Information
-
Patent Grant
-
6799760
-
Patent Number
6,799,760
-
Date Filed
Monday, September 30, 200222 years ago
-
Date Issued
Tuesday, October 5, 200420 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Walsh; Donald P.
- Bower; Kenneth W.
Agents
- Cummings; Michael J.
- Malandra, Jr.; Charles R.
- Chaclas; Angelo N.
-
CPC
-
US Classifications
Field of Search
US
- 271 207
- 271 212
- 271 178
- 271 179
-
International Classifications
-
Abstract
An embodiment of the present invention comprises a means for holding the stack in a tilted position, the means comprising a tilted base; a sliding retainer positioned to support a side of the stack that is tilted toward the sliding retainer by the means for holding the stack in a tilted position; a first input area positioned above retainer element; a second input area positioned below the retainer element and above the means for holding the stack in a tilted position; a second input area positioned below the retainer element and above the means for holding the stack in a tilted position; and a translating carriage means attached to the means for holding the stack in a tilted position, the translating carriage means movable in an about vertical direction in response to a control signal indicating the direction of about vertical movement; whereby the apparatus is configured to selectably add mailpieces to the top of the vertical stack via the first input area or the bottom of the vertical stack via the second input area.
Description
BACKGROUND OF INVENTION
1. Field of the Invention
The invention disclosed herein relates generally to the field of paper handling preparation and more particularly, to a stacking apparatus.
2. Background of the Invention
Mailpiece stacking devices are known for taking singulated items and forming them into stacks or columns. Stackers are commonly used in conjunction with photocopier machines, printers, facsimile machines, mailing machines, folders, folder/sealers, small envelope inserter devices, mail openers, envelope printers and labelers. In many of these applications, such as mailing machines and envelope printers, an envelope is imprinted with an address and then immediately fed into a stacker. The ink on the envelope is often not dry as the mailpiece enters the stacker. Failure of the ink to dry enables a successive envelope to smear the ink on a previous envelope in the stacker.
In order to obtain the postal rate discounts, the order of the mailpieces that have been presorted and processed by the mail-processing machine in consecutive order needs to be maintained. The removed stack of mailpieces can be manually placed in a mail tray that is sent to the postal service. In this manner, the user can take advantage of lower postal rates that are provided to users who tray envelopes according to predetermined criteria. The predetermined criteria includes the maintaining of mailpieces in the exact order in which they were processed in the mail processing machine. Generally, the predetermined criteria relates to a reduction in the postal service's handling of the mail from the mailers. The United States Postal Service (“USPS”) offers several levels of discounts to mailers. The level of discount typically is based on the number of criteria met by the mailer. For example, in order to maximize such postage discounts, the USPS requires that high volume mailers presort the mailpieces, apply a ZIP+4 bar code to each mailpiece, and package their mail into trays with each tray tagged in accordance with the Domestic Mail Manual.
The instant invention relates to a method and apparatus for stacking documents to either the top or the bottom of the stack. Users of mailing machines, inserting equipment or other mail preparation devices often would like the flexibility of being able to add mailpieces to the bottom or the top of a mailpiece stack. Thus, some mail processing systems prefer top stacking in some applications and bottom stacking in other applications. For example mailing machine systems having bottom feeder for which top stacking is preferred in order to keep the mailpieces in their original order. Another example is an addressing system configured to print addresses from multiple data bases. Some of the databases may list the addresses in forward order, while others may list addresses in reverse order. It is generally preferred to stack the mailpieces in forward order. A system such as the present invention, with selectable top or bottom stacking, could accomplish this modification the database.
Another example of a system which could benefit from an output device which can selectably stack either on top or on the bottom of the stack is a meter/mailing machine combination capable of handling mixed sizes of mailpieces and selectably sealing the mail or not sealing it during the franking operation. Pitney Bowes” Paragon® and DM950™ are examples of such a system. Bottom stacking may be preferred when processing a consistently sized batch of mailpieces which need to be sealed. Since the weight of the stack is felt by the new mailpiece added to the bottom and the weight assists in sealing the new mailpiece as well as other mailpieces in the stack. Additionally, when the mailpieces have glossy surfaces (and are thus more prone to image smearing during the stacking operation than regular mailpieces), the customer may prefer bottom stacking to minimize the probability of image smearing. Top stacking may be preferred for mailpieces that have already been sealed, or for jobs having intermixed mailpiece sizes, in which case top stacking may be the only option which will handle the stacking function.
