CA2367823C - In-line rotary inserter - Google Patents

Abstract

A rotary feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of moving inserts. The feeder includes a gripper drum disc for transporting the inserts and a detector caliper assembly having a follower roller that rides upon and along the periphery of upon moving inserts transported upon the periphery of the gripper drum disc. The feeder also includes a mechanism for sensing the field of a magnet to provide a measure of relative displacement between the sensor and the magnet and thereby a measure of the radius of the periphery from an axis of rotation. The sensory mechanism provides reference signals corresponding to zero thickness of the inserts in the absence of inserts upon the gripper drum disc. The sensory mechanism also provides thickness signals corresponding to the thickness of the inserts in reference to the reference signals when the inserts are transported upon the gripper drum disc interposed between the follower roller and the periphery.

Description

IN-LINE ROTARY INSERTER
This is a division of copending Canadian Patent Application 2,014,543 filed on April 12, 1990.
1. Field of the Invention:
This invention relates to apparatus and method for handling high volume mail and, in particular, it relates to in-line rotary inserter devices having a plurality of hopper-held insert feeding assemblies positioned along conveyors t.o dispense inserts onto the conveyors, and having devices for stuffing envelopes with the inserts.

2. Prior Art and Other Considerations:
Many present devices for stuffing inserts into envelopes employ conveyors to convey stack-dispensed inserts to an envelope stuffing device. Multiple inserter devices rely on a plurality of hoppers disposed along conveyors and dispensing inserts onto the conveyor in predetermined manner to achieve collated insert packages that are subsequently inserted into envelopes.
Such equipment is required to operate at increasingly higher celerities with high reliability and shortest possible down-times. Many problems, which either do not exist or which are inconsequential in low-speed operation need to be overcome in high-speed operation. For instance, such problems involve frictional, inertial, and other speed-related effects of moving apparatus components and of handled document materials.

Prior art inserter devices include U.S.Pat.Nos.4,043,551 and 4,079,576 to Morrison et al, U.S.Pat.No.4,177,979 to Orsinger et al, U.S.Pat.No.4,649,691 to Buckholz, U.S.Pat.No.3,825,247 to Fernandez-Rana et al, U.S.Pat.No.3,423,900 to Orsinger, U.S.Pat.No.2,621,039 to Kleineberg'et al, and U.S.Pat.No.3,809,385 to Rana.
It is an important feature of the present invention to provide apparatus and method for automatically inserting into envelopes at high celerities a plurality of inserts in predetermined and preprogrammed continuous manner and to further automatically process such insert-filled envelopes through diverting, flap-sealing, turn-over, stacking, and other operations associated therewith, substantially under computer control and supervision, while providing higher production rates than heretofore practically feasible.
SUMMARY OF THE INVENTION
In accordance with principles of the present invention, envelopes are conveyed from a hopper to an inserting station, where envelopes are opened and inserts are inserted therein.
The inserts are furnished by a plurality of modular insert hoppers which are positioned in line above an endless insert conveyor of the pusher pin type. Envelopes having inserts inserted therein are transported to a vacuum-belt transporter/diverter unit and are directed and transported thereby along at least one path that includes a turn-over module, a sealing module, and an on-edge stacking unit.

2a The inserter apparatus operates under preprogrammable computer control and supervision. Automatic error handling and visual display of operational status and program information are provided.
In accordance with one aspect of the present invention there is provided a rotary feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of moving inserts, comprising: a gripper drum disc for transporting said inserts thereupon, said gripper drum disc having an axis of rotation and a periphery; a detector caliper assembly including an arm having a first and a second end, said arm having at said first end a follower roller and at said second end a magnet, said arm being pivotally mounted and spring-loaded so that said follower roller spring-loadedly rides upon and along said periphery and upon moving inserts transported upon said periphery of said gripper drum disc; and means for sensing the field of said magnet, said means for sensing including a stationary Hall sensor to provide a measure of :relative displacement between said sensor and said magnet and thereby a measure of the radius of said periphery from said axis of rotation; wherein said means for sensing provides reference signals corresponding to zero thickness of said inserts in the absence of inserts upon said gripper drum disc, said means for sensing providing thickness signals corresponding to the thickness of said inserts in reference to said reference signals when said inserts are transported upon 2b said gripper drum disc interposed between said follower roller and said periphery.
In accordance with another aspect of the present invention there is provided a method of dispensing inserts by a rotary insert feeder module including detecting thickness of moving inserts and, comprising the steps of: revolving a gripper drum disc about an axis, said gripper drum disc having a periphery;
rolling a follower roller upon said periphery, said follower roller being comprised of a follower roller assembly that includes a pivotabl.e arm, said follower roller being disposed at a first end of said pivotable arm and being spring loaded toward said periphery, said pivotable arm having a magnet disposed at a second end of said pivotable arm; sensing position of said magnet with respect to and by a stationary Hall sensor; transporting inserts upon said periphery and interposing and spring-loadedly nipping the moving inserts between said periphery and said follower roller; and providing signals corresponding to insert thickness as a measure of the displacement of said magnet while said step of transporting inserts is being effected.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which 2c like reference numerals refer to like parts throughout different views. 2'he drawings are schematic and not necessarily to scale, emphasis instead being placed upon illustrating principles of the invention.
FIG.1 is a schematic diagrammatic plan view of a preferred embodiment of an in-line rotary inserter apparatus according to the present invention;
FIG.1A is a schematic diagrammatic plan view of another preferred embodiment of an apparatus of the present invention;
FIG.2 is a schematic fragmental side elevational view of a main portion of the apparatus shown in FIG.1;
FIG.2A is a schematic fragmental side elevational view of a main portion of the apparatus shown in FIG.1A;
FIG.3 is a schematic partial detail view of a vacuum aripper drum shown in FIGS.'> and 2A;
FIG.3A is a :;thematic fraqmental side elevational detail view of portions of the inserter mechanism of the apparatus, for instance as indicated in FIGS.2 and 2A;
FIG.3B is a schematic top view of a partial detail of an insertion jam detection arrangement according to an embodiment of the invention;
FIG.3C is a schematic side view of a partial detail of the insertion jam detection arrangement of FIG.3B;
FIG.4 is a schematic partial side elevation view of a speed change device of a modular rotary inserter station indicated in FIGS.1 and 1A;
FIG.5 is a ;schematic partial detail side view of an embodiment of an insert thickness sensing arrangement of the invention;
FIG.SA is a schematic partial detail side view of another embodiment of an insert thickness sensing arrangement of the invention;
FIG.6 is a :schematic fracrmented top view onto a portion of an insert convryinq surface of an in-line rotary inserter of the invention;

