Abstract: A method and apparatus are disclosed for establishing a random fault limit for hoppers in a collating machine. A plurality of hoppers are arranged in an array, each adapted to feed signatures, one at a time, to a conveyor. A miss feed base number and a double feed base number is established in a microcomputer for each of the hoppers equal to either (i) a predetermined number of signature feeds by that hopper, (ii) a predetermined number of books assembled, or (iii) a predetermined number of collator machine cycles. A miss feed fault number and a double feed number is established in the microcomputer for each of the hoppers. Each hopper has an associated miss feed detector and a double feed detector electrically connected to the microcomputer.

Abstract: A method and apparatus are disclosed for providing a collator having a variable raceway jam fault detection arrangement. A plurality of hoppers are arranged in an array, each adapted to feed signatures onto a raceway having a moving chain. The chain has spaced apart chain pins, the distance therebetween defining signature feed locations. A plurality of jam detector switches are located along the raceway and are adapted to detect a signature jam, e.g., a signature overlying a chain pin. A controller monitors each of the jam switches. The operator enters into the controller a desired rejection pattern for each of the jam switches separately.

Abstract: A method and apparatus are disclosed for controlling a collator. A microcomputer learns hopper insertion points, jam switch insertion points, and hopper miss and double feed service angles relative to a reject gate. Based on the learn collator configuration, the controller controls collator operation. When a hopper phase adjustment is made by an operator, the controller automatically re-learns the hopper service angles during a ripple start of the collator and adjusts its reject data in response thereto. A miss verify sensor arrangement permits the controller to monitor for phase adjustments after a ripple start and to warn the operator upon such occurence.