An additional problem with the prior art is that the stackers typically have large space requirements, for example power stackers typically have a long run length. For some customers, the relatively large space requirements for the stacker can inhibit sales and placements of the product.
Additional difficulty with the prior art is that vertical top stacking operations can create untidy stacking. This is because mailpieces drop a long distance to the top of the stack and often do not settle neatly on top of the stack. Some mailpieces settle on edge, or sometimes flip over, or the mailpieces end up sticking partially out of the stack. In general, the stacking operation requires operator vigilance and frequent unloading or manual tidying the stack to insure continuous operation.
Thus, one of the problems of the prior art is that an ink from an envelope can smear onto an adjacent envelope. Another problem is that it is desirable to maintain the ordered of the mailpieces being stacked. Another problem of the prior art is untidy stacking. Another problem of the prior art is the need for a large footprint. Another problem of the prior art is unavailability of selecting stacking sequence (via top or bottom). Therefore, a system and method for stacking envelopes is needed which provides decreased smearing, maintains mailpiece order, provides tidy stacking, provides a smaller footprint and allows operator selectability of stacking sequence.
SUMMARY OF INVENTION
This invention overcomes the disadvantages of the prior art by providing an apparatus and method for stacking mailpieces. In particular, an embodiment of the present invention is an operator selectable top or bottom stacking apparatus that arrays the stack of mailpieces in a vertical orientation, increases the stacker capacity while reducing the footprint, and improves the tidiness of the stacking when either the top or bottom stacking feature has been selected. The bottom stacking feature of this invention reduces sliding contact with other mailpieces or portions of the stacker mechanism for portions of the mailpiece that are likely to be recently imaged, thus reducing the possibility of smeared images. It enhances sealing since recently stacked mailpieces feel the weight of the stack. And it enables simple unload while running capability without operator skill and without shutting down the system in the middle of a job. The top stacking feature adds further benefits such as enabling stacking of mixed mail sizes, and it improving the tidiness and reliability of the top stacking function by maintaining a preferred minimum dropping distances for mailpieces added to the top of the stack.
An embodiment of the present invention comprises an apparatus for stacking mailpieces in a vertical stack. The apparatus includes a means for holding the stack in a tilted position, the means comprising a tilted base. A sliding retainer is positioned to support a side of the stack that is tilted toward the sliding retainer by the means for holding the stack in a tilted position. A first input area is positioned above retainer element and a second input area is positioned below the retainer element and above the means for holding the stack in a tilted position. A translating carriage means is attached to the means for holding the stack in a tilted position, the translating carriage means is movable in an approximately or about vertical direction in response to a control signal indicating the direction of about vertical movement; whereby the apparatus is configured to selectably add mailpieces to the top of the vertical stack via the first input area or the bottom of the vertical stack via the second input area. It is further contemplated that the apparatus may be tilted a predetermined magnitude.
In another embodiment, the present invention comprises a method of stacking mailpieces in a vertical stack, the method comprising: a) providing a means for holding the stack in a tilted position; b) delivering mailpieces to the top of the stack; c) detecting whether the top of the stack has reached a predetermined height; d) lowering incrementally the means for holding the stack in a tilted position to a predetermined position that will provide the means for holding the stack in a tilted position space to accept additional mailpieces. The method further comprises e) detecting whether the top of the stack has reached another predetermined height indicating that a portion of the stack has been removed from the means for holding the stack in a tilted position; and f) raising the means for holding the stack in a tilted position to a predetermined position that provides a preferred dropping distance for mailpieces that are added to the stack.
