Patent Grant
7866661
The present invention relates to systems which buffer sheet material in advance or upstream of a sheet handling apparatus, and more particularly, to a sheet/page buffer for a mail creation system which receives, holds and delivers sheet material to and from an upstream printer and downstream mailpiece inserter.
A mail creation system or a “mailpiece inserter” is commonly employed for producing mailpieces intended for mass mail communications. Such mailpiece inserters are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mail communications where the contents of each mailpiece are directed to a particular addressee. Also, other organizations, such as direct mailers, use mailpiece inserters for producing mass mailings where the contents of each mailpiece are substantially identical with respect to each addressee.
In many respects, a typical inserter resembles a manufacturing assembly line. Sheets and/or other raw materials (i.e., a web of paper stock, enclosures, and envelopes) enter the inserter as inputs. Various modules or workstations of the inserter work cooperatively to process the sheets until a finished mail piece is produced. Typically, inserter systems prepare mail pieces by arranging preprinted sheets of material into a collation, i.e., the content material of the mail piece, on a transport deck. The collation of preprinted sheets may continue to a chassis module where additional sheets or inserts may be added based upon predefined criteria, e.g., an insert being sent to addressees in a particular geographic region. Subsequently, the collation may be folded and placed into envelopes. Once filled, the envelopes may be closed, sealed, weighed, and/or sorted. A postage meter may then be used to apply postage indicia based upon the weight and/or size of the mail piece.
These inserters typically require the use of “preprinted” sheets which are presented to the various downstream devices by a feed module for subsequent processing. That is, a mailpiece job run is printed to produce an “ordered” stack of mailpiece content material which may be fed to the mailpiece inserter. Scan codes disposed in the margin of the first or last sheet of each mailpiece document provide the instructions necessary to process the mailpiece, i.e., whether additional inserts will be added, how the content material is to be folded (C-fold, Z-fold, etc.) and/or what size envelop will the content material be contained. To facilitate communication of these instructions, a user computer and a printing device are typically network-connected to the mailpiece inserter such that scan codes can be easily printed and interpreted.
More recently, printers have been integrated with mailpiece inserters so that mailpiece content material may be supplied “on-demand”, and/or “just-in-time”. Examples of inserters having integrated printers include the DI 900 and DI 950 desktop mailpiece inserters manufactured by Pitney Bowes Inc., located in Stamford, Conn. To facilitate throughput, a sheet or page buffer is commonly employed between the printer and inserter modules. In
The rate of change of the position signals 122 (i.e., the signals issued by the page buffer 100) may be used by the controller 114 to determine the throughput that content material is processed. Fundamentally, the “throughput” or “throughput rate” is the magnitude at which sheet material is processed, whether in terms of a steady number of “sheets per unit time”, bundles of sheets (e.g., bundles of five (5) sheets requested every several seconds) or a non-steady flow of sheets. Generally, it is the objective of the system controller 114 to drive the printer 110 to generate content material, i.e., printed pages 116 at a rate consistent, or commensurate, with the rate of processing by other downstream devices of the mailpiece inserter 112. Therefore, as pages are processed by the inserter 112, the controller 114 issues a request signal 124 to the printer 112 to generate additional pages 116.
The design of a page buffer is influenced by a variety of factors including: (i) the space envelope (i.e., length and height availability) of a mailpiece (ii) the number of page stations desired/required, (iii) the travel/conveyor distance from the printer to the inserter, (iv) the processing or throughput speed of the printer as compared to the inserter (i.e., can one module print/process pages faster, slower or at the same rate as the other module), and (v) other unique requirements such as whether pages must be inverted as a result of duplex or dual-sided printing. With respect to the page buffer described above, five (5) page stations are employed and spaced serially end-to-end. Assuming that the page stations accommodate conventional 8.5″×11.0″ letter-size pages, the minimum conveyer or feed path length is approximately five feet (5′), i.e., five times the length of each station.
