Patent Application
20110132722
Various systems have been developed for the creation and processing of mail. This can involve the insertion of material into an envelope or other enclosure, the sealing of the enclosure, and printing of information on the enclosure, all of which can occur at high throughput speeds. Additional processing can involve printing of postal indicia on the enclosure and the sorting and stacking of the finished mailpiece. The systems can be organized to create mailpieces in a manner that are entitled to obtain certain favorable pricing by the mail delivery services due to the ability of the carrier such as a postal service to automate processing or where the mail is presorted or organized by carrier route.
To accomplish the various steps in the processing of the mailpiece, proper alignment and orientation of the mailpiece is needed. This facilitates high speed operation of the equipment and helps avoid equipment jams and also improper preparation of the mailpiece, as, for example, where the printing on the enclosure is not properly located. Where this occurs, the mailpiece may be rejected and diverted from the mail processing stream to be recreated. Also, where the mailpiece is not rejected and recreated, improper preparation may negatively impact downstream mail processing. For example, when a delivery point bar code or other delivery or processing code cannot be read by the processing equipment due to improper positioning or alignment on the mailpiece, alternative processing such as manual sorting may be required.
Systems for the creation and processing of mail have included arrangements to provide mailpiece enclosure alignment and orientation. For example, a mailpiece rotation module has been commercially marketed by Moore's Business Forms to change mailpiece orientation from a landscape orientation to a portrait orientation with respect to the mailpiece path of travel by means of rotating the mailpiece. However, such systems do not provide skew correction for the mailpiece, nor flexibility in the manner in which the mailpiece is controlled.
The problems associated with alignment and orientation of enclosures is exacerbated with large size mailpieces. This is the case with flats mail. Flats mailpieces are mailpieces that are larger than normal sized business type mail. The dimensions of flats mail vary from country to country. Flats mail, as defined by the United States Postal Service (USPS) in the USPS Domestic Mail Manual (DMM), is generally characterized by mailpieces that are more than 11½ inches long, or more than 6⅛ inches wide or more than ¼ inch thick. Among other items, these new standards require the delivery address to be located in the upper portion of flat-sized mailpieces mailed at automation, presorted, or carrier route prices. The new standards enable the USPS to process flat-size mailpieces in delivery sequence at high speeds and output the pieces in vertical bundles that are optimized for carrier delivery.
Improving proper alignment and orientation of a mailpiece increases the effectiveness of mail creation and processing equipment by helping to enable increased processing speed, fewer mailpiece rejects, few paper jams and enhanced downstream mailpiece processing. It also facilitates obtaining more favorable pricing from carrier delivery services. The foregoing is particularly applicable to flats mailpieces where the physical handling of the mailpiece is more difficult due to the size of the mailpiece which may be mixed in with mailpieces of other sizes.
The present invention helps to ensure mailpieces are properly aligned and oriented for processing regardless of the original alignment and orientation when the mailpiece enter the system or the orientation when the mailpiece exits the system. A system and method are provided that improve the handling of flats and other size mailpieces, including mixed mail, and provide enhanced mailpiece skew correction and proper mailpiece orientation.
A method for skew correction of a mailpiece according to an embodiment of the present invention includes moving the mailpiece along a path of travel in a first orientation with respect to the path of travel toward a first and a second drive roller. Control of the mailpiece is established in the first orientation by the first and the second drive roller. A first skew correction of the mailpiece in the first orientation is implemented by employing the first and the second drive roller to align the mailpiece with respect to the path of travel.
In accordance with another embodiment of the present invention, the method for skew correction of a mailpiece further includes employing the first drive roller and the second drive roller to change the orientation of the stopped mailpiece from the first orientation with respect to the path of travel to a second orientation with respect to the path of travel.
In accordance with yet another embodiment of the present invention, the method for skew correction of a mailpiece further includes implementing a second skew correction of the mailpiece in the second orientation by employing the first and the second drive roller to align the mailpiece in the second orientation with respect to the path of travel.
