GB2201403A - Buffering feeding system for envelope inserting machine - Google Patents

Description

- t - 0 01 r) e-. -7 .1-0 1403 BUFFERING FEEDING SYSTEM This invention

relates to a system for feeding enclosures in an envelope inserting machine.

In document handling devices where large volume-s of documents are processed at high speeds, various transport efficiency problems have been encountered. Generally, these document handling systems comprise sheet feeding mechanisms' integral with sheet transport mechanisms. Obviously, the sheet feeding is usually at a varied speed while the transport mechanism is usually operated at a uniform or a constant high speed. There is thus a time lapse or time loss during the interim or varied feeding while the sheet transport continues to move at a constant speed. There have been various attempts to solve this speed difference between transport means and feeder means so that the most efficient sheet handling means are provided. Generally in envelope inserting machines, a wide range of sizes of sheets, documents, tabulating cards or other enclosure material are processed and inserted into envelopes which are registered and appropriately positioned on the output end of the machine. Inserting machines generally have a frame for supporting the plurality of feeders in an aligned row. Each feeder,is programmed to deliver one or more documents by a predetermined method which utilizes a signaling device such as a printed code on a master enclosure document. In this way, the-'feeders deliver sequential enclosures to a -cyclic conveyor which in turn pushes the individual or staced enclosures along a path leading to an appropriate' waiting envelope located downstream at an insetting station. It is along this conveying path that the enclosures are pushed where document jams and lateral misguiding of the.enclosures 1 frequently occurs which in turn results in decreased effectiveness of the throughput capability of the inserting machine due to machine down time and increased operator maintenance. The guiding and feeding devices presently used for lateral positioning and guiding of the enclosure documents provide undesirable gaps, openings and seams for causing those documents to become jammed at their leading end corners or lateral edges.

Therefore, there is a present need for a system that provides constant or near constant feeding to the inserter in spite of the varied speeds of these two mechanisms.,. thus providing a more efficient and time expedient device for use in a document conveying apparatus.

In U.S. Patent 4,034,973; 4,273,319 and 4,502-,676 a "two up" in line system is suggested where documents are conveyed in two rolls and these two rolls or channels feed to a inserter. In this manner, the two channels can be programmed at different speeds toprovide a somewhat efficient system. In 4,034,973 an automated in-line mailing system is described having a continuous two channel sheet web wherein the sheets travel along two separate channels through the register, folder and collector to the inserter. In 4,273,319 an automated "two up" in line mailing system is disclosed which comprises two collectors positioned at discharge ends of separate channels of the folder. One collector accumulates the sheets from both the folder and the other collector in sequential order in piles for subsequent discharge. In 4,502,676 a "two up" system is suggested wherein documents are conveyed in a shingled two up fashion between low speed input rollers and the high speed rollers. Documents are then delivered to a two stage collector assembly where documents having like indicia are passed through the first collector assembly then to a second collector assembly. Thus documents whose indiciaindicate that they do not belong to a preceding group of documents are retained in an upper collector stage until documents belonging to a preceding group of documents have been dumped on an insert track.

1 i1 -Y In each of these prior art systems, separate controls, indexing and registration are required which tend to slow down rather than speed up the output of the systems. Also the mechanisms tend to be relatively complex and seem to be difficult to prevent or minimize jamming of documents.

In U.S. Patent 4,541,,764 it was recognized that it would be desirable to have a document stacking and conveying apparatus which utilize various stacks of documents to later combine into a single stack for inserting into envelopes. The device utilized to accomplish this is directed to a conveying apparatus in which there are a number of stacking and conveying devices which are arranged in parallel relationship to each other. Another document stacking and conveying device is disposed in perpendicular relationship to the pair of document stacking and conveying devices adjacent to one end of the pair of document stacking and conveying devices for receiving the stacks of documents therefrom and for stacking the stacks one on top of another. This mechanism contains a plurality of document stacking and conveying units which are perpendicularly disposed at one end of a third elongated stacking and conveying apparatus. This third unit has a conveyor for moving a stack of documents while a compressing device holds another stack which is stationery upon the conveyor deck of the third unit so that the moving stack of documents can be added to the downstream stack. It is required in -this prior art system that each feeding station have documents which are properly indexed for the system to operate effectively. The plurality of holding gates are located in parallel but all are outside of the paper transport path, each located perpendicular to the paper conveying belts or paths. Each gate is in substantial alignment with the others and are all loca.ted along.the same axis of the conveyor belt or transport means. If the documents are not in line o r not indexed properly, the entire system must be stopped to index and align the documents along the transport paper path.

