Abstract: An in-line inserter device comprises envelope and insert feeding assemblies, an envelope inserting station assembly, a sealing and stacking assembly, and various diverter stations. The envelope feeding assembly withdraws envelopes from a hopper-held envelope stack and conveys them to the inserting station. Each modular insert feeding assembly comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor. The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station. Diverter stations are disposed ahead of the envelope inserting station for diversion of envelopes and inserts and ahead of the inserted envelope stacking assembly to divert inserted envelopes, for normal operational purposes and for rectification of sensed faults by rejection and extraction of processed faulty items.

Abstract: A turnover module for turning over envelopes comprises a plurality of pulleys and disposed thereabout a driven endless belt in the general shape of a flattened figure `8`. The belt includes a crossover region and a first and a second reach extending therethrough. The reaches contact one another resiliently along length portions thereof while crossing over and twisting about one another. Envelopes are received in a first orientation at an entry end of the reaches; nipped between the reaches; transported thereby through the crossover region while being turned over by virtue of the twist of the reaches about one another; and, delivered from the turnover module in a second orientation.

Abstract: In an inserter, a skew and misalignment detector for measuring skew misalignment of inserts that are conveyed on and along a conveyor comprises a plurality of photosensors disposed above the insert-conveying path in transverse relation thereto and a plurality of retroreflective targets disposed beneath the insert-conveying path in transverse relation thereto and directed toward the photosensors. Inserts obstruct the targets while being conveyed thereover. The photosensor signals are sampled in synchronism with the insert-conveying motion. The obtained signals are evaluated in relation to pre-established skew rejection threshold criteria in dependence on insert conveying speed. Inserts are diverted when the skew detector arrangement provides measures of skew and misalignment of inserts that exceed rejection threshold criteria.

Abstract: An inserter with collation tracking comprises a programmable computer, means for tracking handled items including individual tracking and collation tracking, sensing means for sensing individual items in different locations, as well as for sensing defective, multiple or missing items, corrective action means, and, means for updating tracking information in correspondence with corrective action taken. The inserter performs corrective action in the form of the rejection and diversion of defective items. Further, the inserter provides for complementarily associating envelopes with particular inserts intended for insertion thereinto, for collation tracking of such complementarily-associated items, and for the diversion of such associated items if at least one of the associated items has been stigmatized as defective.

Abstract: An envelope flap opener comprises a revolving gripper drum for conveying envelopes thereupon in flap-up orientation with flap edge trailing and a revolving rotor disposed vicinally to the gripper drum, the rotor having at least one sucker cup extending from its periphery. Vacuum is valved to the sucker cup at a time when an envelope is conveyed upon the gripper drum past the rotor, the sucker cup grabs and opens the envelope flap, and subsequently the flap is released. Prior to release of the flap, a plow device intercepts the flap and further unfolds it. The plow device includes a photo-sensor for checking of proper flap opening and for detecting missing envelopes.

Abstract: An inserter station for inserting inserts into envelopes comprises an insert conveyor for conveying inserts to an inserting location, a gripper drum for delivering envelopes to the inserting location, vacuum means for holding bottom surfaces of envelopes, suction cups for lifting top sides and opening envelopes, and an insert pusher for pushing inserts into opened envelopes. The insert pusher moves along a noose-shaped path in a vertical plane. The path has a horizontal, forwardly-directed portion along which the pusher moves to engage and push inserts into evelopes. The path has a retracting portion that curves downwardly and backwardly out of the way of envelopes and inserts being provided to the inserting location. In operation, an envelope is delivered to the inserting location and has its bottom surface held by vacuum applied thereto. The top side of the envelope is lifted by suction cups so that the envelope is opened to receive inserts.

Abstract: A feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of inserts comprises: a gripper drum disc for transporting the inserts upon its periphery; a detector caliper assembly including a pivotable arm having a follower roller borne at one end and a magnet mounted at the other end, the arm being spring loaded with the follower roller against the periphery of the gripper drum disc; and, a stationary Hall sensor to measure relative displacement between the sensor and the magnet. As an insert is transported upon the periphery of the gripper drum disc, the insert is interposed between the periphery and the follower roller and the Hall sensor senses the consequent magnet displacement as a measure of the thickness of the insert. In one embodiment, an adjustable anvil having a peripheral surface is mounted on a face of the gripper drum disc. The anvil is pre-adjusted so that its peripheral surface is disposed at a constant radius from the axis of rotation of the disc.

Abstract: An in-line rotary inserter device comprises an envelope feed station (30) and insert feeding modules (20,22,24,26), an inserting station (32), a sealing and stacking assembly (38,40,42), and various diverters (33,36,56). The envelope feed station (30) withdraws envelopes from a hopper-held envelope stack )66,94) and conveys them to the inserting station (32). Each insert feeding module comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor (34). The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station (32). Diverter stations for diversion of envelopes and inserts in various locations along their feed paths are provided for normal operational purposes and for rectification of sensed fault conditions. Subsequently to inserting, insert-filled envelopes are conveyed from the inserting station (32), are sealed, turned, stacked, and processed through operations that are customary in preparation of mailable items.

