Abstract: A mailpiece inserter includes a feed conveyor adapted to feed a shingled stack of mailpiece envelopes along a feed path to an insert module and a chassis module adapted to produce content material for insertion into the mailpiece envelopes processed by the insert module. An envelope position detector is operative to sense a discontinuity in the shingled stack and issues a first position signal indicative thereof, and an input conveyor module is adapted to convey mailpiece envelopes into shingled engagement with an aft end of the shingled stack of mailpiece envelopes on the feed conveyor. The input conveyor module has an input end proximal to a single workstation of the chassis module which enables an operator to (i) feed mailpiece envelopes to the input module and (ii) supply content material to the chassis module.

Abstract: An adjustable item transport includes a deck for supporting items, a transport element for transporting the items along the deck on a transport path, a plurality of support elements rotatably supporting the transport element, and an adjustment member. Each support element may include a plurality of recesses configured to receive the transport element. Each recess corresponds to an operating position of the transport element. The adjustment member may include a handle portion, a first guide portion adjacent to a first edge of the transport element, and a second guide portion adjacent to a second edge of the transport element. Movement of the handle portion substantially perpendicular to the transport path engages one of the first guide portion and the second guide portion with a respective edge of the transport element to move the transport element between recesses in the support element to change the operating position of the transport element.

Abstract: A method for feeding a shingled stack of sheet material to a downstream processing device includes the step of identifying a discontinuity in the shingled stack of sheet material wherein the discontinuity has a length dimension from an aft end of a downstream portion of the shingled sheet material to a forward end of an upstream portion of the shingled sheet material. In a next step, the motion of first and second serially arranged conveyors are controlled such that the length dimension of the discontinuity is substantially equal to a prescribed gap of known length dimension. The first conveyor supports the upstream portion of the shingled sheet material and the second conveyor supports the downstream portion of the shingled sheet material. The deck of the first is advanced over the deck of the second conveyor toward the aft end of the downstream portion by the length dimension of the prescribed gap.

Abstract: A mailpiece inserter includes a feed conveyor adapted to feed a shingled stack of mailpiece envelopes along a feed path to an insert module and a chassis module adapted to produce content material for insertion into the mailpiece envelopes processed by the insert module. An envelope position detector is operative to sense a discontinuity in the shingled stack and issues a first position signal indicative thereof, and an input conveyor module is adapted to convey mailpiece envelopes into shingled engagement with an aft end of the shingled stack of mailpiece envelopes on the feed conveyor. The input conveyor module has an input end proximal to a single workstation of the chassis module which enables an operator to (i) feed mailpiece envelopes to the input module and (ii) supply content material to the chassis module.

Abstract: A method for feeding a shingled stack of sheet material to a downstream processing device includes the step of identifying a discontinuity in the shingled stack of sheet material wherein the discontinuity has a length dimension from an aft end of a downstream portion of the shingled sheet material to a forward end of an upstream portion of the shingled sheet material. In a next step, the motion of first and second serially arranged conveyors are controlled such that the length dimension of the discontinuity is substantially equal to a prescribed gap of known length dimension. The first conveyor supports the upstream portion of the shingled sheet material and the second conveyor supports the downstream portion of the shingled sheet material. The deck of the first is advanced over the deck of the second conveyor toward the aft end of the downstream portion by the length dimension of the prescribed gap.

Abstract: An adjustable item transport includes a deck for supporting items, a transport element for transporting the items along the deck on a transport path, a plurality of support elements rotatably supporting the transport element, and an adjustment member. Each support element may include a plurality of recesses configured to receive the transport element. Each recess corresponds to an operating position of the transport element. The adjustment member may include a handle portion, a first guide portion adjacent to a first edge of the transport element, and a second guide portion adjacent to a second edge of the transport element. Movement of the handle portion substantially perpendicular to the transport path engages one of the first guide portion and the second guide portion with a respective edge of the transport element to move the transport element between recesses in the support element to change the operating position of the transport element.