The page buffer 100 described above accommodates the length of the feed path by incorporating an upper turn-around section 100T, i.e., a vertical portion extending above the printer 110. However, should the design envelope of the page buffer not facilitate or accommodate the upper turn-around section 100T, or require additional page stations, (i.e., the addition of two (2) or three (3) page stations for a total of eight (8) stations), the total length of the feed path may preclude this design option. Even when the design envelope accommodates the overall increase to the page buffer dimensions, the length of the conveyer can impact other design parameters such as the speed, power and acoustics required and/or generated by the page buffer. That is, as the length of the feed path, i.e., from the output tray of the printer to the entrance of the inserter, increases, the conveyer speed must also increase to transport pages in the same time interval. As a consequence, the speed, power and acoustics can exceed threshold levels which place yet other limitations on the design of the page buffer.
In addition to the factors discussed in the preceding paragraph, the throughput capacity of the printer must be compatible, or made compatible, with the throughput of the inserter. In addition to the processing speeds of the respective modules, other factors such as the number of pages being processed at a particular point in time must be considered. For example, any time that the printer is processing pages, other pages, internal to the printer are being processed, including duplex or dual-sided pages. As a consequence, the page buffer must also accommodate or be prepared to queue pages “in process”. As printers process pages at a higher rate, i.e., process more pages on a “per unit time basis”, page buffers must accommodate the additional throughput.
A need, therefore, exists for a page buffer which minimizes the space envelope, reduces the length traveled by, i.e., the feed path of, a printed sheet, and optimizes the number of page stations available for printed pages to be processed by a mailpiece inserter.
A page buffer is provided for receiving and holding, in queue, pages prepared by a printer and subsequently processed by mailpiece inserter. The page buffer includes pairs of vertically-aligned rollers defining a plurality of page stations therebetween. Each pair of rollers is spaced-apart and defines a nip for driving the printed pages along a feed path. Furthermore, each page station is defined by and between a first pair of rollers disposed downstream of an adjacent second pair of rollers. A drive means is also provided for independently driving the pairs of vertically-aligned rollers. The drive means is controlled such that, in a first operating mode, the pairs cooperate to drive printed pages along the feed path. In a second operating mode, the drive means is controlled such that at least one of the page stations causes its respective first pair of rollers to retain and hold a leading edge portion of a printed page while the adjacent second pair drives and releases a trailing edge portion of the printed page. The printed page is, therefore, held within the page station such that the trailing edge droops below the feed path in a predominantly vertical orientation.
The accompanying drawings illustrate a presently preferred embodiment of the invention and, together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
a depicts an enlarged view of a single page station including two adjacent pairs of rollers operative to capture a leading and trailing edge portion of a sheet of mailpiece content material.
b depicts the page station shown in
c depicts the page station shown in
a and 5b depict schematic side views of the page buffer including an inversion mechanism operative to direct pages from the printer to a pair of horizontal rollers to change the orientation of the sheet material, i.e., from a face-up to face down orientation, when preparing pages for processing.
The inventive page buffer and method for controlling the same are described in the context of a mailpiece inserter system, though the inventive page buffer and control methodology may be used in combination with any sheet handling device which requires that sheet material or pages be held in a queue for subsequent processing. Further, the invention is described in the context of a DI 900 Model Mailpiece Inserter, i.e., a mailpiece creation system produced by Pitney Bowes Inc., located in Stamford, State of Connecticut, USA, though, the inventive subject matter may be employed in any mailpiece inserter.
Before discussing the invention in greater detail, it will be useful to understand the basic system architecture and operation of the mailpiece inserter 10, including the cooperation of various system components and elements. In
In
The page buffer 20 includes position sensing devices, (not shown) located at or along each of the page stations 30, to monitor the rate that printed pages enter or leave the page buffer 20. Furthermore, the sensing devices are operative to issue position signals 32 to a system controller 34 such that the inserter 10 may determine whether a page or sheet 12 is positioned at a particular one of the page stations 30. In the described embodiment, the sensing devices are photocells, though any position sensor may be employed.