-. 4 - b- There is a need in the document handling art for a system containing a plurality of independently controlled means for holding registered document enclosures that are positioned in the proper path and need no further indexing or alignment.

According to one aspect of this invention there is provided an envelope inserting machine, comprising:

a document supply means for feeding documents along a predetermined feed path; a collecting station situated downstream from said document supply means; an elongated transport means for conveying said documents from said supply means to said colle6tion station; a folding station adapted to receive, fold, and release documents passing therethrough; a plurality of document holding gates adapted to receive documents from said folding station and release said documents; and inserting means for inserting each of said documents into an envelope, said document holding, gates being positioned in series sequentially along the normal document transport path Of said inserting machine, and each gate being operatively capable of releasing documents to its next adjacent downstream gate and ultimately to said inserting means, thereby providing substantially uninterrupted feeding of documents to said inserting means at a rate approaching the output processing speed of said inserting means.

According to another aspect of this invention there is provided 2 system for inserting documents in envelopes and other containers which comprises in combination:

(a) a source of documents; (b) an accumulating station for receiving and accumulating a plurality of said documents; (c) an endless conveyor transport means for receiving and transporting said documents through said system; (d) a folding means for folding said documents in preparation for insertion into said envelopes; (e) a plurality of holding gates for receiving and releasing the resulting folded documents; and 1:

(f) an inserting station wherein each of said folded 1 i documents is inserted into an envelope; said holding gates being located in the normal paper pathof said documents and each being located on substantially the same axis along saic transport means and each in substantial alignment with each other, each gate comprising a control means, a sensing means and at least two L- shaped fingers and means to raise and lower said fingers.

The embodiment of this invention described hereafter provides a document stacking and conveying apparatus devoid of the above noted disadvantages., which has a plurality of pacer receiving stations in the paper path for release and final processing. The embodiment also provides an efficient and laterally rapid system for use in an inserting machine apparatus wherein the document processing is relatively uninterrupted,aid which provides relatively uncompiicated method for stacking documents in plurality of stations which are located along a common paper path. The embodiment further iDrovides an inserting machine having a transport means containing two or more independently controlled devices for holding. . registered documents until released for final processing.

The described embodiment provides a document inserting and conveying apparatus comprising a pluralil-y-of holding stations in series in the direct paper path of the elongated conveying apparatus. When themost adjacent to inserting means_gate or station is emptied, the next adjacent station or gate releases documents to the adjacent gate. Thus, there is always a short distance from the inserting mechanism or other final processing means a ready supply of registered documents ready for insertion. Immediately after the closest document gate is emptied, a fresh supply of d ocument enclosures ate passed from the second gate to the closest E) gate for processing to the inserter. Obviously, as many ready gates may be used depending upon the space available and the speed required in the system. It is required, however, that the gates all be in the paper path and not at a location requiting document indexing or alignment. The entire system would include a document enclosure source from w, hich-the- documents pass.,_via a first conveyor apparatus to a document accumulator or collection station. A system of "0" ring conveying belts causes the enclosures to pile up against a cyclicable roller until a signal is given to feed the documents further up the line. While "0" ring conveying belts are -described in reference to the embodiment, it is possible to utilize a flat belt, as long as the belt material is elastic or there is provided an adequate belt tensioning system well--known in the art. Once. the signal is given, the documents pass to folding apparatus where the appropriate fold is made in the documents. As the documents pass through the folding apparatus, they pass onto a second conveyor apparatus having at least two collecting gates all located in series in the document or paper path of the system along the same axis on the conveyor belt These gates receive the documents as they exit the rollers after the folding station. A predetermined order of feeding is controlled by known appropriate means and the order of feeding is read from indicia on an address bearing document located at or in the source of the documents. Also, an appropriate count-of enclosures associated with a group of enclosures will enable a first folded group of documents to be released by the gate closest the inserter. The term n downstream" as-used throughout this disclosure and claims will indicate a location closer to the final processing or inserting step. Likewise, the term "upstream" indicates aposition of the gate or station farther from the final inserting step. This release can be accomplished by any suitable actuating means. Once the closest gate has been emptied of documents, the next closest gate releases its documents to the closest gate and from there advances to the inserter. As eacli gate is emptied, actuating means are