Abstract: An item transport system includes a first transport and a divert module for diverting predetermined items. The first transport includes a first deck for supporting items and a first transport element for transporting the items along the first deck on a transport path. The divert module includes a second deck for supporting the predetermined items, a second transport element for transporting the predetermined items along the second deck on a divert path, and a fluid supply element selectively actuable to direct a fluid onto at least a leading edge of the predetermined items to divert the predetermined items onto the second deck.

Abstract: A conveyor assembly utilizes a plurality of rollers or a belt supported in a frame to convey articles. The frame is manufactured from a non-metallic material possessing physical characteristics that are substantially similar to those experienced with structural metals. More specifically, side frames, lower frames, slider beds, and fasteners used by the frame may be manufactured from the non-metallic material. A radio frequency (RF) reader is position on or near the conveyor assembly to read RF tags applied to items conveyed past the reader by the rollers or belt of the conveyor assembly.

Abstract: An automatic tray-handling system for use with a mail sorter (26) having a plurality of tray supporters, comprises a transporter (50) having a conveying surface (56) and an insertion/extraction assembly (58); and respective feed (44a, 44b) and discharge conveyors (46a, 46b) adapted to feed empty trays (38) to the transporter conveying surface (56) and receiving at least partially full trays (38) from the transporter conveying surface. The insertion/extraction assembly (58) is adapted to insert empty trays (38) to tray support areas and remove at least partially full trays (38) from tray support areas. The conveying surface operational is adapted to receive empty trays (38) from the feed conveyor (44a, 44b) and at least partially full trays (38) from the insertion/extraction assembly (58). Moreover from the conveying surface empty trays are dischargeable to the insertion/extraction assembly (58) and to the discharge conveyor (46a, 46b).

Abstract: A shaft capturing device useful for reconditioning worn roller conveyor side frame openings has a shape tapered to narrow in its depth dimension from a base portion toward a flange portion. An opening in the flange portion is sized to receive a roller conveyor shaft. Amounting opening located in the base portion accepts a mounting screw that when tightened pushes against and engages the roller conveyor side frame causing the base portion to move away from the side frame and the opening in the flange portion to close in size to tighten around the received shaft. As an enhancement, a slot may be included passing through the flange portion shaft receiving opening to define a pair of clamping tangs. An opening extending through the tangs accepts a screw that when tightened pulls the tangs together to clamp the flange portion around the received shaft. The mounting screw may then be tightened to further tighten the shaft and engage the roller conveyor side frame.

Abstract: A shaft capturing device useful for reconditioning worn roller conveyor side frame openings has a shape tapered to narrow in its depth dimension from a base portion toward a flange portion. An opening in the flange portion is sized to receive a roller conveyor shaft. Amounting opening located in the base portion accepts a mounting screw that when tightened pushes against and engages the roller conveyor side frame causing the base portion to move away from the side frame and the opening in the flange portion to close in size to tighten around the received shaft. As an enhancement, a slot may be included passing through the flange portion shaft receiving opening to define a pair of clamping tangs. An opening extending through the tangs accepts a screw that when tightened pulls the tangs together to clamp the flange portion around the received shaft. The mounting screw may then be tightened to further tighten the shaft and engage the roller conveyor side frame.

Abstract: A substantially S-shaped side frame for a roller conveyor has a first duct section defining an exterior opening and a second duct section defining an interior opening. Necessary operating components, such as controllers, and associated wiring may be installed in the first duct section. Roller shaft support brackets are installed across the interior opening with a certain longitudinal pitch. The shafts of a plurality of laterally extending rollers are installed in through holes provided in the brackets to define a conveyor path for transporting articles. The brackets each include opposed slots for mounting to opposed rails for the second duct section. The opposed slots in the brackets include an inwardly tapered portion that allows the brackets to be rotatably inserted between the opposed rails. Each bracket may include one or more through holes for stably supporting the roller shafts.

Abstract: A modular power roller conveyor is described having a conveyor section for transporting a product unit. The conveyor section comprises a number of active zones, each active zone containing means for sensing the entry of a product unit into the active zone. A programmable controller generates activation signals to a drive roller in response to the means for sensing. A plurality of carrier rollers are slaved to the drive roller within the active zone such that activation of the drive roller actuates all of the carrier rollers to drive the product unit through the active zone and into the next active zone. The programmable controller also generates a deactuation signal to deactivate the active zone as a product unit exits the zone.

