Patent Application
20070132178
The present invention relates to apparatus for conveying stacked sheets of material, and more particularly, to an apparatus for aligning the peripheral edges of a multi-sheet stack while being conveyed on a transport deck such as those employed at used in high volume mail piece inserter systems.
Various apparatus are employed for arranging sheet material in a package suitable for use or sale in commerce. One such apparatus, useful for describing the teachings of the present invention, is a mail piece inserter system employed in the fabrication of high volume mail communications, e.g., mass mailings. Such mailpiece inserter systems 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 mail inserters for producing mass mailings where the contents of each mail piece are substantially identical with respect to each addressee. Examples of inserter systems are the 8 series, 9 series, and APS™ inserter systems available from Pitney Bowes Inc. located in Stamford, Conn., USA.
In many respects, a typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (i.e., a web of paper stock, enclosures, and envelopes) enter the inserter system as inputs. Various modules or workstations in the inserter system work cooperatively to process the sheets until a finished mail piece is produced. The precise configuration of each inserter system depends upon the needs of each customer or installation.
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 sheet may continue to a chassis module where additional sheets or inserts may be added to a targeted audience of mail piece recipients. From the chassis module the fully developed collation may continue to a stitcher module where the sheet material may be stitched, stapled or otherwise bound. Subsequently, the bound collation is typically folded and placed into envelopes. Once filled, the envelopes are conveyed to yet other stations for further processing. That is, the envelopes may be closed, sealed, weighed, sorted and stacked. Additionally, the inserter may include a postage meter for applying postage indicia based upon the weight and/or size of the mail piece.
The mail piece collation may comprise several individualized documents, i.e., specific to a mail piece addressee, and/or one or more preprinted inserts which may be specifically tailored to the addressee. Generally, a barcode system is employed to command various sheet feeding mechanisms (i.e., one of the components of the chassis module mentioned in the preceding paragraph) to feed/add a particular insert to a collation. Of course, the mail piece collation may comprise any combination of sheet material whether they include personalized documents, preprinted inserts or a combination thereof.
a-1c show the relevant components of a prior art chassis module/station 100 of an inserter system. The figures show the chassis module 100 conveying a sheet material 112 along a transport deck 114 (omitted from
Referring to
Above the transport deck 114 are one or more feeder mechanisms 120A, 120B (two are shown for illustration purposes) which are capable of feeding inserts 122, i.e., sheet material, to the transport deck 114. The inserts 122 may be laid to build a collation 112 or may be added to the sheet material 112 (i.e., a partial collation) initiated upstream of the transport deck 114. A controller (not shown) issues command signals to the feeder mechanisms 120A. 120B to appropriately time the feed sequence such that the inserts 122 are laid in the rectangular region 124 between the fingers 116F1, 116F2. More specifically, as each pair of lateral fingers 116F1, 116F2 is driven within the grooves or slots 144G, one edge of the sheet material 112 is engaged to slide the collation 112 along the transport deck 114. As the sheet material 112 passes below the feeding mechanisms 120A, 120B, other sheets or inserts 122 are added. At the end of the transport deck 114, the fingers 116F1, 116F2 drop beneath the transport deck 114 such that the collation (i.e., the combination of the sheet material and inserts 122) may proceed to subsequent processing stations.
While the drive mechanism 116 of the prior art provides rapid transport of collated sheet material 112, 122 and has proven to be effective and reliable, sheets or inserts 122 fed by the feeding mechanisms 120A, 120B can become misaligned in the rectangular space or pocket 124 provided between the fingers 116F1, 116F2. That is, inasmuch as the pocket 124 is oversized to accept the sheets or inserts 122, the inserts 122 can become misaligned due to a lack of positive registration surfaces on all sides of the collation 112, 122.
Various mechanisms are employed to vary the pocket size, i.e., sometimes referred to as the “pitch”, between the chassis fingers. The ability to change pitch not only enables greater efficiency, i.e., a greater number of pockets for inserts, but also minimizes the misalignment of inserts being laid on a collation. Notwithstanding the ability to minimize pocket size, it will be appreciated that without positive restraint on all free edges of the collation, individual sheets or inserts will be misaligned. Consequently, prior art inserters commonly employ complex registration mechanisms or jogging devices to align the free edges of a collation. For example, inserters may employ a series of swing arms which pivot onto the transport deck, i.e., into the conveyance path of the collation. The swing arms engage and align the leading edge of a collation, i.e., the edge opposite the fingers. While the swing arms effectively maintain alignment of the collation, the mechanical complexity associated with the pivoting mechanism is a regular source of maintenance, jamming or failure.
