Abstract: An apparatus and method for opening an envelope for insertion of a collation. The apparatus includes a plurality of actuated suction cups that are positioned above an envelope in an insertion station. The actuated suction cups move downward to engage a top surface of the envelope and to lift the top surface away from the bottom surface in order to facilitate insertion of the collation. The suction cups include a first group that is actuated for opening all envelopes, and a second group, independently actuatable from the first group, and that is actuated only for opening envelopes having characteristics that require the additional suction cups.

Abstract: The novel solution provides a method for feeding of individual envelopes from a stack of envelopes in a hopper for an inserter machine. At the downstream end of the hopper, a friction feeder serially feeds individual envelopes from the stack. A suction cup is selectively actuated to engage with the envelope to pull a leading portion of the envelope away from the stack to assist the friction feeder in feeding envelopes. Selective actuation is based on monitoring downstream movement of fed envelopes. The suction cup is engaged when the envelopes travel a shorter distance than would be expected based on the movement of the feeder.

Abstract: An improved mailpiece fabrication system assembles finished mailpieces from content materials and from wrapping materials. The wrapping materials include printed cut quality marks at predetermined positions relative to cut lines. Content materials are placed on the continuous web. The continuous web is then folded and sealed around the content materials to form a continuous tube enclosing the content materials. A cutter downstream of the conveyance deck cuts individual envelopes from the continuous tube of folded wrapping material. A downstream imaging device captures image data indicative of a cut quality mark on the individual envelopes. A controller receives the captured image data from the imaging device and compares an actual dimension of an imaged cut quality mark with an expected dimension of a cut quality mark. An error signal is produced if the difference is not within a predetermined tolerance.

Abstract: A method and system for dynamically adjusting the placement of internal content material to optimally position the content material relative to a wrapped enclosure, and obviate the requirement to out-sort the assembled envelope. Upon assembly, a detection system visually images each envelope in predetermined regions of interest (ROIs). A controller captures the image data for comparison with a set of predefined position data and issues a feedback signal indicative of a directional change which drives an error signal to zero. The correction signal is used by the phase nip roller assembly to adaptively adjust the position of the content material by incrementally adjusting, advancing or retarding, the phase-nip roller assembly, i.e., forward or aft. A predefined number of envelopes is selected to acquire a running average of the image data.

Abstract: A method and system for identifying and detecting improperly wrapped envelopes for use in a mailpiece fabrication system. The method/system visually images each envelope in predetermined regions of interest (ROIs) to determine the spatial relationship between the internal content material and one or more points of reference indicative of the internal bounds of a sealing adhesive. By examining the spatial relationship, a determination is made regarding the proximity of the internal content material and the sealing adhesive. If the distance, or spatial separation, therebetween is below a threshold value, then an assumption is made that the content material and sealing adhesive are contiguous and that the envelope has been improperly sealed, i.e., with the content material interposing or otherwise inhibiting the proper closure of the wrapped envelope.

Abstract: The novel solution provides a method for feeding of individual envelopes from a stack of envelopes in a hopper for an inserter machine. At the downstream end of the hopper, a friction feeder serially feeds individual envelopes from the stack. A suction cup is selectively actuated to engage with the envelope to pull a leading portion of the envelope away from the stack to assist the friction feeder in feeding envelopes. Selective actuation is based on monitoring downstream movement of fed envelopes. The suction cup is engaged when the envelopes travel a shorter distance than would be expected based on the movement of the feeder.

Abstract: An apparatus and method for opening an envelope for insertion of a collation. The apparatus includes a plurality of actuated suction cups that are positioned above an envelope in an insertion station. The actuated suction cups move downward to engage a top surface of the envelope and to lift the top surface away from the bottom surface in order to facilitate insertion of the collation. The suction cups include a first group that is actuated for opening all envelopes, and a second group, independently actuatable from the first group, and that is actuated only for opening envelopes having characteristics that require the additional suction cups.

Abstract: An improved mailpiece fabrication system assembles finished mailpieces from content materials and from wrapping materials. The wrapping materials include printed cut quality marks at predetermined positions relative to cut lines. Content materials are placed on the continuous web. The continuous web is then folded and sealed around the content materials to form a continuous tube enclosing the content materials. A cutter downstream of the conveyance deck cuts individual envelopes from the continuous tube of folded wrapping material. A downstream imaging device captures image data indicative of a cut quality mark on the individual envelopes. A controller receives the captured image data from the imaging device and compares an actual dimension of an imaged cut quality mark with an expected dimension of a cut quality mark. An error signal is produced if the difference is not within a predetermined tolerance.

Abstract: A method and system for identifying and detecting improperly wrapped envelopes for use in a mailpiece fabrication system. The method/system visually images each envelope in predetermined regions of interest (ROIs) to determine the spatial relationship between the internal content material and one or more points of reference indicative of the internal bounds of a sealing adhesive. By examining the spatial relationship, a determination is made regarding the proximity of the internal content material and the sealing adhesive. If the distance, or spatial separation, therebetween is below a threshold value, then an assumption is made that the content material and sealing adhesive are contiguous and that the envelope has been improperly sealed, i.e., with the content material interposing or otherwise inhibiting the proper closure of the wrapped envelope.

Abstract: A method and system for dynamically adjusting the placement of internal content material to optimally position the content material relative to a wrapped enclosure, and obviate the requirement to out-sort the assembled envelope. Upon assembly, a detection system visually images each envelope in predetermined regions of interest (ROIs). A controller captures the image data for comparison with a set of predefined position data and issues a feedback signal indicative of a directional change which drives an error signal to zero. The correction signal is used by the phase nip roller assembly to adaptively adjust the position of the content material by incrementally adjusting, advancing or retarding, the phase-nip roller assembly, i.e., forward or aft. A predefined number of envelopes is selected to acquire a running average of the image data.

Abstract: A mail inserter has a first web driver to move a web from a web supply and a second web driver to feed the web to a cutter for cutting the web into sheets, wherein the first and second web drivers have different velocity profiles to allow a web loop to form between the web drivers. The loop is variable between a maximum size and a minimum size. When the loop reaches the minimum size, the first web driver is running at its maximum speed. At this point the first web driver is decelerated at a rate such that when the first web driver stops, the web loop is at its maximum size. The acceleration of the first web driver is at a constant rate which is inversely proportional to the difference between the maximum loop size and the minimum loop size.

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: A method and system for preparing mail pieces that include RFID enabled cards. The improvement provides enhanced tracking and control capabilities for such mail pieces. In an inserter control system, individual RFID signals of the RFID enabled cards are related to particular mail pieces in a mail piece production database. The corresponding RFID enabled cards are fed into the inserter system from a card feeder. An attaching device attaches the cards to a carrier sheet. The inserter system transports the cards and carrier sheets to different stations where other documents are joined with the carrier sheets. The assembled mail pieces are then inserted into envelopes to form finished mail pieces. Sensors are located within the system to detect the RFID signals of the individual cards. The sensed individual RFID numbers are compared with stored mail piece data. The system is programmed to process the mail piece based on instructions in the database corresponding to the sensed number.

Abstract: A mail inserter has a first web driver to move a web from a web supply and a second web driver to feed the web to a cutter for cutting the web into sheets, wherein the first and second web drivers have different velocity profiles to allow a web loop to form between the web drivers. The loop is variable between a maximum size and a minimum size. When the loop reaches the minimum size, the first web driver is running at its maximum speed. At this point the first web driver is decelerated at a rate such that when the first web driver stops, the web loop is at its maximum size. The acceleration of the first web driver is at a constant rate which is inversely proportional to the difference between the maximum loop size and the minimum loop size.

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.