FIG.7 is a schematic fragmented side elevational view of a diverter of the present invention;
FIG.8 is a schematic top view of a vacuum belt transporter/diverr_er_ unit of the present invention;
FIG.8A is a schematic fragmental vertical section view of a portion of the unit of FIG.8;
FIG.8B is a :schematic side view of an envelope scanner as indicated in FIG.8;
FIG.9 is a schematic side elevational view of basic features of an envelope turnover module of the invention;
FIG.9A is an isometric view of basic features of the turnover module shown in FIG.9;
FIG.10 is a schematic partial side elevational view of an envelope sealing module of the invention;
FIG.10A is a schematic partial top view of the embodiment shown ~.n FIG.10;
FIG.11 i.s a schematic. partial fragmented front view and section of a diverter portion of an on-edge stacking unit of the invention;
FIG.12 is a schematic partial fragmented top view of the unit shown in FIG.11;
FIG.13 is a schematic partial fragmented side view and section of an on--edge stacking unit of. the invention;
FIG.14 is a schematic partial fragmented top view of the unit shown in FIG.13; and FIG.15 is a schematic partial enlargement of a middle portion of the view in FIG.13, showing additional details.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the in-line rotary inserter apparatus is shown in FIG.1. and comprises basically the following subsystems: One or more rotary insert feeder modules 20, 22, 24, 26 for furnishing inserts from insert hoppers, each including an insert thickness detector; an envelope feed station 30 for furnishinct envelopes from an envelope hopper;
an inserting station 32 in wlnich envelopes are inserted with inserts that are collated and conveyed thereto upon a pin conveyor 34 (from insert feeder modules); and, a vacuum belt transporter/diverter unit 36 for transport and selective diversion of inserted envelopes.
The vacuum belt transporter/diverter unit 36 can provide selective diversion and transport to one of two paths. At least one path comprises an envelope turnover module and an envelope sealir_g madule. The other path can be used for alternate delivery of incompletely inserted (faulty) envelopes, buckled envelopes, and the like; or it can be used for selective alternate delivery of unsealed envelopes for further handling. Turnover module and sealing module can be arranged in either order, provided that each :i.s structured accordingly.
For instance, the embodiment shown in FIG.1 provides first for sealing of envelopes delivered from vacuum belt r_ransport/diverter unit 36 to sealing module 38. Sealed envelopes are thereafter delivered to turnover module 40, are turned over therein to flap-down orientation, and are i'arther conveyed to on-edge stacking/divert:er unit 42. The embodiment shown in FIG.1A provides first for turnover of unsealed envelopes in a turnover module 40A which delivers turned over envelopes to a sealing module 38A.
The embodiment of the inline rotary inserter apparatus shown in FIG.1 further comprises an on-edge :atacking/diverter unit 42 that receives envelopes and stacks them on edge in an accumulator 44 or passes envelopes on to additional handling equipment 46.
i The inserter .a~naratus shown in FIG.1 .further comprises a main computer 50 for operational control, supervision, a.nd coordination of individual units and modules interconnected therewith, a display/control console 52 to display operational information and receive operator input commands, a skew detector arrangement 54 for sensing of misalignments of collated inserts being conveyed to inserting station 32, and an insert diverter 56 for diversion of inserts (for instance in case of errors in, damage to, or misalignments of inserts). Not specifically shown in FIG. 1 is an envelope diverter 33 (FIG. 2) which is provided in a location between envelope feed station 30 and inserting station 32. Envelope diverter 33 is disposed in a lower equipment region (below pin conveyor 34) along the envelope feed path for selective interception of envelopes that have been stigmatized as being faulty. As specific inserts are intended to be inserted into specific envelopes (and are associated therewith), selective diversion of inserts by insert diverter 56 in case of the occurrence of insert fault conditions is associated with interception and diversion of corresponding envelopes in envelope diverter 33 and vice versa. Thusly, if either inserts or associated envelopes are stigmatized as faulty or otherwise desired to be diverted, the corresponding associated envelopes or inserts, respectively, are also diverted in order to avoid empty envelopes or inserts without envelopes being processed and conveyed farther. Therefore, envelope diverter 33 also serves t.o selectively divert (under preprogrammed computer control of computer 50) those envelopes for whom intended associated inserts are being diverted by insert diverter 56.
Referring now also to FIG. 2, a main track bed 60 is horizontally disposed in the upper portion of a main base 62.
Main track bed 60 carries, in its upper portion, pin conveyor 34 .for receiving in collated manner inserts from insert feeder modules 20, 22, 24, and 26, and for transporting (from left to right) such inserts past skew detector arrangement 54 and insert diverter 56 to i.nsertina station 32. I7isplay/control console 52 is shown adjustably mounted above main track bed 60. Insert feeder modules (20,22,24,26), skew detector 54, insert diverter 56, and inserting station 32 are Generally disposed above main track bed 60 in cantilevered briduing manner.
Envelope fee<3 station 30 is disposed on and within main base 62 at the end thereof shat is opposite to the end which carries insert feeder modules 20, 22, 24, 26. The upper portion of envelope feed station 30 includes an envelope hopper 66 and a :hopper mechanism 68. A transverse pass 64, including first arid second sloping walls 70 and 72, is disposed in upper portion of main base 62 between insert~nq station 32 and hopper mechanism 68. A fall region 74 is disposed in transverse pass 64. Another embodiment of the inserter apparatus i.s shown in FIG.2A to comprise a transverse pass 64A having a substantially horizontal surface 70A with a short fall region 74A thereabove, as will be described in detail later in conjunction with FIG.2A.
Envelope feed ~;tation 30 comprises envelope hopper 66, hopper mechanism 68 for withdrawing of envelopes from hopper 66 and for feeding of envelopes to a first gripper drum 76, a. second gripper drum 78 for transporting envelopes conveyed thereto by first gripper drum 76, a flap opener 80 to open envelope flaps of envelopes transported by second gripper drum 78, and an envelope conveyor device 82, including an a.d~ustable upper belt device 83, for conveying of envelopes from second gripper drum 78 to a vacuum gripper drum 84.
tripper drums 76 and 78 (and their operation) are of generally convent~_onal kind. Envelope diverter 33 is disposed proximatE> to the delivery end of envelope conveyors device 82 to selectively intercept and divert envelope rejects into a reject catch bin. Vacuum gr:ipper drum 84 delivers envelopes onto main track bed 60 :in readiness for inserting with :inserts in inserting station 32.
Flap opener 80 comprises a rotating rotor 88, having a rotary valve arrangement associated therewith for valuing of vacuum to one or rriore sucker cups 90. Sucker cup 90 is disposed upon the periphery of rotor 88 whose rotation (and valuing of vacuum to sucker cup 90) is synchronized anal.
properly phased with the rotation of second aripper drum 76, so that the flap of an envelope transported by second aripper drum 76 past flap opener 80 is momentarily grabbed and opened (unfolded) by sucker cup 90. A plow/sensor device 92 is disposed just downstream from flap opener 80 and intercepts an opened flap and further bends it into the unfolded position as the envelope is transported by and upon second gripper drum 78. Flowjsensor device 92 is equipped with a photo-sensor to check correct flap opening and to detect if an envelope is missing at the time it should be present.
Envelope hopper 56 contains an envelope stack 94.
Envelopes are stacked therein in an orientation as indicated by a typical stacked envelope 96 having a leading edge 100.
a trailing edge 102, and an envelope flap 98 folded along trailing edge 102 onto its lower face. Consequently, withdrawal of an envelope from the bottom of stack 94 onto first gripper drum ?6 is performed in an attitude and a direction that precludes catching of the flap on the next envelope. Transport of the withdrawn envelope by first gripper drum 76 to second gripper drum 78 results in an r orientation of the envelope (upon second gripper drum 78), as it passes by flap opener 80, having unopened flap 98 facing toward flap opener 80. At this time, sucker cup 90 <Arabs envelope flap 98 by vacuum action and hinges it about trailing edge 102 ~.nto an open position during passage of the envelope.. Opened flap 98 is thereupon intercepted by plow/sensor device 92 and thereby further unfolded, whilst sucker cup 90 releases as its vacuum is vented and valued off in accordance with the operation of the rotary valuing arrangement of rotor 88.
Subsequently, an envelope is delivered and released onto envelope conveyor device 82. Envelope conveyor device 82 comprises two driven endless belts that nip therebetween an envelope delivered thereto and that convey it to vacuum aripper drum 84. A typical envelope will be continuously transported from conveyor device 82 to vacuum aripper drum 84.
The two driven belts (comprised in conveyor device 82) are arranged in such a manner as to permit slippage of an envelope with respect to the belt motion if an envelope is stopped by a selectively interposable stop Gate 86. Upper belt device 83 is adjustably mounted for this purpose and i:or accommodation of different thickness envelopes. If an, envelope is intended to be diverted, it is stopped by stop gate 86 until it can no longer be gripped by the next cxrippers (of vacuum gripper drum 84? passing by. Stop aatc 86 is moved out of the way of the envelope path at such time and the envelope will be driven by the belts into a reject bin located in envelope diverter 33.
In an alternate embodiment, stop gate 86 is interposed into the path of. each envelope to register the envelope in position. Stop gate 86 is moved out of the way to release the envelope at the appropriate instant in time to be gripped by the grippers of vacuum gripper drum 84. To reject r and divert an envelope, stop gate 86 is moved out of the way at a time when th.e envelope can miss and bypass the grippers of the vacuum gripper drum 84, so that the envelope is delivered into the reject envelope bin.