An advantage of the present invention is that it decreases image smearing, reduces stacker footprint, improves sealing, provides ordered stacking regardless of the order of the input of the elements, such as, for example, mailpieces (i.e., stacks in 1 to N order), an operator selectable top or bottom stacking apparatus that arrays the stack of mailpieces in a vertical orientation, improves the tidiness of the stacking when either the top or bottom stacking feature has been selected, enables simple unload while running capability and could be unloaded during the processing of a job, and, without shutting down the system in the middle of a job, enables stacking of mixed mail sizes, and it improves the tidiness and reliability of the top stacking function by maintaining a preferred minimum dropping distances for mailpieces added to the top of the stack. Other advantages of the invention will in part be obvious and will in part be apparent from the specification. The aforementioned advantages are illustrative of the advantages of the present invention.
BRIEF DESCRIPTION OF DRAWINGS
The above and other objects and advantages of the present invention will be apparent upon consideration of the following detailed description, taken in conjunction with accompanying drawings, in which like reference characters refer to like parts throughout, and in which.
FIG. 1
is a block diagram that illustrates a computer system
100
, the use of which an embodiment of the invention may be implemented.
FIG. 2
is a block diagram schematic of a typical document inserter system.
FIG. 3
is a partial side view of an embodiment of the stacking device of the present invention configured to bottom stack and also illustrating a sliding retainer and translating carriage.
FIG. 4
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack illustrating sensors used for control of the movement of the carriage.
FIG. 5
a
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack, illustrating the carriage position after a stack has accumulated and the carriage has appropriately moved downward as the stack accumulates, and also illustrating sensors used for control of the movement of the carriage.
FIG. 5
b
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack, illustrating the carriage position after a stack has accumulated and the carriage has appropriately moved downward as the stack accumulates, and also illustrating an angled planar surface for supporting the stack.
FIG. 5
c
is a flow chart illustrating the steps of the operation of the sensors and movement of the carriage during top stacking.
DETAILED DESCRIPTION
In describing the present invention, reference will be made herein to
FIGS. 1-5
of the drawings, in which like numerals refer to like features of the invention. Features of the invention are not necessarily shown to scale in the drawings.
Control Overview
FIG. 1
is a block diagram that illustrates a computer system
10
, the use of which an embodiment of the invention may be implemented. Computer system
10
may be a personal computer which is used generically and refers to present and future microprocessing systems with at least one processor operatively coupled to user interface means, such as a display
2
and keyboard
4
and/or a cursor control, such as a mouse or a trackball
6
, and storage media
8
. The personal computer
10
may be a workstation that is accessible by more than one user. The personal computer also includes a conventional processor
11
, such as a Pentium® microprocessor manufactured by Intel, and conventional memory devices such as hard drive
8
, floppy or CDRW drive(s)
12
, and memory
14
.
The computer system
10
can be connected to an inserter apparatus as illustrated in FIG.
2
. The control system
10
of the inserter system
40
may be the microprocessor-based personal computer system
10
described above. The computer system
10
includes appropriate memory devices
8
,
14
for storage of information such as an address database (not shown). One of ordinary skill in the art would be familiar with the general components of the inserter system with which the present invention may be implemented.
Document Inserter System Overview
The stacker apparatus
58
of the present invention may be part of a document inserter system
40
.
FIG. 2
is a schematic of a typical document inserter system
40
, generally designated
40
. In the following description, numerous paper handling stations implemented in inserter system
40
are set forth to provide a thorough understanding of the operating environment of the inserter. However it will become apparent to one skilled in the art that the present invention may be practiced without the specific details of these paper-handling stations.
As will be described in greater detail below, system
40
preferably includes an input system
44
that feeds paper sheets from a paper web or individual sheets (not shown) to an accumulating station that accumulates the sheets of paper in collation packets (not shown). In this particular example, the apparatus of the present invention provides envelope throat profile information to the control system
10
of inserter system
40
to control the opening of various sized envelopes in the mailing inserter system
40
. Alternate methods of inserting include printing the address on the insert document only and inserting such document into a window envelope which reveals the address, printing the documents in a print finishing
43
area upstream from the input system
44
of document inserter system
40
and feeding the documents directly to the input system
40
from the print finishing area
43
.