In the absence of such swing arms, an inserter may employ other jogging mechanisms downstream of the chassis module to align the edges of the collation. That is, before subsequent processing, e.g., stitching or enveloping, the edges of the collation are aligned to: (i) ensure that stitching does not result in permanent misalignment of the collation or (ii) provide a smooth transition and/or snug fit within a mailing envelope. Such jogging mechanisms often employ a complex arrangement of solenoid activated stops which tap or “jog” each edge by a predetermined displacement with each motion of the stop. By jogging the stops several times, the edges of the collation are aligned. Like the swing arm mechanisms described above, the jogging mechanisms are highly complex and prone to increased maintenance, jamming and failure.
A need, therefore, exists for a transport and alignment system which eliminates mechanical complexity, enhances reliability and minimizes maintenance.
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 aligns 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.
Further details of the present invention are provided in the accompanying drawings, detailed description, and claims.
a is a perspective view of a prior art chassis drive mechanism employed in a mail piece inserter system.
b is a profile view of the prior art chassis drive mechanism shown in
c is a broken-away isometric view of the prior art chassis drive mechanism of
a is an enlarged view of the conveyor and registration chains shown in
a is a profile view of the jogger disc shown in
a is a schematic top view of the transport and alignment system according to the present invention used in conjunction with a plurality of insert feeders of a mailpiece inserter system.
b is a schematic top view of the transport and alignment system wherein the transport and registration fingers are positioned out-of-phase to produce multiple pockets.
The invention will be described in the context of a mail piece inserter for processing mail communications and, more specifically, in the context of two modules thereof, i.e., a stitcher module and a chassis module. While the invention may be particularly useful for processing/producing mail communications, it should be appreciated that the transport and alignment system of the present invention is broadly applicable to any apparatus/system which requires the transport and alignment of stacked sheets of material.
In
Interposing the supports 22a, 22b, 22c, are two (2) pairs of drive belts or chains 26A, 26B, each pair including a conveyor drive chain 26C and a registration chain 26R. In the context used herein, the terms “chain” and “belt” are used interchangeably in the specification and appended claims to mean any flexible chord, fiber matrix, cable, rope, or connecting links which may be frictionally or positively driven under tension by/over a drive mechanism. The conveyor and registrations chains 26C, 26R are driven by a mechanism including drive and idler wheels or sprockets 28D, 28I which are rotationally mounted to the support frame of the stitcher 10. In the context used herein the terms “sprockets” or “wheels” are used interchangeably to mean any circular or cylindrical element or member capable of engaging, i.e., driving or supporting, a chain or belt.
To more clearly view the chains 26C, 26R and sprockets 28D, 281,
In the illustrated embodiment, the drive sprocket 28DC of the conveyor drive chain 26C shares a common rotational axis 28A with an idler sprocket 28IR of the registration chain 26R and visa-versa. Furthermore, the drive sprocket 28DC of the conveyor drive chain 26C is disposed at one comer of the polygon-shaped chains 26C, 26R while the drive sprocket 28DR of the registration chain 26R is disposed at another comer. By sharing axes 28A, the requirement for multiple support shafts is eliminated, thereby reducing mechanical complexity.
The drive mechanism 30 includes a pair of drive motors 30C, 30R and a controller 34. The drive motors 30C, 30R are mounted to the support frame (not shown) of the stitcher 10 and drive the conveyor and registration chains 26C, 26R. More specifically, a first drive motor 30C is rotationally coupled to each of the conveyor drive sprockets 28DC and a second drive motor 30R is rotationally coupled to each of the registration drive sprockets 28DR. Each of the drive motors 30C, 30R may be independently driven, e.g., driven at different rotational speeds, to drive the conveyor and registration chains 26C, 26R at different operational speeds. The import of such speed variation will become apparent when discussing the operation of the inventive transport and alignment system 20.
The conveyor drive and registration chains 26C, 26R each include a plurality of fingers 26F extending orthogonally from the respective chain i.e., from the direction of motion. From another frame of reference, the fingers 26F project through and are perpendicular to the plane of the support deck 24. Each conveyor drive chain 26C includes a plurality of transport fingers 26FT, equally-spaced along its length, while each registration chain 26R similarly includes a plurality of equally-spaced registration fingers 26FR. The transport and registration fingers 26FT, 26FR are staggered, i.e., not aligned, to define a space or pocket therebetween, which, as will be more fully understood when discussing the system operation, will be determined based upon the size of the collated or stacked sheet material 12.