A mailpiece skew correction system embodying the present invention includes a transport adapted to move a series of mailpieces in a first orientation along a path of travel. A first drive roller and a second drive roller are mounted along the transport path of travel and positioned to receive mailpieces moved by the transport along the path of travel. The first drive roller and the second drive roller control and move mailpieces along the path of travel. A first control motor is connected to the first drive roller and a second control motor is connected to the second drive roller. A first detector and a second detector are positioned along the path of travel. The first and the second detectors provide data for the first and second control motor of detected skew of mailpieces moved along the path of travel in the first orientation under control of the first and the second drive rollers. The first control motor is operable to control the motion profile of the first drive roller and the second control motor is operable to control the motion profile of the second drive roller. The control of the motion profile of the first and the second drive rollers is based on data from the first and the second detector of detected skew of mailpieces moved along the path of travel in the first orientation is such that any mailpiece skew is corrected with respect to the path of travel and the mailpiece in the first orientation is aligned with respect to the path of travel.
In accordance with a feature of the present invention, the control of the motion profile of the first and the second drive rollers can be such that the mailpiece is stopped at a position along the path of travel after any mailpiece skew is corrected with respect to the path of travel in the first orientation and the mailpiece in the first orientation is aligned with respect to the path of travel. The orientation of the stopped mailpiece is changed from the first orientation with respect to the path of travel to a second orientation with respect to the path of travel by causing the first drive roller and the second drive roller to rotate in opposite directions.
In accordance with another feature of the present invention, the mailpiece skew correction system includes a third detector positioned along the path of travel downstream of the first detector and a fourth detector positioned along the path of travel downstream of the second detector. The third and the fourth detectors provide data for the first and second control motor of detected skew of mailpieces moved along the path of travel in the second orientation under control of the first and the second drive rollers. The control of the motion profile of the first and the second drive rollers based on data from the third and the fourth detector of detected skew of mailpieces moved along the path of travel in the second orientation is such that any mailpiece skew is corrected with respect to the path of travel and the mailpiece in the second orientation is aligned with respect to the path of travel.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts in the various figures.
Reference is now made to
The output subsystem 14 includes a sealer module 22 connected to the inserter engine 20 for sealing the mailpieces, as, for example, sealing an envelope flap. The sealer module 22 may feed the sealed mailpiece in a landscape orientation to a skew correction module 24, which is shown in greater detail in
The skew correction module 24 after having corrected for any skew in the mailpiece and, where required, changing the orientation of the mailpiece along the mailpiece path of travel, delivers the mailpiece to a printer module 26. The printer module 26 prints any needed information onto the mailpiece. The printed information can include the delivery address, the sender logo, the return address, and other information, such as a delivery point barcode. After printing, the printer module 26 delivers the mailpiece to the weighing module 28 for weighing the mailpiece to determine the correct amount of postage for the particular mailpiece. The postal indicia is thereafter printed by the meter module 30. The meter module 30 delivers the mailpiece to an outsort module 32 for selective outsorting of defective mailpieces. Properly assembled mailpieces are delivered to a stacker module 34.
The skew correction system of module 24 can be employed wherever skew correction and/or reorientation of a mailpiece is desired and need not be part of an inserter system. The inclusion of the skew correction module 24 in the inserter system 10 for the creation and processing of mail is to illustrate one type of system where the skew correction module with all the features enabled may be employed.
Reference is now made to
Reference is now made to
The rollers 56 and 58 cooperate with spring loaded upper rollers 56a and 58a, respectively. In the illustrated embodiment, the drive rollers 56 and 58 are significantly wider than the spring loaded idler rollers 56a and 58a. The difference in width is approximately a 4 to 1 ratio, with the idler rollers 56a and 58a having, for example, a width of 1/16 of an inch and the drive rollers 56 and 58 having a width 4/16 of an inch. The two upper idler rollers 56a and 58a are narrow and have a rounded cross section at the roller periphery. Thus, there is nearly a point contact with the respective lower drive rollers 56 and 58, which facilitates rotation of the mailpiece 36 to change the mailpiece orientation from a landscape orientation to a portrait orientation. The rotation process is described in connection with
Once the mailpiece 36 is captured between the nips of the drive rollers 56 and 58 and associated idler rollers 56a and 58a, and has exited the nip of the constantly rotating drive roller 48 and associated idler roller (not shown) and drive roller 50 and associated idler roller 50a, the mailpiece is positioned so that it is suitable for skew correction by a first skew correction process, and for rotation to the proper orientation for subsequent processing, where needed.