Typically, input system
44
feeds sheets in a paper path, as indicated by arrow A along a deck that is commonly called the main deck (not shown) of inserter system
40
. After sheets are accumulated into collations by input system
44
, the collations are folded in folding station
46
and the folded collations are then conveyed to a transport station
48
, preferably operative to perform buffering operations for maintaining a proper timing scheme for the processing of documents in inserter system
40
.
Each sheet collation is fed from transport station
48
to insert feeder station
50
. It is to be appreciated that a typical inserter system
40
includes a plurality of feeder stations, but for clarity of illustration only a single insert feeder
50
is shown. Insert feeder station
50
is operational to convey an insert (e.g., an advertisement, business reply envelopes, or other documents or documentation) from a supply tray to the main deck of inserter system
40
so as to be nested with the aforesaid sheet collation being conveyed along the main deck. The sheet collation, along with the nested insert(s), are next conveyed into an envelope insertion station
52
that is operative to insert the collation into an envelope. The envelope is conveyed to the printer station
56
where appropriate printing such as addressee information and/or postal indicia is applied on an exterior surface of the envelope. Finally, the envelope is conveyed to stacker apparatus
58
that stacks the envelopes in accordance with the present invention.
The use of the document inserter system
40
, such as, for example, a Series 9 Inserter Systems manufactured by Pitney Bowes Inc. of Stamford, Conn., is well known. Such document inserter systems are used by organizations (e.g., banking institutions, utility companies, insurance companies, credit companies, and the like) for assembling large amounts of outgoing mailpieces for dispatch through the postal system. Typically, such organizations create documents, such as billing documents in a computer such as a mainframe computer system (not shown) that is separate from the document inserter system
40
that will process the documents into such mailpieces.
Stacker Apparatus
The stacking apparatus
58
of the present invention is configured to selectably stack from either the top or the bottom of the stack and is capable of handling mixed sizes of mailpieces. Bottom stacking may be preferred when processing a consistently sized batch of mailpieces which need to be sealed, since the bottom stacker
58
enhances sealing by ensuring that the weight of the stack is felt by each new mailpiece as it is added to the bottom of the stack. Additionally, when the mailpieces have glossy surfaces (and are thus more prone to image smearing during the stacking operation than are regular mailpieces), the user or operator may prefer bottom stacking to minimize the probability of image smearing. Top stacking may be preferred for mailpieces that have already been sealed (in which case the sealing enhancement feature of bottom stacking is not needed), or top stacking may be preferred for mail creation jobs having intermixed mailpiece sizes (in which case top stacking may be the only option which could handle the stacking function).
FIG. 3
is a partial side view of an embodiment of the stacking device of the present invention configured to bottom stack and also illustrating a sliding retainer and translating carriage. The stacking mechanism is positioned such that input area
232
is positioned below the retainer element and above the means for holding the stack in a tilted position. For bottom stacking two intermittently rotating S-elements
201
,
102
, at least one stack guide element
103
and appropriate drive elements (not shown) rotate the rotating S-elements. Further, means are included to move one of the two rotating S-elements
201
into a position consistent with the size of the mailpieces to be stacked while leaving the second rotating S-element
102
fixed. This operation can be automated with the use of appropriate sensors and drive elements. Alternatively, this operation may be manual.
FIG. 4
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack, also illustrating sensors used for control of the movement of the carriage.