Inasmuch as the described embodiment of the transport and alignment system 20 employs two pairs of chains 26A, 26B, the pocket between the transport and registration fingers 26FT, 26FR may be viewed as defining a four-sided rectangle or polygon. More specifically, the transport fingers 26FT of the conveyor drive chains 26C are laterally aligned, i.e., across the support deck 24, to define one side of the polygon. The registration fingers 26FR of the registration chains 26R are laterally aligned to define an opposing side of the polygon. Finally, the adjacent sides of the polygon are defined by registration walls (not shown) which are parallel to, and outboard of, the chains 26A, 26b.
In operation, a controller 34 issues command signals to the drive motors 30C, 30R to position and regulate the speed of the conveyor drive and registration chains 26C, 26R. Initially, the conveyor drive and registration chains 26C, 26R are positioned such that the spacing between the transport and registration fingers 26FT, 26FR is substantially equal to a corresponding dimension of the collated or stacked sheet material 12. The collated or stacked sheet material 12 is placed into the rectangular pocket PK defined by the fingers 26FT, 26FR of the chains 26A, 26B by sliding the sheet material 12 over ramped surfaces 22RS of the longitudinal supports 22a, 22b, 22c. After the sheet material 12 is deposited, the fingers 26FT, 26FR are positioned by independently controlling the drive motors 30C, 30R to jog and align the opposed edges of the sheet material 12. This first operating mode or step is performed by the controller 34 which commands at least one controlled displacement of either the conveyor drive or registrations chains 26C or 26R i.e., relative displacement of the chains 26C, 26R, to move the fingers 26FT, 26FR closer together. In the preferred embodiment, the controller 34 commands at least one controlled displacement of the conveyor drive chain 26C to move the transport fingers 26FT toward the registration fingers 26FR.
Depending upon the thickness or number of sheets in the collation 12, several oscillations of the fingers 26FT, 26FR may be commanded, drawing the fingers of each pair 26FT, 26FR closer with each oscillation. For example, the transport and registration fingers 26FT, 26FR may be displaced in progressively smaller increments. Initially, the fingers 26FT, 26FR may be displaced a first incremental length e.g., one quarter (¼″) inches, while subsequent motions may be commanded which are one half of the prior length, e.g., one eighth (⅛″) inches, one sixteenth ( 1/16″) inches and so on.
In
One noteworthy advantage of the jogging discs 321, 322 relates to the orientation of its rotational axis 32A. That is, inasmuch as the rotational axis 32A is orthogonal and proximal to the conveyor or registration chains 26C, 26R, a simple right angle chain drive (not shown) can be employed to take-off and drive power to the shaft 32S of the discs 321, 322 . Additionally, to adjust the lateral position of the discs 321, 322 (and, consequently, the lateral dimension of the rectangular pocket PK), a simple set-screw (not shown) can be used to position the discs 321, 322 along the rotational axis 32A.
Referring again to
Another embodiment of the transport and alignment system 20 is shown in
Inasmuch as the mechanical components of the drive mechanism, i.e., drive/idler sprockets and drive motor arrangement, can be the same or substantially similar to that previously described, no further/independent discussion of the drive mechanism is necessary with respect its adaptation to the chassis module 40. The principle difference between the two embodiments relates to the control of the drive mechanism and/or control of the conveyor and registration belts 46C, 46R rather than to specific structural differences therebetween.
In operation, sheet material 12 passes beneath several feed mechanisms (not shown) and is disposed between fingers 46FT, 46FR of the conveyor and registration belts 46C, 46R. To transport the sheet material 12, the conveyor and registration belts 46C, 46R move concurrently, i.e., together at the same speed, however, other control motions are superimposed to vary the spacing of the rectangular pocket PK between the fingers 46FT, 46FR. More specifically, a controller 56 drives motors 58DR, 58DC (shown schematically) of the conveyor and registration belts 46C, 46R so as to oscillate the transport and registration fingers 46FT, 46FR. That is, in addition to conveying the collation 12C along a feed direction FD, the controller 56 issues commands to the drive motors 58DR, 58DC to cause the fingers 46FT, 46FR oscillate back and forth in the direction of arrow OS. As such, the fingers 46FT, 46FR move relative to each other to vary the longitudinal spacing or pocket size of the chassis module 40. For example, to facilitate deposition of sheets or inserts 12IS (shown as dashed lines) by one of the feed mechanisms, the controller 56 may increase the speed of the registration belt 46R to open or increase the spacing of the pocket PK. As such, the increased pocket size provides an unobstructed area for laying sheets or inserts onto the collation 12C.