As the mailpiece is moved under control of the drive rollers 48 and 50 and into the control of drive rollers 56 and 58, the leading edge 60 of the mailpiece 36 in landscape orientation passes photo detector cells 62 and 64 (hereinafter “photocells”). The photocells detect the misalignment of the mailpiece 36 in the paper path direction 46 and provide this information to the control motors 52 and 54 via connections 62a and 64a connected to the motor control system 55, as shown in
The drive rollers 56 and 58 are initially rotating in the same direction and at the same speed as the constantly rotating drive rollers 48 and 50 when the lead edge 60 of the landscape-oriented mailpiece 36 engages the nips of the drive rollers 56 and 58 and associated idler rollers 56a and 58a. The detected misalignment (i.e., skew) of the mailpiece 36 provides the control motors 52 and 54 the needed information to impart a differential motion profile via independent control of the rotational speed and direction of the drive rollers 56 and 58 for the mailpiece 36 to be fully skew-corrected when the leading edge 60 of the mailpiece is stopped a distance d (shown in
The control motors 52 and 54, via the drive rollers 56 and 58 and associated idler rollers, convey the mailpiece leading edge 60 the same distance d from the photocells 62 and 64 in the direction of travel as they decelerate the mailpiece 36 to zero velocity. The separate motion profiles cause the mailpiece leading edge 60 (shown in
During the deceleration, eventually the leading edge 60 of the landscape-oriented mailpiece 36 will block one of the photocells 62 or 64 followed by the other photocell, with the duration between the two events depending on the severity and direction of the mailpiece skew. Motion control for the motors 52 and 54 de-skews the landscape-oriented mailpiece 36 before the mailpiece is stopped, as shown in
Once the leading edge 60 has blocked the second photocell, the motors 52 and 54 independently decelerate at different rates to deliver the leading edge 60 of the landscape-oriented mailpiece 36 the fixed distance d downstream of the respective photocells 62, 64 at precisely the same time to the stopped position. This differential motion control of the mailpiece 36 results in correction of any skew of the landscape oriented mailpiece when the mailpiece is stopped. The leading edge 60 of the landscape-oriented mailpiece 36 is stopped perpendicular to the paper path direction 46. This alignment is a result of the first skew correction process.
When the mailpiece 36 has decelerated and stopped, the drive roller 56, under control of motor 52, and the drive roller 58, under control of motor 54, rotate in opposite directions and rotate the mailpiece 36 approximately 90 degrees, to change the orientation of the mailpiece 36 with respect to the path of travel. The mailpiece orientation is changed from a landscape orientation, as shown in
The thickness of the mailpiece may affect the amount of skew that remains after the 90 degree mailpiece rotation. As mailpieces get thicker, the amount of physical rotation from the same motion profile may be less than 90 degrees due to a higher degree of slippage in the nips with heavy, puffy mailpieces. Thus, thicker mail tends to have an actual rotation less than the desired 90-degree rotation. Accordingly, varying degrees of skew may be reintroduced during the 90-degree rotation. The amount of skew introduced by the rotation process may vary based on the implementation of the mechanism rotating the mailpiece, such as the speed of rotation, the material of the rollers, the material of the mailpiece deck supporting the mailpiece, and also based on the nature of the mailpiece, such as the material, the dimensions (i.e., size and thickness), and the puffiness (e.g., compressibility) of the mailpiece, and other factors. The specific motion profile of each of the drive rollers 56 and 58 under control of their respective drive motors, which are in opposite directions to effectuate the rotation, may also be a factor in any introduced skew. To compensate for this skew introduced by the rotational process, an additional, second skew correction process can be enabled after the rotation of the mailpiece 36.
When the rotation process is completed, the mailpiece 36 is accelerated from rest in the paper path direction 46 and passes photocells 70 and 72. The photocells detect misalignment of the mailpiece 36 in the paper path direction 46 and provide this information to the control motors 52 and 54 via connections 70a and 72a connected to the motor control system 55, as shown in
During the acceleration, eventually the leading edge 74 of the portrait-oriented mailpiece will block one of the photocells 70, 72 followed by the other photocell, with the duration between the two events depending on the severity of the mailpiece skew generated during the rotation move. The control motors 52 and 54 provide motion control for the drive rollers 56, 58 to de-skew the mailpiece 36 before the leading edge 74 of the portrait-oriented mailpiece reaches the nips of the skew correction module 24 exit rollers. This is accomplished by measuring the displacement difference between the photocell 70 and 72 events, specifically, the detection by each photocell of the leading edge 74 of the portrait-oriented mailpiece. The skew correction module exit rollers comprise a drive roller 76, and an associated spring loaded idler roller 76a, and a drive roller 78, and an associated spring loaded idler roller (not shown). The exit drive rollers 76 are driven by a motor 80. The drive rollers 48, 50, 76, and 78 are each rotated at a constant speed. The drive motor 80, which directly drives the exit drive roller 76, can also be employed to drive the other drive rollers 48, 50, and 78, such as by means of a drive belt arrangement (not shown) mounted below the deck 44.