Envelopes delivered onto main track bed 60 are positioned by vacuum c~ripper drum 84 for the inserting operation in inserting station 32. Following the inserting operation, envelopes are delivered from the inserting station 32 through a nip between a spring-loaded pressure roller arrangement 104 and a driven conveyor belt arrangement 147 that rides about a pulley arrangement 108.
Envelopes are delivered into fall region 74 in the same orientation as received; i.e. with leading edge 100 leading and envelope flap 98 trailing. The envelope falling into fall region 74 i.s guided by a deflector bar 106 so that it settles against first slooina wall 70 of vacuum belt transporter/diverter unit 36.
Referring now to FIG.3, continuously revolving vacuum crripper drum 84 schematically depicted therein comprises a first and a second face disc 110 and 112 mounted on a drum 1.16, which in turn is rotatably supported upon a drum axle 1.18 in accordance hrith conventional practise. Various mechanisms (not shown here) a:re included in this assembly in conventional manner to perform the required customary gripper functions.
Face discs 110 and 112 are provided with a plurality of vacuum holes 121 and 121' open to the discs' peripheries.
Vacuum holes 121 and 121' are disposed about the disc peripheries in a plurality of groups, whereby each group is disposed in a predetermined relationship to the drum qripper mechanism in positions corresponding to locations whereL~.non envelopes are carried. Vacuum i.s automatically valued to each crroup before an envelope is released by respective arippers on the gripper drum 84. Consequently, an envelope released by arippers remains held to vacuum grippes drum 84 m pon vacuum holes 121 and 121' until it is properly delivered to its substantially horizontal registered position on main track bed 60, Referring now to FIG.3A, a fragmented portion of the inserter mechanism of inserting station 32 ~FIGS.1 and 2f is shown therein. The vario~a.s components are disposed in mutual positional relationships representative of an early stage of the inserting operation. FIG.3A depicts pertinent components disposed in the lower region of inserting station 32 as well as components particularly involved and associated with the inserting operation that are disposed on, in, and beneath the main track bed 60 (FIG.2). The view of FIG.3A represents a region located approximately in the middle of FIG.2 in enlarged form and includes details that have been omitted from FIG.2 for the sake of clarity.
An upper portion of vacuum gripper drum 84 (FIG.3) is shown here comprised in inserting station 32. Further comprised in inserting station 32 are stop fingers 125, suction cups 125A,. n pair o.f opening fingers 125B mounted on revolvable shafts 125C, insert pushers 126, and spring-loaded drop rollers 126A. A horizontally dispcsed top plate i26B having a trailing end 126C is partially shown. Also indicated here is a leading portion of conveyor belt arrangement 1.07. An envelope X127 is shown disposed substantially horizontally _n a registered position to ~7hich it has been delivered by vacuum gripper drum 84. Envelor~e 127 has a top side 127A, a bottom side 127B, and a flap 127C. Flap 1270 is held open in a slightly downwardly directed orientation by and below trailinct end 126C of ton plate 126B.
An air nozzle 123 directs a timed blast of compressed air flow over the upper surface of flap 1270 into the envelope to assist opening of the envelope prior to the insertion operation. Air flaw is valued on as an envelops is delivered to its insertion position. The air flow also serves to force the envelope against its positional registration stops, for instance against stop fingers 125, and aids in holding the envelope downwardly. Air flow is shut off once tlzE1TlSHrtl.orl operation has begun. Also showIl here is an insert stack package 198 disposed upon top plate 126B and being propelled by ~_nsert pushers 126 toward the right for insertion into envelope 127. Positional registration stops can alternately be provided in form of stop finders which are raised from.beneath the upper surface of conveyor belt arrangement 107 in appropriately timed manner.
According to more particular aspects of the apparatus and method of the invention, the travel motion of the uppermost tips of insert pushers 126 in the course of a ~~omplete insertion cycle is indicated by phantom lines as locus pattern 'L'. Locus pattern 'L' follows approximately an horizontally elongated noose-shaped form. Insert pushers 126 are translated in a vertical plane along locus pattern 'L' without changing angular orientation during the travel motion of an insert cycle. Insert pusher 126 is shown in a position during the beginning of an insertion cycle. Othe~-salient positions are also indicated by dotted lines by pusher position 126', representing a low position near the end of the retracr_ion portion of an insertion cycle, and by pusher position 126", representing the end of the retraction portion and the early beginning of the insertion portion of an insertion cycle. The apex of the travel motion of insert pusher 126 at the point of travel direction reversal on the right end of locus pattern 'L' is designated as insertion >nd ' I ' .
It should be recognized that a plurality of identical components are usually present in appropriately parallel positions perpend_ic;.ilarly to the plane of t:he depiction in front of or behind each such r_omponNnt, as is customary in mail handlincr equipment. For example, there is a plura_~_itv of stop finders 125, suction cups 125A, insert pushers 1%6, drop rollers i2E>A, etc. Moreover, the depiction omits >bstructing cony>on~=nt=_; that: cor.ild be detrimental to clarity of understanding.
As hereinbefore described, vacuum gripper drum 84 conveys envelopes in a clockwise direction upwardly to a horizontal position, as indicated by envelope 127 :in FIG.3A.
t~nvelope 127 is delivered to this position through a q~.p between trailing end 126C (of top plate 12HB) and the periphery of vacuum gri.pper drum $4 onto an insert:ina :station surface. .fit this time, opening fingers 125B have orientations that are approximately 80 degrees from the?_r shown orientation so that their tips substantially point toward one another. The envelope is stopped when its leading edge is intercepted by .stop fingers 125. Stop fingers 125 are automatically rotated into the position shown to stop an Envelope, and are rotated out of this position to release an Eenvelope for farther transport by conveyor belt arrangement 7_07.
As an envelope has been delivered to t:he insertion position shown, and air flow into the envelope from nozzle 1.23 has been initiated, suction cups 125A descend and, 1-ravina vacuum valued thereto, attach to for side 127A.
Suction cups are r_hen lifted up, =_ift the envelope's top ~~ide 127A and the envelope forms an open pocket.
Opening fingers 125B are now rotated by their shafts 1.25C (one finger ~:~7_ockwise and the other one anticlockwise) by approximately $0 degrees into the orientation indicated., so that their tips slide into the opened pocket of the envelope; i.e. beneath top side 127A. This finger position.
and orientation i~> now substantially along and parallel to r the internal side edges of the opened envelope. Opening fingers 225B have a substantially rectangular or square C-channel-shaped thin-walled cross-section, whereby the C-channel is di.spo.sed with a side wall facing downwardly ar_d 1~
its open side facing toward t:he middle of envelope 127 in the orientation shown in order to reliably guide insert stack package 198 into envelope 127 during the subsequent insertion operation. For the latter purpose, opening finders are customarily also provided with ramp-like leading edges.
As indicated, the height of fingers 125B is somewhat reduced in direction toward their tips and their tips are smoothed and slightly rounded off to avoid sharp edges that might catch on the envelope during finder rotation therein and on inserts during insertion thereof.
Envelope 127 has now been readied for insertion, as hereinabove described, and insert pushers 126, that have risen from beneath top plate 226B and that have intercepted insert package 198 along its trailing edge, move horizontally towa.r_d the right and push insert stack package 1.98 between opening fingers 125B into envelope 127.. As indicated by insertion end 'I' of locus pattern 'L', insert pushers 126 push :insert stack package 198 to a position vicirzal to the hinge line of the envelope flap 1270.
Thereafter, insert pushers 12b retract along locus pattern 'L', as indicated by arrows thereupon. Vacuum to suction cups 125A is vented and valued off by now and drop rollers 126A descend into the insert-filled envelope 127 and nip it in spring-loaded manner onto driven conveyor belt arrangement 107, whilst: stop fingers 125 are pivoted out of the way of th.e envelope. Other drop rollers can be provided and moved downwardly to nip the envelope in other appropriate locations along the envelope.
Envelope 127 is fractionally engaged by conveyor belt arrangement 107, wi~:hdraws from opening fingers 125B, and is propelled toward the right. Fingers 125B are thereafter rotated approximate=.v by 80 degrees back to the orientation with tips pointing substantially toward one another. The insert-filled envelo,~? is d.zl;.vE~ue~ into faO.l region 7~~