1 pr f) signalled to refill each gate emptied. Upon emptying of the gate closest the inserting means a ready supply of new enclosures is available at substantially the closest available location on 1 ine in the system. No perpendicular feeding means or alignment means are necessary since the documents have already been indexed in the waiting gate. Thus, the lineal distance of the waiting gates from the inserter is in the shortest possible path. There is a significant time advantage in holding the document enclosures in the manner described when the lineal distances of the paper path is considered in view of the potential operating speed of the inserter. The variation therefore of the intermittent speed of the source feeder and the substantially constant speed of the inserter are brought more in phase by the arrangement of the system of waiting gates above described. Typical inserting machines useful in the invention are disclosed in U.S. Patents 4,497,040 issued January 29, 1985; 4,517,650 issued May 14, 1985; 4,525,788 issued June 25, 1985 and 4,527,791 issued July 9, 1985.It is in these general systems that the presently described plurality gate system can be used.

Each gate comprises reversed L-shaped fingers that hold all documents in position when the fingers are up. Upon a signal from the appropriate logic circuitry, a solenoid causes the fingers to be lowered thus perm- itting the documents to be projected forward by endless "0" ring belts. Each finger is movably connected at its lower terminal portion to a shaft which is operated by the solenoid. Upon the appropriate signal, the finger is raised or lowered depending on the circuit's request for filling or emptying of the gate. The occupation of each gate is sensed by photocells positioned adjacent thereto.

- 9 i i'I 1 The invention will now be described by way ot non-limiting example, reference being made to the accompanying drawings, in which: Figure 1 represents a longitudinal sectional view of an example of inserting system according to the invention; Figure 2 is an expanded side view of the conveying apparatus and folding means of the system of Figure 1; Figure 3 is an expanded top view of the conveying apparatus and gates of the system of Figure 1; Figure 4 is an expanded front view of the gate containing apparatus of- the system of Figure 1; Figure 5 is an expanded view side view of the gate mechanism of the system of Figure 1; and Figure 6 is a circuit diagram illustrating the circuitry of the system of Figure 1.

In Figure 1, a section of an inserter 1 is illustrated. Shown at 2 is a typical feeder means for feeding sheets, enclosurest or other insert material. The material fed from sheet burster or feeder 2 is sequentially fed to a horizontally disposed elongated feed deck 3 to an, endless. conveyor means 4 made up of "0" ring endless belts which receive the insert material and advan ces it from the feeder to the remainder of the system. The sheet feeding mechanism can be any suitable apparatus including a bursting 1 1.

