting the proximal and distal segments. An end effector assembly is coupled to the distal segment of the shaft. A plurality of actuation components extends through the support plate and at least a portion of the shaft to operably couple to at least one of the end effector assembly, the articulating portion, or the distal segment to enable selective actuation of the end effector assembly. A seal configuration establishes seals against an interior annular surface of the shaft, about each actuation component of the plurality of actuation components, and within the proximal end portion of the shaft to inhibit fluid communication from the shaft into the housing.

Abstract: An articulation assembly for a robotic surgical instrument includes a plurality of rotatable but longitudinally fixed lead screws extending between first and second base plates, a collar threaded about each lead screws and configured to translate therealong in response to rotation of the corresponding lead screw, an articulation cable coupled to each collar and defining or having a threaded shaft, and a threaded nipple threaded about each of the threaded shafts. Each threaded nipple is engaged with one of the collars to thereby engage each of the articulation cables with a corresponding one of the collars such that longitudinal translation of the corresponding collar pushes or pulls the corresponding articulation cable. Each threaded nipple is configured for further threading or unthreading about the corresponding threaded shaft to vary a pre-tension on the corresponding articulation cable.

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 registration plate assembly for a compliant conveyance system and is adapted for use in combination with an array of print heads each having a print head nozzle. The registration plate assembly includes a mounting plate, a registration plate affixed to the mounting plate and at least one runner fastened to the mounting plate and disposed within an opening defined by the registration plate. The mounting plate has at least one aperture therein for accepting a print head nozzle associated with each of the print head and the registration plate includes and an opening for permitting the deposition of ink from each of the print head nozzles. The runner is aligned with the feed path of the conveyance system and has a blade portion disposed at a location between adjacent print head nozzles which is operative to maintain a stand-off distance from the face surface of each mailpiece to one of the print head nozzles.

Abstract: A system and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

Abstract: A method for printing information on a print medium, such as a mailpiece, that includes determining a thickness of the medium while it is being transported toward a print head, such as an ink jet print head, causing the distance between the top surface of the medium the print head when the medium is located below the print head to be within a specified range based on the determined thickness, and printing the information on the print medium. Also, an apparatus includes a printing station having a print head, a transport mechanism for transporting the medium toward the printing station, and a thickness measuring mechanism. The apparatus is structured to cause the distance between the top surface of the medium and a portion of the print head when the medium is located below the print head to be within a specified distance range based on the thickness of the medium.

Abstract: A print module for printing mailpieces comprises a print head assembly operative to deposit ink on each mailpiece and a registration plate for registering a first surface of each of the mailpieces during print operations. The print module includes a conveyor belt opposing the registration plate and engaging a second surface of each of the mailpieces for conveyance along a feed path. Disposed beneath and supporting an underside surface of the conveyor belt, is a continuous compliant deck operative to urge the conveyor belt and mailpieces toward the registration plate during printing. The compliant deck is also operative to print consecutive mailpieces of variable thickness dimension. The print module also includes a pivotable support rack for mounting the print head assembly to a housing.

Abstract: A compliant conveyance system for processing mailpieces along a feed path, e.g., printing on a first surface of a mailpiece, while being registered against a contact surface of a registration plate. The conveyance system comprises at least one conveyor belt opposing the contact surface of the registration plate, a continuous, uninterrupted, compliant deck disposed beneath and supporting an underside surface of the conveyor belt, and a spring biasing device operative to bias the compliant deck and the conveyor belt toward the contact surface of the registration plate. The conveyor belt includes a drive surface for engaging a second surface of each of the mailpieces for conveyance along the feed path. As each of the mailpieces pass the registration plate, the compliant deck and spring biasing device urge the second surface of each mailpiece into engagement with the contact surface during processing.