(FIG.2).
The translational motion of insert pushers specifically along locus pattern 'L' is provided in order to achieve two main objectives; the horizontal straight-line inserting motion and tf~e rearward and simultaneously downwardly curved retraction motion. Insert stack oackaaes, being conveyed tw pin conveyor ~4 iFIG.l; in main track bed 60 along main tease 62 by pusher pp_ns 1.96 (FIG.7) , are seriatim transported t_c.~
the approximate region indicated in the location of insez~t stack package 198 disposed upon top plates 126B in FIG.3A.
Insert pushers 125 must be moved out of the way of_ a next insert stack package belIlg conveyed to this region and are. therefore, disposed beneath top plates 126B at that time, as indicated by locus pattern '1~' and, for instance, insert positions x.26' and 126" thereal.ong. Thereafter, insert pushers 126 are translated upwardly and eventually toward the right, so that they are raised through yaps between top plates 126B, engage the trailing edge of insert stack package 198, and push its horizontally to the right into envelope 127, as hereinbeforE described.
Once insert packa_a.e 198 is inserted in envelope 127, insert pushers retract from insertion end 'I' and gradually sink downwardly beneath tap plates 1268 along the path indicated by locus pattern 'L". This rearward and downward retraction, however, must not interfere with the nexr_ envelope beinc,~ delivered upors vacuum qripper drum 84. in clockwise direction upwardly. This is an important reason for the downwardly curved path with fast downward and rearward retraction of insert pushers 126, while simultaneously allowing clearance for delivery of the next r envelope and, also simultaneously, permitting an early downward retraction of insert pushers to provide cl.earanc~
for delivery of the next insert stack package. Travel distances and spacinqs bet.we.en successive insert packages are thusly kept t:o a minimum.
The describ:~d translatic>nal rr?otion of insert pushers 126 is provided lay a drive mechanism that comprises a trolley upon which insert pushers are mounted. The troJ_ley i.s free to travel horizontally upon a troJ_ley bar arrangement which is cam-driven vertically up and down. The horizontal motion of the trolley is provided by an endless chain drive. Appropriate dimensional and phase relationships between these trolley drive arrangements achieve the locus pattern 'L'.
Referring now to FIGS.3B and 3C, an embodiment of an insertion jam detection arrangement is shown therein, in particular with respect to apparatus and method aspects of t:he invention. Thf~ insertion iam detection arrangement is disposed in inserting station 32 (FIGS.1, 2, and 3A) and.
broadly, comprises a. horizontal and a vertical ratroreflective sensing arran~xement, More particularly, the horizontal sensincs arrangement co~r?prises a photosensor 128 and a retroreflect:i.ve target surface 128A. The vertical.
sensing arrancfemant comprises a pair o.f photosensors 1288 and 128C (hidden behind 128B) and a pair of retroreflect_~ve target surfaces 128D and 128E that are disposed upon the too surface of each of the openi.na fingers 125B. Target surfaces 128A, 128D, and 128E are of conventionally used retroreflective material, for instance retroreflective adhesive tape or pads as customarily used in conjunction with photosensors. Envelope 127 is shown in the same position as also depicted in FIG.3A, being disposed in inserting station 32 in readiness for insertion. Opening fingers 1258 are shown with their tips disposed in the opened pocket of envelope 12.7.
A horizontal sensing bear: 129 is directed by ohotosensor 128 onto target surface 128A and is reflected back into the photosensor. Photosensor 128 detects any interruption of t;he beam 129. Beam 129 traverses a.t least the entire length of envelope 127 slightly above the upper surface of the opened envelope so that an obstruction of the beam in this regz.on will be detected. For example, interruption of t:he beam 129 calll occur as a conseauence of malfunctions caused b:~ damaged, misaliqned, and buckled envelopes havin<x been .fed to inserting station 32, or by envelopes havincx been bucke..ed or curled up by opening fingers 1258, f.or instance if suction cups 125A malfun~~tion.
Overall, any undesirable lifting up of a portion of the envelope 127 into the path of the beam 7_29 results in detection of a fault condition. Beam 129 also senses problems caused by and during insertion of insert stack packages. For instance, jamming by piling up of insert and envelope material will be detected. Sampling of the photosensor signal at appropriate times during the insertion cycle provides signals that are capable of discerning the type of malfunction more specifically.
Vertical sensing beams 1298 and 129C are directed by ohotosensors 1288 and 128C, respectively, toward target surface 128D and 128E, respectively, and are reflected thereby back into the respective photosensors, provided that the beams are not interrupted. In the depictions in FIGS.3B
and 3C, opening finders 1258 and therewith target surfaces 1.28D and 128E hove r'IltCT'E'd into th~r opened pocket c~f envelope 127. Consequently, sensing beams 129B and 129C are interrupted by thw top side of the oven enc7elope 127.
Vertical sensinct beams 1298 and 129C primarily serve to detect the presence of a correctly opened envelope (having both fingers 1258 inserted therein) by sampling of the l signals generated by photosensors 1288 and 128C at the appropriate time during the insertion operation. It has been found that the insertion jam detection arrangement, as described, is capable of detecting most, if' not al:L, fault conditions that can potentially occur in the course of insertion. In case of detection of a fault condition, appropriate action is taken automatically under computer <,ontrol, for example wither by subsequent diversion of jammed material or by stoppage of the equipment and by fault_ location indication for the machine operator's attention.
Referring to F~~G.4, a speed change device 130 is disposed within ear_h insert feeder module, and serves to selectively change drive speed of the insert feeder.
operation. In a particular embodiment such speed change is selectable between a normal speed and half speed (in a relationship to the speed of the pin conveyor 34). In general though, other ratios can be used; for instance 1 to 1/3, 1 to 1/4, anci the like. Speed change device 130 comprises an angle drive box :L32 for driving the mechanism of insert feeder module (for :instance 20) via a box axle 134, a box drive shaft 136 LipoIl whlCh a (first and a second pulley 138 and 140 are mounted on either side of angle drive box 132, and a first and a second clutch pulley i42 and 1a4, both pulleys being borne in free-running manner upon a clutch drive shaft 146, and each pulley comprising a clutch half coaxially disposed therewith; namely a first clutch half 148 being comprised in first clutch pulley 142 and a second clutch half 150 being comprised in second clutch pulley 144.
Further comprised ;in speed change device 130 is a clutch shaft 152 disposed coaxially upon clutch drive shaft 146 between first and second clutch pulleys 144 and 146.
Clutch shaft 152 is secured tc> clutch drive shaft 146 or it c,an be of unitary construction therewith. A double-sided claw clutch 254, including a clutch securing means 156, is borne coaxially slideably upon clutch shaft 152. Claw clutch 154 is selectably securable to clutch shaft 152 by clutch. .
securing means 156 to either engage first clutch half 148 (as shown) Or second clutch half 150 for drivincr of either first clutch pulley 142 or second clutch pulley 144, respectively. Clutch securing means 156 can be any conventional device used far such purposes (for instance screws) and claw ~:=hitch 154 can be sl:ideably keyed upon clutch shaft 152 ~=n conventional manner. Appropriate bearings (not specifically shown here) are provided for box drive shaft 7.36 and for clutch drive shaft 146. Clutch drive shaft 146 is provided with an inserte_r drive pulley 158 secured to one end thereof. An inserter dr~_ve belt 150 provides motive poTaer to inserter drive pulley 158 from a here not shown ?not:c~r-driven lack shaft that i~ located in main base 62 of the inserter apparatus.
First box pul.l:~y .!.38 is connected with first cl~.itc~.
pulley 142 by a first belt 1.62. Second box pulley 140 is connected with second clutch pulley 144 by a second belt 164. In the embodiment shown in FIG.4, second clutch pulley 144 is one half the diameter of the first clutch pulley 142, while pulleys 238 and 140 are of the same diameter. The shown clutch engagement results in a first drive speed transmitted to angle drive box 132. The alternate selectable clutch engagement results in a drive speed transmitted to angle drive box 132 that is one half of the first drive speed. Other preselectable drive chancre ratios can be chosen by appropriate relationships between pulley diameters.
The half speed ~acilaty is generally pr°eselected when inserts may be difficult to handle a.t high speeds, as for instance Given by :insert.s from. very thin mate_rial_s. Tn such cases, for example, two feeder modules are used to p.r.ovi~le the same more difficult to handle inserts, each moc3.u7_e operating at one half of the speed of other insert feeder modules. This provides the capability of high delivery rate without a need for slow-down of the entire apparatus.

Referring now to F'IG. 5, insert thickness detector 28, disposed in every feeder module (for irrst.ance 20), comprises an insert gripper drum disc 166 of an insert gripper drum employed for delivery of inserts from a hopper to pin conveyor 34. Thickness detector 28 furtYrer comprises a detector caliper assembly 168 and a Hall sensor device 170.
First and second anvils 172,174 are adjustably secured to a face of drum disc 166 and are spaced apart by 180 degrees.
Peripheral surfaces of anvils 172,174 are flush with or slightly raised above the periphery of insert gripper drum disc 166. Detector caJ.iper assembly =L68 comprises a caliper arm 176, a follower roller 1'78 mounted at. one end of arm 176, a permanent magnet: 180 mounted at the other end of arm 176, a caliper pivot 182 upon which arm 176 is rotatably borne, and a tension anchor sp~:ing 184 spring-loading arm 176 so that roller 178 rides upon the pex:iphery of disc 166 and over anvils 174. Spring 184 is anr_hcred to an anchor 186 that is secured to the module's frame. Caliper pivot 182 and Hall sensor device 170 are also secured to the inserter module frame. Hall sensor 1°TO :senses lateral displacement of the magnet 180 and generates a corresponding electrical signal which is a measure of the thickness of an insert passed between disc: 166 (or anvil4. :L72,174) and roller 1'78. For example, an insert 188 is indicated in a proper position while f:~eing conveyed by and upon the gripper drum (disc 166) .
In operation, the insert gripper drum revolves about its axis carrying inserts gripped upon its periphery and transporting such inserts in generally cc;nventional manner.
In particular, inserts are carried upon the periphery of drum discs, specifically as shown in FIG. 5 by example of 2 :L
insert 188 disposed upon insert grippes drum disc 166.
Insert 188 is disposed over first anvil. 17'~' . Anvils 1.72, 174 are adjusted to have their peripheral surfaces concentric about the axis of rotation of grippes drum disc 166, as the periphery of the latter may not: be sufficiently concentric with respect to its rotational axis to serve as a reference for insert measurement thickness. The signal generated by the Hall sensor 170 corresponds to the radius followed by follower roller 178 about th~v axis of rotation of disc 166.
Consequently, the signal from the Hall sensor provides a measure of insert thickness calipered between roller 178 and an anvil. That is, the signal from the Hall sensor device 170 is sampled during the time when anvils 172 and :174 pass by the follower roller 1?8. Cr~rr~~ctiy adjusted anvil positions result in identical signals din absence of insert 188) that., therefore, reflect equal radii (of rotation) for both anvils. Presence of insert 188 causes a lifting of follower roller 178 by the thickness of ~.nsert 188 and a consequent relative change in signal generated by Hall sensor device 170 that provides an accurate measure of thickness of insert 188.
Anvils 172 and 174 are not required in another embodiment, wherein the Hall sensor provides reference signals corresponding to disc periphery radii in insert-carrying locations in absence of inserts thereupon. These reference signals are computer--stared and compared with the insert thickness signals obtained when an insert :is present.
Consequently, lack of concentricity of tl-ae periphery of disc 166 is compensated.