apparatus of the type disclosed in U.S. Patent 4,261,497. The insert material generally passes through rollers or feed wheels 5 to conveyor means 4. The feed rollers 5 are driven constantly by a main drive member activated by a typical state of the art-electroma'netic clutch which is engaged to 9 a main drive member such as an electric motor 17 of inserter apparatus 1. A typical device of this nature is disclosed in U.S. Patent 4,501,417 and U.S. Patent 4,640,506 - - which is incorporated by reference hereby. From conveyor means 4 the insert material is transported to an accumulating station 6. A system of 110"-ring conveying belts 7 and 8 causes the enclosure or insert material. to pile- up against cyclicable rollers 6 until a signal is given to feed further downstream. Roller 6 also is operatively connected to an appropriate clutch means which also-is engaged with an appropriate drive member or motor 18. once the signal is given by a suitable controller, the insert material is advanced to a folding apparatus 10 (of the type described in U.S. Patent-3,193,983 issued July 13, 1965) which receives the accumulated enclosures and causes-an appropriate fold therein. A second conveyor apparatus 11 driven by motor 19 has positioned thereon a first gate 12 which is nearest the end of the system and a second gate 13 for receiving the enclosures or insertmaterial as they exit from the exit rollers 14 of the folding apparatus 10. A predetermined order of feeding is read from indicia on an address bearing document within feed source 2, and an appropriate_countof enclosures associated with a group-,Pf enclosures will enable a first folded group of documents 15 to be released by the gate 12 upon demand signal from main. inserter. The enclosures l6vaiting at the gate 13 are then released upon photocell 1 22 signal from main inserter. The enclosures 16 waiting at gate 13 are then released upon photocell 22 signal to the electronic system that gate 12 has been emptied. Gate 13 is then refilled with the next folded collation by activation of rollers 6 upon uncovering of photocell 21. Photocells 23 sense when the predetermined - to - number of documents have passed on to gate 12. The enclosures 15 meanwhile go forward downstream to be processed by the conveying apparatus 1 of the inserting apparatus 20 and are gathered along with any other pertinent enclosures or insert material. In Figure 2 an expanded side view of the conveying means 11 is shown beginning with folding means 10. As the documents exit from means 10 they are transported by "0" ring conveying belts 24 and 25 to holding gate 13. Holding gate 13 comprises address bearing document within feed source 2, and an appropriate count of enclosures associated with a group of enclosures will enabl a first folded group of documents 15 to be released by the gate 12 upon demand signal from-main inserter. The enclosures 16-waiting at the gate 13 are then released upon photocell 22 signal to the electronic system that gate 12 has been emptied. Gate 13 is then refilled with the next folded collation by activation of rollers 6 upon uncovering of photocell 21. Photocells 23 sense when the predetermined number of documents have passed on to gate 12. The enclosures 15 meanwhile go forward downstream to be processed by the conveying apparatus 1 of the inserting apparatus 20 and are gathered along with any other pertinent enclosures or insert material. In Figure 2 an expanded side view of the conveying means 11 is shown beginning with folding means 10. As the documents exit from means 10 they are transported by "0" ring conveying belts 24 and 25 to holding gate 13. Holding gate 13 comprises preferably two fingers or L-shaped stops 26 which house and prevent the paper or documents from traveling further downstream. Positioned above and below gate 13 are photocell components 21 which sense when the documents are in or out of gate 13. When the documents are to be released from holding gate 13 signal is generated to solenoid.34 which causes finger 26 (or 27 in the case of gate 12) to depress and permit the paper or documents to proceed to ready gate 12. Figure 5 illustrates the finger 26 of holding gate in both the hold and depressed states. Photocell 23 senses when all of the documents in gate 13 have passed to gate 12, then signals e 11 ? 1 - k j additional documents upstream to travel'to gate 13 to refill the gate. As gate 12 is emptied photocell units 21,-22 and 23, all of which are connected along a common circuit, insure that gates 13 and 12 are filled as soon as possible after emptying.- Finger 27 of gate 12 is of the same, construction as finger 26 and operates also as shown in Figure 5. Gates 12 and 13 are located apart from but adjacent to "0" ring endless belts 24 and 25 as shown in Figure 3. Rollers 28, 29 30 and 31 provide means for endless belts 24 and 25 to be held in position for proper transport of the documents through the system. There is thus a plurality of suitable elastic conveyor belts 24 and 25 which-are suspended over suitable pulley or rollers 28, 29 30 and 31, all of which are operatively connected to their respective shafts. There is a power drive or motor 19 which_-is provided with a drive member 32 which is in turn engaged with pulley 33 to move the system. Solenoids 34 which are both connected in the circuitry of the system operate the finger 26 and 27 respectively to thus lower and raise said fingers to permit the documents to move forward or when in the up positions fingers 26 and 27 hold the documents in gates 13 and 12 until photocells 21 and 22 sense a document change in each gate. Upon emptying,-of each gate, photocells 21, 22 and 23 signal the solenoids 34 and the feed system upstream for fresh documents to be fed to the emptied gates.