Abstract: A substantially S-shaped side frame for a roller conveyor has a first duct section defining an exterior opening and a second duct section defining an interior opening. Necessary operating components, such as controllers, and associated wiring may be installed in the first duct section. Roller shaft support brackets are installed across the interior opening with a certain longitudinal pitch. The shafts of a plurality of laterally extending rollers are installed in through holes provided in the brackets to define a conveyor path for transporting articles. The brackets each include opposed slots for mounting to opposed rails for the second duct section. The opposed slots in the brackets include an inwardly tapered portion that allows the brackets to be rotatably inserted between the opposed rails. Each bracket may include one or more through holes for stably supporting the roller shafts.

Abstract: A modular power roller conveyor is described having a conveyor section for transporting a product unit. The conveyor section comprises a number of active zones, each active zone containing means for sensing the entry of a product unit into the active zone. A programmable controller generates activation signals to a drive roller in response to the means for sensing. A plurality of carrier rollers are slaved to the drive roller within the active zone such that activation of the drive roller actuates all of the carrier rollers to drive the product unit through the active zone and into the next active zone. The programmable controller also generates a deactuation signal to deactivate the active zone as a product unit exits the zone.

Abstract: A roller conveyor has rollers mounted on laterally-spaced side frames by brackets that have a frame attachment opening extending through a base portion of the bracket, and a roller shaft end receiving aperture extending through a flange portion of the bracket. The shaft receiving aperture is aligned at an oblique angle with respect to the frame attachment fastener opening such that when a fastener is inserted through the frame attachment opening and the bracket installed on a respective side frame, the shaft receiving aperture becomes misaligned with the end of the roller shaft to an extent sufficient to lock the shaft end in fixed relationship with the bracket and maintain a bias force on the fixed connection between the shaft receiving aperture of the flange and the roller shaft end.

Abstract: A vehicle bumper protector for golf spikes is disclosed and includes a thin flexible rubber strip that drapes over the rear bumper of a vehicle upon which a golf shoe may be placed. The protector is attached to the interior of the vehicle trunk by means of a VELCRO.RTM. brand fastener, snaps, or the like for easy, one-step installation and removal. The protector may also include one or more of the following: (1) a golf shoe spike cleaner composed of a brush; (2) a detachable golf accessory bag for holding golf tees, balls, ball markers, and the like; and (3) two pairs of elastic straps on opposite sides of the protector for restraining the golfer's shoes when not in use with the spikes in a protected position. The device adapts readily, without any adjustments, to any vehicle with a trunk or rear door and rear bumper at step height.

Abstract: A sensor roller and method for detecting the presence of a tray located thereon, where the tray is traveling along a conveyor system, includes a housing having an interior chamber and a plurality of apertures. The apertures are in one-to-one correspondence with actuators, where the actuators each have an exposed portion protruding through the apertures. The sensor roller further includes a piston slidable in the interior chamber of the housing and engaging the actuators. The piston slides between a non-actuated position to an actuated position in response to a tray travelling along the conveyor system depressing an actuator into the interior chamber of the housing. A sensor detects the presence of the piston in the actuated position and generates a detection signal in response thereto.

Abstract: A bi-directional belt sorter for unloading items into a selected bin located along a travel path of a conveyor system includes a carrier and a support frame secured to the carrier. The carrier has a plurality of orientations with respect to the support frame. The carrier includes a conveyor belt for unloading items into the selected bin located to the side of or in-line with the travel path of the conveyor system. The conveyor system includes a host computer for controlling the distribution of items to selected bins.

Abstract: A package and bundle singulator having a cone shaped housing with an input receiving opening and an outlet discharge opening. A helix or spiral is formed on an inner surface of the housing to engage and separate packages and bundles entering the input receiving opening. A support frame rotatably supports and maintains the housing in an orientation where the input receiving opening is at a higher level than the output discharge opening. The housing is rotated by a drive assembly engaging the housing.