21a Insert thickness detector 28 is used in insert feeder modules particularly as a so-called "miss and double detector" to detect faulty equipment operation such as given by an absence of an insert or the presence of more than one insert thickness. In general, Hall sensor signals are compared with preset limits, ccarresponding to thickness ranges, to allow for permissible thickness variations and tolerable dimensional structural changes.
Yet another embodiment .Jf an insert thickness detector, designated by the numeral 28A, is shown in F'IG. 5A. An insert gripper drum 166A and a caliper assembly 168A are borne and mounted on a common frame structure 167, Caliper assembly 168A comprises a fined Hall sensor device :170 and caliper arm 176A. The latter is pivotably borne upon a caliper pivot 182A which is mounted in a. fixed position with respect t.o frame structure 167. Caliper arm 176A has a follower roller 178 freely rotatably mounted at one end thereof. The other end of c~lipex~ arm 176A is provided with a permanent magnet 180 whose magnetic field is sensed by Hall sensor device :170.
A pulley 171, mounted on the axle of the insert gripper drum 166A, is commonly driven at the same angular velocity as the insert crripper drum. A further pulley 173 is freely rotatably borne upon a shaft that is mounted in a :Fixed position with respect to common frame structure 167. Pul7.~v :L7.3 is driven from pullev 1.77. ~W.:~ ;~ belt 1T.3A. A nr_ecis~.wn cali~aer roll 173B is coaxially mounted with pulley 173 anal driven there.bv. A point on the periphery of r.ali.rer_ ro1_1 1738 is always d.:isnosed so as to substantia.lJ_V colnclde =a? th a cylindrical surface within which falls the periphery of t:he insert grippe:r dru_rr~ 166A. Caliper roll 1738 and follower roller 178 are both disposed in substantially the same vertical plane which is located on one side and in the vicinity of one face of insert Qripper drum 166A. The rsip formed between ro.'L1 173B and roller 178 intercepts c>verhanginq portions of inserts being transported upon drum 166A. In absence of inserts being calipered, follower roll?r 1.78 contacts caliper roll 173L~ and is driven thereby. This contact is enforced by spring loading of caliper arm 176A by torsion spring 184A.
The transmission ratio between drum 166A, pulleys 171 and 173, and calixaer roll 1738 is such that the peripheral velocities of inser-r- cxripper drum 166A and caliper rol)_ 773B
are identical. Belt :L73A is resiliently elastic, particularly alonrx its lenath, in order to accomodate velocity fluctuations between the two pulleys.
In operation, when an in:7ert, for instance indicated insert 188, is transported upon insert qripper drum 166A, the insert is also nipped between caliper roll 1738 and follower roller 178, and is di°iven thereby substantially at the speed of the aripper drum periphery. Follower roller i78 is displaced by r_r.~.e in::ert thickness, and magnet 18U is correspondingly displaced from its reference position along Hall sensor device 17U. The difference between the Hall sensor signals in absence and in presence of a nipped insert provides an accurate measure of insert thickness. As inserts extend beyond both sides of the insert gripper drum into the nip region between caliper roll 1738 and follower roller _L7E, lack of concentricity, vibration, and other aripper drum periphery deviations do not affect the measurement, because caliper roll 173B is riaidl_y borne in the frame structure of the apparatus and is not subject to errors due to such causes. The elasticity of belt 173A. facilitates also c:alipering of relatively thick inserts, as the belt. will >tretch to adapt to corresponding fluctuations in velocity of caliper roll 173B.
Referring no« particularly to FTG.6 in conjunr_tion with FIGS.1. 1A and 2, 2A, skew detector arrangement 54 is disposed on and above main track bed 60 and comprises a skew detector bridge 1~~0 having a ~?lurali ty of downward.ly-J.ooki ncr ohotosensors mounted therein. A plurality of retroreflectors ~~..92 is disposed bei_ow skew detector brid.qe 190 upon the upper surface of rna~..n track bed 60 . Skew detector ~~ridc~P ~ 90 is indicated in dotted lines in FIG.6. Pin conveyor 34 (indicated by dash lines) is disposed beneath the surface of rrlain track bed 60 and comprises, in two parallel rows, a plurality of equi-spaced upwardly-pointing pusher pins 196 (two of which are shown here) which protrude above the main track bed through slots 194 and which move therein along the track bed. A typical insert stack package 198 (indicated by phantom lines) is shown as it is pushed along the surface of track bed 60 by pusher pins 196, being conveyed thereby from inserter modules to envelope inserting station 32.
Photosensors in skew detector bridge 190 are directed toward retrorefler_tors 192 so that the presence of an insert stack is sensed. in paz-ticular, the sensincr operation is timed in synchrons.srr! with the conveying motion of pin conveyor 34. Broadly the apparatus and method of the present invention pravide~for sensing of leading and. t.rai7_ina edges of insert stack p~:m°~.-:~cye 198 in a x~lurality of transverse locations across main track bed 60 over retroreflectors 19.-'.
riore particularly, detected signal levels of individual photosensors are compared for transversal incidence timing by sensing of relative obstru~~tion of retroreflectc>r areas by insert stack package edges. In a more specific embodiment, these signal are evaluated in dependence on machine speed, thusly establishing limiting tolerance leve-.~
for permissible s~;ew and other misalignments as a function of machine speed. i~imiting i:olerance levels are preprogrammable :in order to provide allowance for differeW
insert materials and, particularly, to establish automatic rejection thresholds for insert stack package skew and misalignment.
Referring now to RIG.7, an insert diverter 56 is depicted in side elevation as it is disposed upon main base 62. Also indicated here is a pusher pin 196 of pin conveyo~~-34 as it pushes insert stack package 198 along upper surfac=
of main track bed 60 (from left to right). Broadly, insert diverter 56 comprises a diverter housing 200, an insert reject catch tray 202, and a divert pulley system 204.
Although disposed within main base 62, a selectively positionable two-position reject gate 206 including' its actuating mechanism is a part of insert diverter 56. In a more particular embodiment of the invention, divert pulley system 204 comprises a motor-driven divert drive roller/pulley 208, a motor-driven belt drive pulley 210, arid a triple pulley belt arrangement 212 including an endless divert belt 214. Belt arrangement 212 comprises a floating idler pulley 216 which is carried by a here not shown lever-that freely pivots about the axis of belt drive pulley 210 and that is spring loaded in a clockwise direction against an adjustable stop. This lever also carries an idler lever pivot 222 which is linked by a here not shown link to the axle of a take-up pulley 218. This link is spring loaded a. 5 about the axis of p~_vot 222 in counter-clockwise d~.rect~_on t:o keep divert be~.t 274 tensioned. A fixed idler pulley 220 i.s borne in fixed. pos~.ti on within housing 200. Resa.li_ent~ y tensioned divert >>E.,.t 214 ~.s ;given by belt drive x>ullev 210. It should be i.znd.erstood that a plurality of substantially identical compor?ents is disposed in spaced ~>arallel arrangements perpendicularly to the plane of the depiction, as is ~:m.istomary in sheet material handling rr~echanisms .
In operation, the apparatus and method of the invention provides for diveosion of an :insert stack package when reject gate 206 i=~ raised to -its upward reject position 224 .from its by-pass ~~os,'_tion below the surface of main track bed 60. The insert: =tack package (such as package 1.98, for e-.~ample) is c~onse<:~n~ently pushed onto reject Gate 206 by the normal conveying motion from rusher pins 196. The insert package is thuslv guided into a reject nip region 228 between divert belt 214 and divert drive roller!nul.lev 208.
The package i.s arar>bed in n_p region 228 and 1 ifted unG,ar-d.ly away from the path of pusher pins 196, is carried about roiler/pulley 20~g, and is thereby transferred into reject.
catch tray 202. Reject Gate 2U6 is thereafter returned to its by-pass ~>ositi.an 225. Positioning of reject ante 206 is performed in conventional manner, for example by a sprina-loaded solenoid :ir:~ response to appropriate energizi.na signals that are, for example, supplied from main computer 50 (or from a subsystem thereof). Insert stack packages stigmatized as faulty (for example misaligned or skewed) are thusly diverted.
Another preferred embodiment of the in-line rotary inserter apparatus is shown diagrammatically in FIG.1A. The left hand portion of FIG.1A is identical to the left portion of FIG.1 (including also envelope feed station 30 and a vacuum belt transt_:~orrer/di.vert:er unit), but diff2r~ from ?6 FIG.1 in that unit 36, now designated 36A, is somewhat modified. Unit 36A r:~ow feeds (toward the right) a turnover module 40A via a d:iverter section 47A. Turnover module 40A, in turn feeds a sealine~ module 38A which is further connected to and .feeds a postage meter module 49A via a lift sate section 48A. On-edge stacki.na/diverter unit 42, fed from postage meter module 49A, i.s sns.bstantially the same as unit 42 shown in FI~.1 (and FIGS.i.J_-15) and can be further r_onnected to additv.csnal handling eauipment a6.
Diverter secta_c»~ 47A can be substantially similar to the devir_e depicted in FIG.7 and as described in conjunction therewith, a.lthoucxh other diverters can be employed instead.
Diverter section 47A serves to divert unsealed enve~lop~s either for normal operation processinCf reasons or when fa7_ilt conditions occur.
Referring now to tx~.e embodiment shown in FIG.2A (for instance also in conjunction with FIG.1A), it will be seen that the depiction is in many respects substantial=Ly identical to FIG.3, exr_ept that the vacuum belt t:ransporter/diverter unit., now designated with the numeral 36A, comprises a transverse pass 64A having a substantially horizontal surface '70A with a short fall region 74A
t:hereabove. Further in this embodiment, the envelope conveyor device, now designated with the numeral 82A, ~.ncludes an upper belt device 83A following a somewhat different belt path (than device 83 of FIG.2), anal the envelope diverter, now designated with the numeral 33A, includes a deflector and belt device 86A (and. excludes stop date 86 of FIG.2). The embodiment of FIG.2A will be described hereinafter only in regard to those aspects i differing significantly from the aspects of: FIG.2. In other respects, ref=rence should be made to foregoing detai_1 descriptions given in conjunction with FIG.2.