Once the leading edge 74 has blocked the second photocell, the motors 52, 54 independently accelerate at different rates to deliver the leading edge 74 of the portrait-oriented mailpiece to a fixed distance downstream of the respective photocells 70, 72 at precisely the same time and velocity before reaching the exit roller nips. This differential motion control of the mailpiece 36 results in correction of any skew, and positions the top 60 of the mailpiece 36 at the distance d from the center of rotation, as shown in
During the second skew correction process, one of the motors 52 and 54 drives its driven drive roller at a first rate of speed and the second motor will drive its driven drive roller at a greater speed or lesser speed to correct for the remaining skew. However, many different drive arrangements may be implemented, with both drive rollers have varying and different motion profiles for the mailpiece skew correction provided by the first and the second skew correction process. When the mailpiece is captured by the driven rollers 76 and 78 and associated spring loaded idler rollers to exit the skew correction module 24, skew has been essentially eliminated within the tolerances established for the system and the mailpiece 36 is thereafter presented in aligned and proper orientation for further processing by subsequent modules.
The distance d shown in
Reference is now made to
Reference is now made to
As described above, the skew correction module 24 can have mailpieces presented to the module from upstream module that are substantially skewed. When this occurs, if the first skew correction process is not employed, and the rotate module provides a rotation angle that is exactly 90 degrees, the mailpiece will exit the module with the same amount of skew as when the mailpiece was presented to the skew correction module 24. Also, since as mailpieces get thicker, the amount of physical rotation becomes less than 90 degrees, the original skew may be increased or decreased, and will generally leave the skew correction module 24 skewed unless the nature of the original skew is exactly offset by the skew introduced by the rotational process. Thus, both sources of skew can, for example, result in indicia and address printing that will not be properly aligned with the mailpiece and will also result in an increased frequency of paper jams in downstream modules.
However, when the first mailpiece skew correction process is applied before the mailpiece has come to the stopped position and before the mailpiece is rotated 90 degrees, the original skew of the mailpiece is corrected. At this time, the landscape-oriented mailpiece lead edge has moved a predetermined distance to the stopping point and rotation is applied to the mailpiece. As the portrait-oriented mailpiece is accelerated from the rotated, stopped position toward the skew correction module exit, the second mailpiece skew correction process is applied and any skew introduced by the rotational process is corrected.
Moreover, should the first skew correction process not fully eliminate the original skew, the second skew correction process can eliminate and correct any remaining original skew and any skew introduced from the rotation process. With the two drive rollers 56, 58 and the associated idler rollers 56a, 58a under control of the control motors 52, 54, two skew correction processes are implemented and the mailpiece orientation is changed for subsequent processing. By aligning the mailpiece, whether in the first or the second orientation, with respect to the path of travel, any skew of the mailpiece is corrected. When the mailpiece skew has been corrected, the mailpiece is aligned with respect to the path of travel.
In many instances the second skew correction process may not be needed and can be disabled or omitted from the skew correction module. For example, in those instances where mailpiece orientation rotation is employed and the amount of skew, if any, introduced by the rotation process is within acceptable limits, any such skew can remain uncorrected without adversely impacting subsequent operations. Also, where the mailpiece exits the skew correction module in landscape orientation, the second skew correction process is not required and can be omitted or implemented at a subsequent point in the process if the mailpiece is rotated from a landscape to a portrait orientation. In such case, another set of motor controlled drive rollers may be employed.
The present system may provide flexibility in the control of the mailpiece. The system can employ one or two skew correction processes. The system can handle mixed mail having various thicknesses and can skew correct mailpieces after the mailpiece orientation has been completed. Moreover, the system can be configured to bypass normal size mail in the mail stream by moving the mailpiece through the skew correction module without processing such mail or implement only a first skew correction process, if desired.
It will be apparent to those skilled in the art that various modifications and variations can be made to the structure and methodology described herein. Thus, it should be understood that the invention is not limited to the examples discussed in the specification. Rather, the present invention is intended to cover modifications and variations.