The rate of change of the position signals 32 (i.e., the signals issued by the page buffer 20) may be used by the controller 34 to determine the throughput of the inserter 10. Fundamentally, the “throughput” or “throughput rate” is the magnitude at which sheet material 12 is processed, whether in terms of a steady number of “sheets per unit time”, bundles of sheets (e.g., bundles of five (5) or ten (10) sheets requested every several seconds) or a non-steady flow of sheets. Generally, it is the objective of the system controller 34 to drive the printer 8 at a rate consistent, or commensurate, with the rate of processing by other downstream devices of the mailpiece creation system 10. While in the described embodiment the initial/first downstream device is a page buffer 20, it should be appreciated that any downstream device may be adapted to issue a throughput signal indicative of a processing rate. In
The system controller 34 monitors the throughput data and issues command signals 40 indicative of the number of pages 12 to be printed by the integrated printer 8. More specifically, the command signals 40 are indicative of a specific page number to begin printing along with the number of pages 12 to follow. For example, the controller 34 may issue a command signal 40 which requests the printer 8 to generate page number thirty (Page #30) plus five (5) additional pages of data. Before this request is issued to the printer 8 (in the more conventional sense), the controller 34 issues the command through a page-based language monitor 42. In the preferred embodiment, the system controller 34 generally issues command signals 40 to print between three (3) and seven (7) pages with each request, though several command signals 40 may be generated within a very short period of time.
The mailpiece inserter 10 further includes a User Interface Module (UIM) 44 interposing the page buffer 20 and the system controller 34. The UIM 44 is responsive to the position signals 32 of the page buffer 20 for determining when additional pages, sheets of content material 12, can be accepted by the page buffer 20. Specifically, the UIM 44 is operative to issue request signals 48 to the system controller 34, i.e., the request signals 48 to print additional pages 12. Hence, conversion of the position signals 32 to command signals 40 may be performed by either the system controller 34 or by the UIM 44, depending upon where the program logic/intelligence is located. It should be further appreciated that while the request signal 48 may be made by the UIM 44, the controller 24 may have received a message that the print job, i.e., determined at the User PC 14, is complete. Consequently, in this instance, the controller 34 will not forward a command signal 40 to the language monitor 42 for issuance to the printer 8.
The page-based language monitor 42 (hereinafter the “language monitor” or “LM”) receives print stream data from a page-based print processor 50 and is interposed between the system controller 34 and the dedicated printer 8. In the broadest sense, the LM 42 is the gate-keeper of data communicated to the printer 8 from the controller 34. More specifically, the LM 42 retains material content data, including an object-data dictionary, for each page of material content and triggers the printer 8 to generate a particular page (i.e., page number) along with N number of additional pages. While this request to print is made by the system controller 34, the LM 42 contains the active program code which intercepts the print stream data, i.e., the print control language (PCL), from the printer driver to throttle the rate at which content material 12 is generated by the printer 8.
More specifically, the page-based LM 34 is operative to vary the flow of print stream data to the printer 8 and vary the production rate of mailpiece content material. Additionally, the LM 42 includes a bufferfile capable of storing 300 MB (300,000,000 bytes) of data and, accordingly, the buffer file is capable of storing multiple pages of data, including duplex pages. Hence, in the context used herein, a “page” of data includes all data which may be found on a one-or two-sided sheet of paper.
In operation, the language monitor 42 and print processor 50 issue a print command signal 52 to throttle/control the output of the printer 8 in order to be consistent with or match the throughput of the mailpiece inserter 10. As more pages are processed by the inserter 10, additional or more frequent requests for additional printed pages 12 can be made. Should the inserter 10 require additional processing time to collate and/or combine a complex variety of inserts, requests can be made for a fewer number of printed pages or at less frequent intervals to prevent an overload condition or too many sheets from being printed over a prescribed period of time.
In
While the page stations 30 lie between adjacent pairs of rollers 60, i.e., between, for example, an upstream pair 602 and a downstream pair 603, the page stations 30 also lie below the feed path FP in a predominantly vertical orientation. In the context used herein “predominantly vertical orientation” means that that page stations extend vertically downward by a dimension less than about the length of a printed page. The horizontal distance or distance from one page station to an adjacent station, e.g., from 301 to 302 should preferably be less than about one-half the length of the printed page. Furthermore, the page stations 30 are essentially face-to-face. The significance of the spatial orientation and the method for loading and unloading the page stations will become clear in subsequent paragraphs.