Vacuum belt transporter/diverter unit 36 of FIG.2 can feed other modules or subsystems as depicted, f_or instance, _~r_ FIG.1A and, simi:l.arly, vacuum belt transporter/diverter 36A of FIG.2A can feed other modules or subsystems as depicted, for instance, in FIG.1, provided suitable k:ransition means are interposed to adapt the r_espec:tivel~
sloping and horizontal envelope orientations along the envelope transfer delivery path.
Referring to FIG.2A. envelope conveyor device 82A
comprises a pair of driven endless belts disposed one above the other. Upper belt device 83A includes a generally straight lower portion in nipping contact with the upper portion of the lower belt. An upper portion of the upper belt device 83A is partially carried and driven by a pulley having substantially the same diameter as second stripper drum 78 and formincr a part thereof, as indicated in FIG.2A.
Envelopes are delivered by and upon second gripper drum 78 to the nip betweer:mpper be~.t device 83A and the ~.t>'~per portion of tr~.e lower belt, and are transported thereby toward the left -i_nto proximity of vacuum grippes drn~m 84 ~.n.
readiness for pick-up by appropriate grippers of drum 84.
According to an embodiment of the invention, an envelope diverter 33A come>r:ises a deflector and pelt device 86A and an en.velox~e r eject bin 85C. Deflector and belt device 86A of the diverter .3A is disposed in the region between envelope conveyor device 82A and vacuum grippes drum 84, and comprises a deflector 85 and an endless belt 85B
driven about a pair of pulleys. The axle of the upper pulley serves also as pivot 85A about which deflector 85 is selectively pivotable between two positions. In accordance with the apparatus and method of the present invention, deflector 85, in the position indicated, offers an upper deflector surface to envelopes delivered thereto, so that an envelope resting upon this upper deflector surface can be picked up by the next arippers of vacuum gripper drum 84.
reflector 85 is p.i.voted into the other position anticlockwise by a small angle so that the right-hand scoop-li.ke face of deflector 85 scoops and diverts therealong a delivered envelope downward:ly. The leading edge of a thusly downwardly deflected envelope will contact the right-hand side of belt 85B, and will. tae driven thereby farther downwardly until it falls into bin 85C. The envelope diverter 33A serv?s to selecti.vel.y divert envelopes (for.
instance, reject or faulty envelopes) before they can reach ~..nsertina station ~2.
FIGS.8, 8A, ara.d 8R depict detail aspects of vacuum belr_ t.ransporter/divertez- unit 3hA anc~ show a delivery end z>ortion of conveyor belt arrangement 107 for conveying from inserting station 32 envelopes filled with inserts. FIG. BA
shows additional details in the short fall region 74A of the transverse pass 64A in a partial side view similar to the view of this region ~xiven in FIG.2A. Conveyor belt arrangement 107 conveys envelopes into fall region 74A of, transverse pass 64A and deposits envelopes onto surface 70A
of vacuum belt transporter/diverter unit 36A.
In broad aspects of embodiments, vacuum belt transporter/diverLer unit 36A comprises surface 70A of a support structure for the unit, first and second parallel vacuum belts 232 <~nd 234 having a plurality of vacuum openings 236 disposed in a region therebetween in surface i'0A for in a blo~=k mounted in surface 70A), at least one Guide rail 238 and one adjustable rail 240, and a mounting bar 242 fixed on surface 70A. In more particular aspects, vacuum belt transnorter/diverter unit 36A further comprises r a pair of fall brushes 244 disposed, in the vicinit;~ of a.nd above the delivery end of conveyor belt arranctement ?07, at 1_east one ad~usta.lW..r spring-loaded pressure roll unit 246, and at least one drive pressure roll 248 spring loaded against a driven roll that is disposed beneath surface 70A.
more oarticul_ar ~~.r:~ects, vac,~um belt t_r~inspo._rte:r/diveut-N~.
unit 36A includes a monitoring photosensor 250 a.r_d a raised envelope scanner 25~, a deflector 254 inclu.dina bristles 254A disposed upon the deflector's lower su.rfacz. and brr.isb :arrangements 255 inr=luded in adjustable pressure roll unit :?46.
It should be recognized that vacuum belt t:ransporter/diverter unit 36A is substantially symmetrical about a vertical plane disposed through the middle of conveyor belt arrangement 107, although the depiction in FIG.8 shows one side partly fragmented.
In respect to further apparatus and method aspects of t:he invention, first and second vacuum belts 232 and 234 are driven endless befits having their upper surface disposed substantially slicxhtly above surface 70A, so that an envelope can be transported upon these belts. In particular, a.n envelope delivered by conveyor belt arrangement 107 onto these belts i_n the reai_on above vacuu-n openings 235 clings securely to the :belts by the action of vacuum fed v1a Vacuum openings 236 (fro.rn a vacuum soux-ce here not shown.) . A. tr~.usl.v delivered envelope is deflected downwardly by fall brushes 244 and by defle~~~tc~r 254, rind is stomped by rai7_ 240.
Bristles 254A are oriented in direction of the envzlo~e delivery movement end ::~rve tra reduce envelope bounce upon delivery. Rail 240 z~.rovid.es for registration of an envelope edge, and is repositionable by adjustable fastening means 256 to accommodate d~_f'erent~ size envelopes.
Guide rails 238, curved alon_q their leading ends, serve to Guide opposed envelope edges into definite posit.ional r registration therealong and along rail 24. Pressure roll units 246 each comprise an idler roller mounted in a sp_rincr-loaded crank device whose position is relocatable by a block 257 along an adjustm:~nt rail 25?A. Units 246 also include brushes 255 mounted thereon with bristles directed downwardly and angled to facilitate delivery of envelopes thereunder. Brushes 255 serve to push envelopes onto belts 232 and 234, particularly as envelopes ale transported by the belts toward one or the other side and away from the region of vacuum openings 236. Idler rollers of pressure roll units 246 are positioned above and spring loaded onto belt 234. Pressure roll units are adjustably relocatable t~_ accommodate different envelope sizes, so that envelopes transported .by belts 232 and 234 are engaged by the nip between the idler roll and belt 234 before they leave the influence of vacuum in the region of vacuum openings 236, and so that envelopes remain engaged in this nip at least until they are transported in the nip between drive pressu:-~' roll 248 and a driven roll therebeneath. Drive pressure ro-~..~
248 is an idler roll mounted upon a crank arm, and is spri=g loaded against the driven roll therebeneath.
A monitoring photosensor 250 is shown in surface 70A c.1 the left side of drive pressure roll 248 for purposes of sensing and monitoring envelopes being delivered to farther equipment. Sensor 250 facilitates supervisory and control functions of multiple subunit arrangements, for instance, via computer 50.
In respect to further more particular aspects of embodiments of an apparatus of the invention and a method cr operating the apparatus, FIG. BB shows details of a raised envelope scanner 252 (also indicated in FIG.8). Raised envelope scanner 252 comprises a beam emitter 258 generati~.g a light beam 258A and includes a beam pick-up 259 arranged in line therewith. Emitter 258 emits beam 258A angled across a corner formed between surface 70A and guide rails 238 through slots 260 (in rail 238) and 260A (in surface 70A).
Beam 258 is intercepted by an envelope transported through vacuum belt transporter/diverter unit 36A, provided the envelope is c~arreevtl.y reaiste:r_ed between rails 238 and 240 and provided that it_s inserts are properly fully inserted.
Thi s is indicated by envel ope 261 ( in dashed 1i nes 1 ha-..%~_ncr flan 262A raised. Tf inserts are, for instance, incompJ_et~~v inserted and pro d°ude past the flap hinge edge, the en«etanc flap is stiffened s.n a mare horizontal_ orientation.
Cansequently, sucra an envelape is not disposed upon surface 70A in the vicinity of guide :rail 238 subsequently to its delivery to and di.iring transport by vacuum belt transporter/divert:er unit 36A, and it will not be scanned.
while passing by raised envelape scanner 252. Such an envelope may ride with its stuffened flap upon rail 238.
Other faulty envelopes, such as for example having damaged, bulged, improperly folded or other insert faults can also result in absence of a interception by scanner 252. Thus scanner 252 serves to detect such malfunctions.
In operation of vacuum belt transporter/diverter unit 36A, an insert-filled wnvelapE:e is de1_ivered with flap-edge trailing by conveyor belt arrangement 107 onto vacuum belts 232 ar_d 234. Vac~.mm is fed to the bottom of the enveloae via vacuum openings 2~6 to pull the envelope onto the belts, and the envelope is transported an and by the belts either to the right or to tYae left, depending on the direction of belt.
moti on. The envelope is further transported. to t1_,_e side of the unit and to farther equipment th_rouqh a nin between drive pressure ral7 248 and a driven roller therebenNath. A
reversing qearincr and cl~.atch arrangement can be provided to reverse the drive t:o vacuum belts 232 and 2.34 and to thusly facilitate selective quick change over and diversion of envelopes to the right or the left. For example, as indicated in FIG.IA, vacuum belt transporter/diverter unit 36A can deliver insert-filled envelopes via a reject d:iverter section 47A to a turnover module 40A and farther to a sealing module 38.~~.