FIG. 4
illustrates the position of the carriage
202
for receiving first mailpiece
107
to be stacked on top of the S-elements, which are configured for holding the stack in a tilted position. The carriage
202
is positioned below input area
232
in order to receive mailpieces
107
on top of the stack. The embodiment comprises a carriage
202
and lead screw elements
205
. In this arrangement, the S-elements
102
and
201
, associated drives (not shown), and the sliding retainer element
103
are mounted on a translating carriage
202
, which is capable of being driven in a slightly off-vertical direction by a lead screw
205
activated by a lead screw motor
206
. The lead screw
205
, motor
206
, and associated bearings and drives are suitably mounted to fixed frame
208
. For bottom stacking operation, the carriage
202
is first positioned so that individual mailpieces
107
enter the stacker
58
just above the shelf areas of the S-elements. Thereafter, the carriage
202
and lead screw
205
remain substantially stationary while stacker
58
is in operation. The S-elements
102
and
201
rotate, for example, up to 180 degrees after each mailpiece
107
enters, thus lifting the individual mailpiece
107
to the bottom of the stack. The stack grows in an approximately vertical direction as more mailpieces are added to the stack. Note that the S-element
201
of the present embodiment is larger than the S-element
102
. The differently sized S-elements create a slight tilt of the stack against the sliding retainer element
103
to help support of tall stacks. Alternately, the two S-elements could be the same size, and the frame could be tipped further in order to tilt the stack. The sliding retainer element
103
(shown in
FIG. 3
with an elongated vertical element roughly equal to the maximum stack height) rests on the top of the stack and assists in sealing and in keeping the stacked mailpieces tidy as the stack grows in the approximately vertical direction.
Note the mailpiece input position
207
in
FIG. 4
remains at the same location as shown in
FIGS. 3 and 5
(described herein).
FIG. 4
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack illustrating sensors used for control of the movement of the carriage.
FIG. 4
illustrates the carriage
202
repositioned down, for example, a few inches from the position shown in
FIG. 3
, to a position suitable for the beginning of top stacking operation. For the top stacking operation of the present embodiment, the S-elements
102
and
201
do not rotate, and the mailpieces are stacked on top of the S-elements
102
,
201
and the sliding retainer
103
. As the stack grows with repeated stacking of new mailpieces, the carriage
202
moves downward to keep a relatively constant drop distance for the new mailpieces.
FIG. 5
a
is a partial side view of an embodiment of the stacking device of the present invention configured to top stack, illustrating the carriage position after a stack has accumulated and the carriage has appropriately moved downward as the stack accumulates. In the embodiment of
FIG. 5
, two sensor systems are used to control the position of the carriage
202
to help the top of the stack remain in the preferred position of 1 to 2 inches below the mailpiece input position during active top stacking operation. The sensor scheme illustrated in this embodiment is not meant to be limiting; other sensor schemes as may be determined by one of ordinary skill in the art can also accomplish the sensing function. The sensor arrangement of the present embodiment comprises a first optical sensor
211
and first rotating flag
210
which operate to determine when the mailpieces in the stack have accumulated to a predetermined height. As is further illustrated in
FIG. 5
a
, a second flag
212
and second optical sensor
213
are positioned to detect when an operator has removed a portion of the stack
106
.
FIG. 5
b
is a partial side view of an alternate embodiment of the stacking device of the present invention configured to top stack, illustrating the carriage
202
position after a stack
106
has accumulated and the carriage
202
has appropriately moved downward as the stack
106
accumulates and also illustrating an angled planar surface
222
for supporting the stack. As is shown in
FIG. 5
b
, the planar surface
222
is inclined toward the translating carriage means. The incline is achieved by configuring a first side
222
a
of the planar surface
222
at a height greater than the height of a second side
222
b
of the planar surface
222
a
.
FIG. 5
b
also illustrates that carriage may be moved such that the input location remains constant whether a top stacker or bottom stacker is used. Alternatively, as will be apparent to one skilled in the art in view of
FIG. 5
b
, two separate input areas may be used with the present invention.
FIG. 5
c
is a flow chart illustrating the steps of the operation of the sensors and movement of the carriage during top stacking. At step S
100
, the method begins. At step S
102
, a mailpiece is added to the top of the stack. At step S
104
, a query is made as to whether the edge of the stack has caused the first flag
210
to rotate and break the beam of the first optical sensor
211
. If the answer to the query of step S
104
is yes, meaning that the edge of the stack has caused the flag
210
to rotate and thus break the optical sensor
211
beam, then at step S
106
the carriage
202
is lowered. The lowering of the carriage for step S
106
takes place when the optical sensor
211
beam is broken, and a signal is made (by control system
10
) to the lead screw drive motor
206
to rotate the lead screw
205
to drop the carriage
202
by a suitable amount (preferably about 1 inch) to make space for additional mailpieces to be added to the top of the stack. If the answer to the query of step S
104
is no, then steps S
102
through S
104
are repeated as described above.