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: An item handling system includes a vacuum source, a transport element defining a plurality of vacuum openings in fluid communication with the vacuum source to create a securing force on an item proximate to the transport element for holding the item in contact with the transport element, and a drive element for driving the transport element to transport the item. The transport element further defines a plurality of sensor openings arranged in two substantially parallel arrays along a longitudinal direction of the transport element. The system further includes a sensor associated with each array of sensor openings for sensing energy passing through the sensor openings to thereby sense the item on the transport element. Each sensor is disposed at a common longitudinal position relative to the transport element. Sensing the item corresponds to a condition where the sensor associated with each array is blocked.

Abstract: A system for processing nested/unnested content material in a mailpiece inserter includes a first accumulator, a second accumulator and a folding module disposed therebetween. The first accumulator is operative to feed individual sheets of content material, in one operating mode, and accumulate multiple sheets of content material in another operating mode. The second accumulator is operative to accumulate unnested, folded sheets of content material in one operating mode, and feed sheets of nested, folded sheets of content material in another operating mode.

Abstract: An item handling system includes a vacuum source, a transport element defining a plurality of vacuum openings in fluid communication with the vacuum source to create a securing force on an item proximate to the transport element for holding the item in contact with the transport element, and a drive element for driving the transport element to transport the item. The transport element further defines a plurality of sensor openings arranged in two substantially parallel arrays along a longitudinal direction of the transport element. The system further includes a sensor associated with each array of sensor openings for sensing energy passing through the sensor openings to thereby sense the item on the transport element. Each sensor is disposed at a common longitudinal position relative to the transport element. Sensing the item corresponds to a condition where the sensor associated with each array is blocked.

Abstract: An apparatus for registering sheet material while being conveyed along a feed path including: (i) a conveyance deck for conveying sheet material along a support surface, (ii) a registration member defining an abutment surface operative to align an edge of the sheet material as the sheet material is conveyed along the support surface of the conveyance deck, and (iii) a drive mechanism disposed adjacent to the registration member and along the conveyance deck. The drive mechanism includes a flexible belt disposed about and supported by at least two rolling elements, and a means for driving the flexible belt about the rolling elements. The flexible belt includes a twisted section defining a plurality of spiral edge segments operative to (i) frictionally engage a surface of the sheet material to urge the sheet material against the abutment surface and (ii) convey the sheet material along the conveyance deck.

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 and method for producing printed sheet material for use in a mailpiece inserter. The system comprises an input module for supplying the printed sheet material associated with a mailpiece fabrication job of the mailpiece inserter and a transfer module adapted to receive the printed sheet material from the input module and dispense the printed sheet material. An output module is adapted to receive the printed sheet material from the transfer module and convey the printed sheet material along the transport deck. A processor is operatively coupled to a mail run data file of the mailpiece fabrication job for controlling the input, transfer and output modules to stack the printed sheet material in accordance with the mail run data file. In the method, the output module includes at least two transport decks which may be repositioned such that one of the transport decks receives/stacks the printed sheet material in a manner which is best suited for subsequent use by the mailpiece inserter.

Abstract: An item handling system includes a vacuum source, a transport element defining a plurality of vacuum openings in fluid communication with the vacuum source to create a securing force on an item proximate to the transport element for holding the item in contact with the transport element, and a drive element for driving the transport element to transport the item. The transport element further defines a plurality of sensor openings arranged in two substantially parallel arrays along a longitudinal direction of the transport element. The system further includes a sensor associated with each array of sensor openings for sensing energy passing through the sensor openings to thereby sense the item on the transport element. Each sensor is disposed at a common longitudinal position relative to the transport element. Sensing the item corresponds to a condition where the sensor associated with each array is blocked.

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 method for printing information on a print medium, such as a mailpiece, that includes determining a thickness of the medium while it is being transported toward a print head, such as an ink jet print head, causing the distance between the top surface of the medium the print head when the medium is located below the print head to be within a specified range based on the determined thickness, and printing the information on the print medium. Also, an apparatus includes a printing station having a print head, a transport mechanism for transporting the medium toward the printing station, and a thickness measuring mechanism. The apparatus is structured to cause the distance between the top surface of the medium and a portion of the print head when the medium is located below the print head to be within a specified distance range based on the thickness of the medium.