Referring now to FIGS.9 and 9A, key aspects of turnover module 40A depir_ted therein comprise a module frame and housing 262, idler' pulleys :?6~!,, 264, and 265, and a dr?Ven pulley 266. A11 l=our pulleys are disposed substantially in.
the same plane and are rotatably borne. Pulleys 265 and 266 have their centers dJ_sposed in fixed positions with respect to housing 262. In a particular embodiment, pulleys 263 and 264 revolve about horizontal axles which are spring-loaded downwardly. These axles can move by a small distance substantially vertically between stops in the spring-loaded range. One stop is set to provide a fixed smallest e~ap between upper and lower pulleys. The other stop is adjustable to provide a maximum gap between upper and lower pulleys. For instance, axles of pulleys 263 and 264 are first axles of aporoximatelv ~~orizontally oriented sprina-loaded cranks whose second axles are rotata_.r:,ly borne ir_~
module frame and housing 262. The angle of spring-loadeo.
crank rotation is limited by and between the two stops.
An endless flat belt 267 is carried in figure-ei~xht form by the four pulleys in such a way that. the mutuaJ_ly contacting cross-over belt portions form a one hundred and eighty degree twist about one another in the stratch between the left pulleys (263, 2661 and the right pulleys (264, 265). In a particular embodiment of the invention, endless flat belt 267 is ;produced by twisting a~straiaht flat belt by seven hundred and twenty degrees and by joining the ends to one another. As carried upon the four pulleys, mutually contacting cross-over belt portions twist in clockwise direction about one: another to provide clockwise turnover of envelopes, as indicated in FIG.9A by arrow 268, when envelopes are tran~,)~>orted from right to left through turnover module a0f,. In illustration of the method of onaratinq the tuarnover module, a typical enterinct envelope 269 is shown in phantom lines being delta eyed to the nip of the cross-over belt portions. A typical caressing envelope 269' is shown in ~~hantom limes being delivered from the nip of the cross-over belt port:i.ons, having been turned from a f ~ ao-up to a flau--down ori.entat:ion .
The fixed smallest crap between upper and lowe.r_ pulleys is set to facilitate nipping ~!nd t.rar?.sport passage betwaPn the belt portions o_r a thinr~e~:t anvelope to br handled. The other stop is adjL~sted to a gap between upper and lower o~_illeys to facilitate n:i.pnir~.a and transport passage between t:he belt rortions of r_rze r_h~ckest envelope to be handled.
Referring noun to FIGS 10 and 10A, features of sealing module 38A shown th.e~~ein comprise a first belt conveyor 270 and a second belt: conveyor 27a; upon which envelopes are conveyed, a flap rnoisteninu section 274, a flap sealincr section 276, and a frame st.r.ucture 278 on which the various components are mounted. A typical envelope 280 is shown (in phantom lines) as it is delivered from turnover module a0A
to flap moistening section 279. Envelope 280 is oriented substantially in a horizontal plane having its still open, flap oriented substantially vertically and pointing do~ar!.ward ly .
Broadly, flap moisr_eninq section 274 comprises a spray nozzle 282 for issuing of a water spray onto the inner surface of flaps of envelopes that interce~at the spray cahi. ~_e being conveyed through flan moistening sect~_an 274. The spray is particularly directed at the Gummed portion ~:~f envelope flaps, and is provided preferably in form o.f a fan pattern that has a w?11-defined fan angle and pattern thickness extent in order to reduce moistening of other than f:Lap surfaces of ~n envelopE. In a particular embodiment.
i the fan pattern is preferably oriented in a Qenerally lateral and vertical plane, but can be alternately oriented in other generally lateral planes. For example, suitable spray nozzles can. b~~ of a conventional. shear type having a slit exit and providing high liquid shear forces to break u.
flow into droplet spray. In a particular alternate embodiment, spray nozzles are advantageously of a fluidic oscillator type which break up flow into~relatively well-defined droplet spray patterns. An appropriate nozzle of try latter type :is described, for instance in U.S.Patent 4,184,636.
First belt conveyor 270 comprises a driven endless be~'~
arrangement having an upper belt surface 284 oriented substantially horizontally for conveying of envelopes through sealing module 38A. Disposed at least in the regior_ of flap moistenin<~ section 274, a plurality of pressure rolls 286 is spring loaded onto upper belt surface 284 to form a nip for nipping and thereby more securely conveying envelopes through sealing module 38A. Second belt conveyor 272, commonly driven with first belt conveyor at the same speed, is provided with pressure rolls 290 for exerting of pressure onto a moistened and folded closed flap of an envelope whilst the envelope is conveyed under rol7_s 290 on top of belt conveyor 272.
A closing guide 292 is disposed in a region that lead:
into flap sealing section 276. Guide 292 serves to intercep;~
moistened envelope' flaps and to bend the flaps upwardly into substantially closed orientation, so that the flap can be sealed subsequently by compression action between second belt 272 and pressure rolls 286, as an envelope is conveyed through flap sealing section 276. As indicated in FIGS.10 and 10A, guide 292 has a compound shape, being curved both downwardly and laterally in direction toward an incoming envelope, and is disposed entirely beneath the horizontal envelope conveying plane (given by the upper surface of second conveyor belt 272). Gu.~de 292 intercepts and slides along the outer surface of an envelope flap fed thereto, while gradually pushing the flap into its closed position.
In a method c~f operation of sealing module 38A, envelopes are fed thereto ser~.atim in the orientation and position shown by typical env~:lope 280. As an envelope is conveyed by first belt 27Cj ttoward the left) past spray nozzle 282, its flap is moistened over its gummed region by spray from r_his noz.zl. and, wriile the Envelope is conveyed farther to the 1~=ft into the rip between ser_ond. belt 272 ancL
r~ressare rolls 2~C, the flap is r_1_osed by closing guide 29a.
Thereafter, roils 290 ;_n combination with belt 272 seal the flap while the ewve~_ope is conveyed to the left hand side of the sealing modu7_e anti deli vered therefrom too farther equipment. A phot:osensor 294 can be provided to detect ingress of an envelope in order to actuate a solenoid va.~ve to feed water to nozzle 282 during passage of the e:nveJ_o~~~e, so that water is sprayed. only when a flap requires moistening. Alternately, spraying r_an be continuous while a continuous stream of seratim envelopes is conveyed.
It should be recognized that the generally vertical orientation of the downwardly pointed envelope flap during the spray moistening operation is particularly advantageous.
For all practical. purposes, this orientation avoids wetting of the envelope body and of inserts contained therein.
Moreover, spray droplets that miss a flap or that bounce off or flow down on the flap cannot wet the envelope. The latter droplets are collected in a here not specifically shown tray wuth appropriate wall shields a.nd are drained away. It should be .further :recognized. that nozzle 282 land its ope-rating pressure) is preferably chosen to provide a sorav with droplet sizes above those which could. form a significant pro.porr_ion of floating mist in order to minimize moistening of mach:i.ze parts. Consequently, preferable droplet sizes are cruosen to be above approximately 100 microns, and are pry=ferably substantially in a range ab~~m about 200 microns a~~d a.arcrer .
Sealed enve:Lopes are delivered by seal3_na module 38A, for instance, to a lift c~a.t~ section 48A that Zs indicated in FIG.1A. Lift gate section 48A is prov~_dec~. for oassinc.-r sealed envelopes delive~~e~~ thereto onward to postage meter module 49A (FIG.IA). Lift r~rate section 48A includes a transport conveyor mechanism of conventiona7_ kind and is arranged to facilitate lifting and tilting of its structure out of the way to pF~rmi.t , for instance , a machine o~oerator to pass from one to the other side of the equipment when operation i.s interrupted. Envelopes delivered by lift gate 48A are processed :in postage rr~eter module 49A and are delivered therefrom to on-edge stackingldiverter unit 42.
Postage meter module 49A is a conventional apparatus as customarily employed in mass-processing of mailable articles, and will not be further described herein.
Referring now to FIGS.11- _15, on-edge stackina/divert~r unit 42 is depicted therein. FIGS.1?, 12, and 14 include f_raa?~nental depicti,~ns of turnover module 40 (for instance, as indicated in FIG.?_> which delivers envelopes to on-edge sta.cking/diverter v.m.~:~~t 42. It shoti.l_d J:~e understood l:hat, in aJ.ternate embodime~nt:s of the invent~.on, turnover module 40 can be replaced by c>t_.her system modmles that can deliver envelopes to unit 42. In particular also, this _refer.-enre t.r~
module 40 is inte:n<af::,c~ to alternately also refer to x~ost.ar_r~, meter module 49A, for instance in an arrangement as indicated in FIG.1A.
In broadest aspects of an embodiment of the apparatus and the method of the invention, on-edge stacking/diverter unit 42 comprises a diverter section 350 to selectively pass on or divert envelc>x>es, a stacker section 352 for stacking of diverted envelopes and including a stacking spider 353, and accumulator 44 for_ accumulating stacked envelopes.