Following step S
106
, at step S
108
a query is made as to whether the operator has removed a portion of the stack
106
and the second flag
212
has rotated and triggered the second sensor
213
. During the stacking operation the carriage
202
appropriately moves downward in small increments or steps as the stack
106
accumulates. First flag
212
is typically in contact with the edge of the stack
106
during normal stacking operation, and in that contact position, it breaks the beam of second sensor
213
. When the operator removes a portion of the stack
106
, as in step S
108
(when the answer to the query is yes), the drop distance for new mailpieces
107
is greater than the preferred 1 to 2 inches. The second flag
212
works with the second sensor
213
to detect that the operator has removed a portion of the stack
106
by pivoting to the dashed position
212
B, and exposing the optical beam of sensor
213
. Next at step S
110
the carriage is raised. The method of raising the carriage is preferably performed by the sensor sending a signal to control system
10
to cause lead screw motor
206
to operate in reverse and drive the carriage
202
in an upward direction until the remaining stack
106
, or a feature on the carriage
202
(not shown) engages the flag
212
and rotates the flag
212
to block the optical beam
213
again, at which time the carriage
202
motion stops and the top of the stack
106
is in position to receive additional mailpieces with a minimal drop distance. Note this same sensor is used to position the carriage
202
back to a position just below the mailpiece input position
207
(as shown in
FIG. 4
) after the mail creation/stacking job is completed and the operator removes all mailpieces from the stacker. In this embodiment, it is a feature on the carriage
202
(and not the stacked mailpieces
106
) that engages the flag
212
and positions it to break the beam of second sensor
213
. At step S
112
, the method ends.
The embodiments described herein can provide the advantages such as decreased image smearing, reduced stacker footprint, improved sealing, ordered stacking, operator selectable top or bottom stacking, unloading while running capability, stacking of mixed mail sizes and tidiness and reliability of the top stacking function. While the present invention has been disclosed and described with reference to a various embodiments thereof, it will be apparent, as noted above, that variations and modifications may be made therein. It is, thus, intended in the following claims to cover each variation and modification that falls within the true spirit and scope of the present invention.
Claims
- 1. An apparatus for stacking material pieces in a vertical stack, the apparatus comprising:a means for holding the stack in a tilted position; a sliding retainer positioned to support a side of the stack that is tilted toward the sliding retainer by the means for holding the stack in a tilted position; a first input area positioned above the stack; a second input area positioned below the stack; and a translating carriage means attached to the means for holding the stack in a tilted position, the translating carriage means movable in an about vertical direction in response to a control signal indicating the direction of about vertical movement; whereby the apparatus is configured to selectably add material pieces to the top of the vertical stack via the first input area or the bottom of the vertical stack via the second input area.
- 2. The apparatus as claimed in claim 1 wherein the control signal indicating the direction of the about vertical movement of the translating carriage means is the result of data provided by first and second sensors positioned in an area of the apparatus suitable for detecting desired stack height.
- 3. The apparatus as claimed in claim 2 wherein the first sensor operates to determine whether the carriage needs to be moved in an about vertical downward direction in order to make room for additional material pieces on the top of the stack.
- 4. The apparatus as claimed in claim 2 wherein the second sensor operates to determine whether the carriage needs to be moved in an about vertical direction upward in order to position the means for holding the stack to receive additional material pieces with a minimal drop distance from the first input position.
- 5. The apparatus as claimed in claim 1 wherein the means for holding the stack in a tilted position comprises a first S element of a first diameter and a second s element of a second diameter, the second diameter larger than the first diameter and the first s element position proximately to the translating carriage means, the second s element positioned distally to the translating carriage means, whereby the size and positioning of the first and second S-elements causes a tilt of the means for holding the stack in a tilted position toward the translating carriage means.
- 6. The apparatus as claimed in claim 1 wherein the means for holding the stack in a tilted position comprises a planar surface with an incline sloped toward the translating carriage means.
- 7. The apparatus as claimed in claim 1, wherein the apparatus is tilted a predetermined magnitude.
US Referenced Citations (5)