Figure 4 which is a front view of the conveyor system 11 clearly illustrates fingers 26 in the up or locked position holding documents 35 in place in the gate. Photocells or sensing means 21 sense that gate 13 is occupied with documents thus signals solenoid 34 to maintain finger 26 in the up position. Upon emptying of gate-12, solenoid or control means 34 causes fingers-26 to belowered, thus permitting documents 35 to pass closer-to the inserterand subsequently out the system. In Figure- 5, finger 26 is shown in both the up and down position. Finger 26 is rotably mounted on a shaft 36, the shaft 36 movably mounted to the frame. Finger 26 is shown in the up % M - 1) position, thus holding documents 35 in gate 13. As shown in Figure 3 at least two fingers are used in each gate to securely hold the documents in place. Solenoid 34 operatively controls the position of the fingers at each gate upon receiving the appropriate signal from photocel 21, 22 and 23 shown in Figure 2. Focal arm 37 is spring biased by spring 38 to permit the required change in position of the respective fingers 26 and 27. While this Figure 5 shows gate 13 and finger 26, it is equally applicable to gate 12 and finger 27.

ls Spring 38 is connected to ground 39 for proper functioning of system. As finger 26 is lowered as shown, documents 35 are projected forward by the forward motion of "0" ring belts 24 and 25. The er,tcdiment as illustrated has been described with reference to two waiting gates 12 and 13; however, it should be understood that any-number of gates greater than one may be used in the present invention. The type of inserter mechanism 1 described herein is similar to inserter described in U.S. Patent 4,527,791 with the built in addition of a plurality of holding gates such as gates 12 and 13 described herein.

-The flow of documents or paper in the present system is regulated by a transport stops control circuit. The second conveyor apparatus 11 is called a "slave transport" and the transport including and beginning with ninserting apparatus" 20 is called the "master transport", The master transport is the entire transport means that follows exit rollers 30 and 31 through which the documents flow to the inserter. on demand from the master transport, document material will flow via the-slave transport. The stops or gates 12 and 13 on the slave transport insure that there is proper spacing between collations being cycled to the master transport. The following defines the various elements of the circuit diagram of Figure 6., IN1 - Transport Feed Time Pulse This signal occurs when the Master Transport is ready Qi to receive paper.

1 1 I,:

(1 IN2 - Transport Off This signal is high when the input to the slave transport is turned off.- IN3 - Transport Photocell #21 Exit Pulse This signal occurs when paper clears photocell #21.

IN4 - Transport Photocell#21 This signal is high when paper is blocking photocell #21 and low when paper is clear from photocell #21.

INS - Transport Photocell #22 This signal is high when paper is blocking photocell #22 and low when paper is Clear from photocell #22.

OUTPUTS OUT1- Transport Feed This signal is low when the slave transport is feeding the master transport.

OUT2- Stop 1 On This signal is low when Stop 1 is down and high when stop 1 is up.

OUT3- Stop 2 On This signalis low when Stop 2 is down and high when Stop 2 is up.

And Gate Or Gate Invertor R/S Latch D >>0 4 MQ 0 R Detailed Circuit Description

Latch #41 is enabled when Transport Off (IN2) signal is low and is set when Transport Feed Time Pulse (IN1) is received. This causes Transport Feeding (OUT1) to go low signaling the master transport that the slave transport is. feeding and stops #1 and #2 are energized (down) via gates #43, 44, 45 and 46. When paper blocks Photocell #21, Latch #50 sets via gate #48 keeping stops 1 and 2 energized. After Photocell #21 is cleared Latch #41 resets via gate #12 Transport P hotocell #21 Exit Pulse UN3). This causes Transport Feeding (OUT1) to go high signaling the master transport that the slave transport has completed feeding.