a, 4b and 4c depict the operation and control of two adjacent pairs of rollers 601, 602 to capture and temporarily hold or “buffer” a printed page 12 in a single page station 301. Any of the adjacent pairs 60 could be used for illustration purposes, though it should be appreciated that the page stations 30 will generally be loaded from a downstream page station to an upstream page station. For example, pages will be stored or buffered in a sequence beginning with page station 3010 (see
The page buffer 20 can be operated in various operational modes and controlled by driving the pairs of rollers 601, 602 independently. In
In
In
In addition to providing a page station support, the tray 80 may additionally provide an inclined surface 80N for guiding the leading edge 12L of the printed page 12. That is, the inclined surface 80N may be spatially and angularly adapted to guide the leading edge 12L into the nip of the downstream pair of rollers 602. Furthermore, the upward inclination of the guide surface 80N may offset any downward inclination of the leading edge caused by the concave surface 70CS of the arcuate guide 70.
In
The horizontally-aligned rollers 94 may extend above or below the feed path FP and are operative to accept, momentarily hold, and return the printed pages to the original or primary feed path. More specifically, the rollers 94 rotate in a first direction to accept a printed page. When the nip of the horizontal pair 94 rotates through threshold angular displacement, or when a leading edge sensor 96 (see
While the inverter mechanism 90 may be controlled by a dedicated microprocessor, in the described embodiment, the system controller 34 issues and receives signals from the various driven components. For example, the controller 34 may be operative to drive a rotary actuator MD connected to the movable diverter 92, control a drive motor M2 associated with the horizontally aligned rollers 94 and receive/process signals from the leading edge sensor 96.
In
The system controller 34 may drive the individual motors M to first remove, in sequential order, the pages 12 in page stations 308, 309 and 3010 to fulfill the fabrication of three individual mailpieces. Thereafter, the system controller 34 may drive the motors associated with stations 305, 306, though, the printed page in station 305 may be released first to shingle with the leading edge of the page in station 306, thereby creating a two sheet collation 12C2. The system controller 34 then drives all motors M in connection with stations 306, 307, 308, 309, and 3010 for conveying the two sheet collation 12C2 along the feed path FP. The system controller 34 then drives all motors M in connection with stations 301, 302, 303, releasing the pages in reverse order i.e., stations 303, 302, and 301, to shingle the pages into a three sheet collation 12C3. Finally, all of the drive motors M are activated to convey the final collated group 12C3 along the feed path FP. Accordingly, the page buffer 20 can be controlled in a variety of ways to buffer and release pages 12, individually or as a group to increase throughput, or accelerate collation in the accumulator module 35 of the mailpiece inserter 10.
In summary, the page buffer 20 of the present invention provides multiple page stations within a low-profile, space-efficient design envelope. Whereas prior art configurations employed sequential end-to-end page stations, the present invention employs vertically-oriented face-to-face pages stations. These vertically-oriented page stations provide a unique opportunity to minimize the overall length requirements of the page buffer 20. Furthermore, the page buffer 20 can be operated efficiently with or without the requirement to buffer pages. That is, the closely-spaced rollers and nips allow the page buffer to operate efficiently as a linear transport, but also provide the opportunity to buffer the printed pages as required. The relatively short distance between the input and output of the page buffer 20 reduces the speed and, consequently, the noise, generated by the driving motors, i.e., the motors which drive the transport and buffering rollers 60. Furthermore, such reduced speed requirements translate into reduced power requirements.
Finally, the page buffer 20 provides other operational modes which reduce complexity and facilitate throughput. The vertically-oriented pairs 60 simplify assembly and provide commonality of components. As such, fabrication and maintenance costs are minimized. Furthermore, the linear arrangement of rolling elements facilitates the ability to invert sheets from a face-up to face down orientation. Finally, such linear arrangement enables the grouping and/or shingling of sheets 12 internally of the page buffer 20 to transport a collation of sheets 12 along the feed path. Such grouping of printed pages enables higher system throughput by transporting a plurality of sheets while minimizing the spacing therebetween.
It is to be understood that the present invention is not to be considered as limited to the specific embodiments described above and shown in the accompanying drawings. The illustrations merely show the best mode presently contemplated for carrying out the invention, and which is susceptible to such changes as may be obvious to one skilled in the art. The invention is intended to cover all such variations, modifications and equivalents thereof as may be deemed to be within the scope of the claims appended hereto.
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| Number | Date | Country | |
|---|---|---|---|
| 20090057974 A1 | Mar 2009 | US |