Abstract: An in-line inserter device comprises envelope and insert feeding assemblies, an envelope inserting station assembly, a sealing and stacking assembly, and various diverter stations. The envelope feeding assembly withdraws envelopes from a hopper-held envelope stack and conveys them to the inserting station. Each modular insert feeding assembly comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor. The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station. Diverter stations are disposed ahead of the envelope inserting station for diversion of envelopes and inserts and ahead of the inserted envelope stacking assembly to divert inserted envelopes, for normal operational purposes and for rectification of sensed faults by rejection and extraction of processed faulty items.

Abstract: The size of the gap separating first and second jaw members (26, 28) comprising a gripper arm is made adjustable by the provision of a translatable bracket (80) upon which an actuator (30) is supported. As the bracket (80) translates, so do the actuator (30) and a linkage (32) which connects a pivotable jaw member (28) to the actuator (30). Translation of the actuator (30) and linkage (32) changes the size of the gap separating the pivotable jaw member (28) and the other jaw member (26), thereby permitting the gripper arm to accommodate and engage articles of differing thicknesses.

Abstract: A bottom-type sheet feeding mechanism having a suction-type separator includes a linkage system (38,40) mounting the suction-type separator (10) to a main frame (42) for imparting an arcuate path (12') to the suction-type separator (10). The linkage system (38,40) is mounted on the convex side of the arcuate path (12'). The linkage system (38,40) includes two links (38,40) which are pivotally attached to the main frame (42) and to the suction-type separator (10). The lengths of the links (38,40), and the positions of their pivots (44,46,50,52) on the suction-type separator (10) and the main frame (42) are such as to cause arcuate movement of the suction-type separator (10) about an axis (0) positioned close to a plane of a bottom-most sheet (14) on the concave side of the arcuate path (12'). The arcuate path (12') extends about the axis (0) over an angle of approximately 23.degree..

Abstract: A break-away device includes a lower arm 15 pivotally connected to an upper arm 19 by a coupling 17. The lower and upper arms 15,19 are generally maintained in a rigid, colinear relationship by a spring-biased detent pin 39. When the lower arm 15 undergoes a lateral impact, the detent pin 39 is displaced from a grooved detent recess 37 of the lower arm 15 and rolled about an upper convex surface 31 thereof, thereby permitting the lower arm 15 to pivot about the coupling 17 and break away from the upper arm 19.

Abstract: An envelope flap opening apparatus 11 includes a suction cup 21 mounted on a slidable rotatable shaft 23. The shaft 23 both rotates the suction cup 21 so as to partially open an envelope flap 17 engaged thereby and advances the suction cup 21 alongside the travelling envelope 15 until the partially opened flap 17 passes beneath a stationary blade member 91 which fully opens the envelope flap 17.

Abstract: Sheets of address labels are scanned to determine when zip code changes occur. When such changes are detected an ultraviolet dye is sprayed by an air brush through a mask onto the first and all successive labels having the changed zip code. When the next zip code change is detected the spraying is terminated until a still further change occurs. The labels are then cut and affixed to envelopes for further detection and sorting into various zip codes for mailing.

Abstract: A signature gathering machine (14) comprises a plurality of hoppers (16) which can be randomly spaced relative to one another and to collating chain pusher pins (30 a,b,etc). The hoppers (16) can be moved to various positions along a frame 70 and fixed in place at those positions. An adjustable power linkage (FIGS. 3-5 and 7) to the hoppers allows the respective synchronization of the hoppers to be set relative to the collating chain pusher pins for new positions.

Abstract: In a modified embodiment of the pull-foot sheet feeding device described in U.S. application Ser. No. 608,970, filed Aug. 29, 1975, now Pat. No. 4,013,283 the bottom roller is replaced by a roller segment. The roller segment is pivotally mounted on a carrier which is fixedly mounted on a driving shaft. The pivotal axis of the roller segment is offset from the axis of the driving shaft. The roller segment has an outer surface for pinching sheets between it and the pull-foot while rolling on a sheet in response to rotation of the driving shaft. The position of the roller segment relative to the carrier is constrained by a spring, which provides biasing of the roller segment surface against the pull-foot, and an adjustable stop. The pull-foot is driven outwardly to pull sheets from a hopper by the roller segment but is under the control of a biasing spring and cam during its return.

Abstract: In a mechanism for feeding individual sheets of paper separately from a stack of paper sheets, a separating device exposes an edge of an outer sheet and a "pull-foot" is oscillated between the separated sheet and a remaining stack. A roller is concurrently moved into position to pinch the separated sheet between the pull-foot and the roller. The pull-foot is oscillated away from the stack and, in doing so, the outer sheet is pulled from the stack by interaction between the pull-foot and the roller.