Before passing beneath another of the feed mechanisms, the controller 56 may increase the speed of the conveyor belt 46C relative to the registration belt 46R, or alternatively, decrease the speed of the registration belt 46R relative to the conveyor belt 46C, to close or decrease the spacing of the pocket PK. By reducing the pocket size, the fingers 46FT, 46FR jog the leading and trailing edges 12EL, 12ET to align the sheets of the collation 12C. This cycle may repeat for as many feed mechanisms as the chassis module 40 contains. Alternatively, the pocket spacing may remain one dimension, e.g., oversized, relative to the corresponding dimension of the collation 12C until all additional sheets or inserts 12IS are deposited by the feed mechanisms. After depositing all of the sheets or inserts 12IS, the relative spacing between the fingers 46FT, 46FR may close to jog and align the leading and trailing edges 12EL, 12ET of all collations 12C on the transport deck. In this embodiment, registration walls 58 may be disposed along each side of the transport deck 44 to guide and align the side edges 12SE of the collation 12C.
While accurate control and alignment of the sheet material 12 is generally desirable for any material handling operation, the independent control of the conveyor and registration belts enables the chassis module 40 to be operated in different modes. Without distinguishing the function of the belts 46C, 46R as being one used for transport or registration, the relative position of the belts 46C, 46R may be phased to produce additional pockets to handle additional collations 12C. As such, increased efficiency may be achieved. For example, by positioning the fingers 46FR of a first pair of belts, e.g., the innermost belts 46R, midway between the fingers 46FT-A, 46FT-B of a second pair of belts, e.g., the outermost belts 46C, two (2) pockets PK-1, PK-2 may be created in place of a single pocket. That is, in one operational mode, a large pocket PK may be required to handle sheet material of a first dimension whereas, in a second operational mode, a smaller pockets PK-1, PK-2, e.g., ½ the size of the first, may be used to handle or accept sheet material of a second dimension. Consequently, by shifting or phasing the relative position of the fingers, a greater or smaller number of pockets may be produced. In this embodiment, the fingers dually function to convey and align the sheet material, albeit the requirement for jogging or oscillatory motion may no longer be necessary or desired.
In summary, the transport and alignment system 20 of the present invention provides controlled displacement of the conveyor and registration chains/belts to transport sheet material while additionally or concurrently aligning the edges thereof. Further, the transport and alignment system minimizes the number of moving parts and/or the need for independent mechanisms, e.g., prior art swing arms, solenoid activated stops, or dedicated jogging stations, to align the edges of a sheet material. The invention provides additional functionality by uniquely controlling common components, i.e., chains/belts typically employed in transport mechanisms. Consequently, the invention may be implemented and practiced with relatively minor structural modification to pre-existing transport mechanisms and/or equipment.
Additionally, the transport and alignment system 20 of the present invention facilitates the initial set-up and dimension requirements for the sheet material pocket. Simple control inputs can be made by the controllers 36, 56 to establish the initial dimensions of the pocket. More specifically, the controllers 36, 56 may be programmed, through software inputs, to establish or change the relative spacing between the transport and registration fingers. In contrast, the prior art transport and alignment systems typically rely upon laborious/painstaking adjustments of various components e.g., the pusher fingers and stop mechanisms to establish or vary the pocket size. Each time that sheet material of different dimensions is processed, an operator is required to manually set or move the position of pusher fingers, swing arms and stops. The present invention, on the other hand, eliminates these labor requirements by programming/software modifications.
Along the same lines discussed in the preceding paragraph, the transport and alignment system facilitates multiple operating modes. That is, by varying the relative position of the fingers, multiple pockets for accepting sheet material may be created. Finally, the transport and alignment system provides for nearly infinite adjustment of the pocket size. Whereas, in the prior art, finite or incremental adjustment of the pocket size is made possible through manual adjustment, the present invention enables fine differential adjustments of the position and/or speed of the belts for virtually infinite adjustment of the pocket size. Furthermore, such adjustments can be made through software algorithms/programming logic run and controlled by the motor controllers.
While the transport and alignment system has been described in the context of a stitcher and chassis module of a mailpiece inserter system, it will be appreciated that the transport and alignment system is applicable to any sheet material handling system. Furthermore, while two pairs of conveyor drive and registrations chains/belts are shown, a single pair of chains/belts may be employed depending upon the alignment capability of the transport and registration fingers. Conversely, a greater number of paired chains/belts may be employed if, for example, larger size sheet material is handled. Furthermore, while the transport and registrations fingers are shown to be equally-spaced along each chain or belt, the spacing between each finger may vary depending upon the spacing of the feeding mechanisms and/or the timing established for laying sheet material. Moreover, while a rectangular shaped chain/belt configuration is shown, the configuration may have any shape provided that a portion of the chain/belt is substantially parallel to the support deck. Hence, an elliptical, triangular, trapezoidal or other polygon shape may be employed.
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.