14.1 1) When paper blocks Photocell #22 (INS), Latch #50 resets and de-energizes stop #1 via gates #13 and #12 to hold back paper behind stop #1._ When paper blocks Photocell #21 (INC stop #2 de-energizes via gates 45, 46, 47 and 48 to hold back paper behind stop #2.

Therefore, having above described-a specific inserting system forspeeding up the processing of documents, it will be recognized that many modi fications and ramifications can be made without departing f rom the scope of the invention. These are intended to be encompassed within the described invention 1 1 15; -

Claims (17)

1. CLAIMS rI, r 1 Q . I 'I An envelope inserting machine, comprising: a

   document supply means for feeding documents along a predetermined feed. path; a colecting station situated downstream from said document supply means; an elongated transport means for conveying said documents from said supply means to said collection station; a folding station adapted to receive, fold, and release documents passing therethrough; a plurality of document holding gates adapted to receive documents from said folding station and release said documents; and inserting means for inserting each of said documents into an envelope, said document holding gates being positioned in series sequentially along the normal document transport path of said inserting machine, and each. gate being operatively capable of releasing documents to it.s next adjacent downstream gate and ultimately to said inserting means, thereby providing substantially uninterrupted feeding of documents to said inserting means at a rate approaching the output processing speed of said inserting means.
2. 2. An inserting machine according to claim 1, wherein eachi: of said gates has a sensing means which releases documents wh_en the next adjacent downstream gate is emp-tied.
3. 3. An inserting machine according to claim 1 or claim 2, wherein each of said - gates containsautomatic indexing means to provide proper document indexing while in the normal document path.

   . 1
4. 4. An inserting machine according to any one of the preceding claims, wherein each of said gates is downstream from said folding station and- on approximately the same plane.
5. 5. An inserting machine according to any one of the preceding claims, wherein each of said gates is in functional relationship with said elongated transnort means.
6. 6. An inserting machine according to any one of the preceding claims, wherein all of said-gates are upstream from said inserting station.
7. 7. A system for inserting documents in envelopes and other containers which comprises in combination:

   (a) a source of documents; (b) an accumulating station for receiving and accumulating a plurality of said documents; (C-) an endless conveyor transport means for receiving and transp orting said documents throughsaid system; (d) a folding means for folding said documents in preparation for insertion into said envelopes; (e) a plurality of holding gates for receiving and releasing the resulting folded documents; and (f) an inserting station wherein each of said folded documents is inserted into an envelope; said holding gates being located in the normal paper path of Said documents and each being located on substantially the same axis along saia transport means and each in substantial alignment with each other, each gate comprising a control means, a sensing means and at least two L-shaped f ingers and means to raise and lower said fingers.

   1 l, Q ;A 1.)
8. 8. An insert ing system according to claim 7, wherein each of said gates has a sensing means which releases documents when the next adjacent downstream gate is emptied.
9. 9.. An inserting system according to claim 7 or claim 8, wherein. each of said gates contains automatic indexing means to provide proper document indexing while in the normal document path.
10. 10. An inserting system according to any one of claims 7 to 9, wherein each of said gates is downstream from said folding station.
11. 11. An inserting system according to any one of claims 7 to 10, wherein each of said gates is in functional relationship with said elongated transport means.
12. 12. An inserting system according to any one of claims 7 to 11, wherein all of said gates are upstream from said inserting station.
13. 13. An inserting system according to any one of claims 7 to 12, wherein said sensing means comprises at least one photocell.
14. 14. An inserting system according to any one of claims 7 to 13, wherein said control means comprises a solenoid.
15. 15. An inserting machine, substantially as hereinbefore described with reference to,and as illustrated in,any of the accompanying drawings.
16. 16. An inserting system substantially as hereinbefore described with reference to,and as illustrated in,any of the accompanying drawings.
17. 17. Any and all novel combinations and subcombinations of features disclosed or illustrated herein.

    Published 19B8 at The Patent Office, State House, 66171 High Holborn, London WClR 4TP. Further copies may be obtained from The Patent Umce, Wes Branch, St Mary Cray, Orpingto3a, Kent BRS 3RD. Printed by Multiplex techniques ltd, St Mary Cray, Kent. Con. 1/87.