'7 In more particular aspects of an embodiment, refer_rzna nnw to FIGS.1:L and 1.?, diverter section 350 comprises a base structure 354 (common also ~~rith stack_er section 352), an upper level 356 for receiving, diverting, and passing on of envelopes delivered thereto, and a lower level 358 to which envelopes are diverted for stacking.
Upper level 356 comprises a plurality of conventional pressure rollers 350 that provide pressure onto envelopes a,:rainst a dr_ ive roll. 363 and a dr°iv~= belt 364 which thuslv convey env?)_opes u~ao~, upper J.evel (to the right) . Fu.rthe~~
comprised in the f'_oor of ubT~er level 356 is a selectively ox>erable hinged divert gate 36H that is shown. in its closed x)OSltl.On flush with the floor of upper level 356 and whose open position is i~zdicatzd. by dashed lines, Additiona7_~..v, tree floor of upper :Level 356 comprises a ph.otosensor 368 for sensing of envelopes leaving toward the right side to subsequent envelop~:~ laandlincr equir~ment, a rear wall 370 and an adjustable aligner° 372; the latter two serving for al.ianment of envelopes therebetween, being adjustable to different envelope widths. Aliqner 372 is provided with a partial cutout above divert gate 366 to permit openinct of tyre latter. Above the floor of lower level 358, in the vicinity of the hincte of gate 366, is disposed a guide strip 373 to guide downwardly diverted envelopes onto the floor.
Guide strip 373 is,. for example, of Teflon or other low-friction material to promote downwardly sliding deflection of envelopes along ~.ts lower surface.
Lower level 35%~ comprises selectably operable adjustable length-stot~s 374 and 376 that are Ganged toaeth.rr for commoncpositionai shifts along rear wall 370 to provide selectable envelope offset in stackinct. Further, lower level..
358 comprises an ad~i_~.stabl a aligner 372' thar_ is cta_n_~xed with aligner 372. Alicfner 372' is spaced from the floor of loWe1 level 358 to form an opening adeguate to clear envelopes propelled therethroucth. Further comprised in and beneath the .fl_oor of 1 over level 358 i.s a photosensor 378 for detect; on of envelopes diverted thereupon, a pair or rotatable na,d.~31_es 380 mounted ubor.~ a ~.:orr.~.mon shaft that is borne beneath. t'-m>
floor of lower level 358, and an upper and a lower pair rotating nip rolJ.,s 382 and 38a, respectively, each pai?°
being borne upon a separate shaft. One of r_he pair of n3.p rolls is motor-driven, so that a nipped envelope is transported toward stacking spider 353.
A curved arm =385 of resilient flat spring material a_s freely pivotably disposed in the envelope path between nip rolls 382,384 and st~ackincx spider 353, as indicated in FIGS.13 and 14, so that an envelope propelled along this ~>ath is restrained from bouncing (and possibly misalianing) once it has left the nip of the rolls. Arm 385 is secured to a. pivotable mount 386. Mount 386 is mounted within the structure of the lower level 358. Arm 385 is held in the position shown by its weicxht and allows an envelope to pass slidinaly thereunder.
Paddles 380 are= selectively commonly rotatable~ in increments of x.00 decrraes with respect to the posi t:i_on shc_~wn in FIG.13 by a motor via a conventional solenoid-actuataks7_e one-half revolut:ic>n cJ_utcr~ in response to appropri.a.te control signals. ~Ihen .rotated, ends of paddles 380 protrude and move through apor_opriate clearance slots in floor of lower level 358 so that their motion propels an envelope disposed thereupon. into the nip between rolls 382 a.nd 384.
For example, an envelope 388 ishown in phantom lines in FIG.11) falls frorra. upper level 356 to lower level 358, having been diverted by gate 366. This envelope is then indicated as envelope :388' (in FIG.13) subseguent to its diversion and disposed upon the floor of level 358. A
subsequent selective operation of paddles 380 (clockwise) propels envelope 388' to the right.

.~ 9 Referring noaa als<s to FItTS . 1 ~ anc~ 14 , in fur_ they r~articular aspects c:>f the invention, stacker section 352 comprises a horiz~~ntally slidsbly adjustable table 390 that is partially bornF, ~..n and upon base structure 354 in a telescoping manner, and stacking spider 353 which is borne in table 390 and which is .motor-driven via a selectively enerqizable clutch ir~ clockwise direction. Spider 353 includes a timing disc revolving commonly therewith and a photosensor sensinct the position of the disc (not shown here). As will be described hereinafter in more detail, stackin~x snider 3'i3 is borne in table 390 i_n_ floating manner, beincr fret:- to move foal a short distance in a substantially hor.3_zontal mlana away from accumulator 4a, Sr_ack_ina snider 3~~~ is sx,_rina--loaded toward accumulator 44.
'fable 390 included> an. u.nr~er s?.ir.face 392 and a stacking surface 394. Ur~pei° surface 39'? is disposed at subs t.antiall v the same level as or slightly lower than the surface of the floor of lower level 358. Stacking surface 394 is disposed at a lower level than upper surface 392 and adjoins, a downwardly curved extension thereof.
Stacking spider 353 further comprises a pair of parallel spider wheels 395 anc~ 396' commonly mounted and driven by a shaft 398. Spider wheels are identical in shape, having disposed about their peripheries a plurality of equally spaced spider leas 400 of generally sawtoot:h-like shape in a trailincr orientation in respect to their normal clockwise direction of rotation. Spaces between spider legs 400 are such th at a st,.offed envelope can easily be disposed therein, as i.ndi~~r~ted for example by envelope 402. Spacing between spider wha=e~_s 396 and 396' is somewhat less than the lenctth of thE> sr,ort:est envelor,e that is rea,_iired to be handled by the eauir,ment. Slidable adjustment of table 390 is provided for ad.a,r~tation of the equipment to different size envelopes , iTr ~,artic,.zlar to different widths and. i fi _s , therefore, ganged to the adjustment of aligners 372 and 372', as indicated by dotted lines of gang connection 404 (FIG.13).
Accumulator 44 is substantially a conventional stack accumulator device that is customarily used to accumulate flit articles, such as documents, envelopes, and the like side-on-side in vertical orientatic:_.
Accumulator 44 is borne on table 390 and comprises a powered conveyor belt arrangement 406 having its upper surface disposed slightly above stacking surface 394. It comprises a back plate arrangement 408 that includes an L-shaped back plate 910 having permanent magnets 412 attached to its bottom surface for repositionable attachment seating upon the upper surface of the belt of belt arrangement 406. Back plate 410, in the manner of a "magnetic bookend", can be removed and replacef' for instance for removal of an envelope stack. Alternately, other back plate arrangements of conventional type can be used, as for instance a back plate slideably (with relatively high friction) and hingeably bor:-e upon a rod suspended on a side above an accumulating stack (above belt arrangement 406). The latter arrangement allows upward.hinging of the back plate about the rod for removal of stack 414. Powered conveyor be'_t arrangement 406 facilitates orderly accumulation of a stack by incrementally moving on-edge stacked envelopes in unison in response t~-increasing stack thickness detected by a photosensor. This photosensor detects horizontal movement of stacking spider 353 Clue to increase of stack thickness.
When only short stacks of envelopes are to be handled :in accumulator 44, conveyor belt arrangement 406 need not be powered, but can be free-running. In this case, sensing of stack accumulation is no':
needed and stacking spider 353 need not be arranged in the indicated floating manner, Envelope stack 414 has an offset portion 416 disposed therein to illustrate the result of the hereinabove described selectable envelope offset capability comprised in lower level 358. For instance, to distinguish a particular set of diverted envelopes (for example by specific zip codes), the indicated offset capability is provided so th~~t offset portion 4J.4 may be recognized and selectively handled subseauentlv to ~..ts a.ccurnuaat:ion.
Referring now to FIG.15, further particular aspects of an embodiment of the apparatus and method of the invention are shown. Stacking spider 353 is suspended in a floating manner as it is borne in table 390, and is provided by a floating drive suspension arrangement 500. Spider wheels 396 are borne on and revolved by shaft 398. Arranctement 500 serves to drive and suspend shaft 398 so that stacking spider 353 is free to move for a short distance in a substantially horizontal direction toward t:he left and away from stacking surface 394 (toward which it is spring loaded).
Arrangement 500 comprises a worm reducer gearbox 502.
The output of Gearbox 502 i.s provided via shaft 398. Gearbox 502, driven by an input shaft 504, is supported via rocker arm means 506 whose one end is securely mounted within table 390. Additionally, Gearbox 502 is sunlao-rted in spring-loaded rnanner by sp:rinci ?oadzn.a means 508. Means 508 comnri.ses a guide rod 600 that is secured, at one end t?~ereof, to a post E>02. Post 602 is rigidly affixed to table 390. The free end of rod 600 extends through a clearance hole in a bracket 504 that is rigidly attached to or is a part of the housing of gearbox 502. A compression spring 606 is threaded cover guide rod 600 and, in pre-compressed manner, extends between post 602 and bracket 604 and thusly forces gearbox 502 toward the right. A mechanica_L. stop in form of a stop collar 607 limits the possible travel distance of gearbox 502 toward the right. Stop collar 607 is secured to the free end of rod 600 and contacts bracket 604 at the limit of floating travel of gearbox 502.
Input shaft 504 is coupled via a pin coupling 608 to drive axle 7U0. Axle 700 extends through and is borne by post 602 in an appropriate bearing therein. A drive pulley 702, that is attached to the end of axle 700, is driven via a belt (not shown here) by a drive mechanism. Pin coupling 608 couples the rotation of axle 700 to input shaft 504, while permitting axial. displacement (as we:l1 as a small amount of angular misalignment) therebetween.
It will. be understood that rocker arm means 506 comprises at least two parallel rocker arms or a unitary rocker arm having adequate bearing lengths and rigidity to r~rovide the required supbort for gearbox 502. This support must avoid substantia=_ ancxular and axial displacement ~f shaft 398; in other words, sk_ewina and rocking motions of s~ai der wheel s 396 must. be avoided.
With reference to FIGS.11 through 15, in operation of on-?dge stackincr/divex-t~er unit 42, envelopes are seriatim delivered thereto in horizontal orientation and in aliar.~ment ubstantially along rear wall 370 upon the floor of upper level 356. If divert gate 366 is in its closed position, envelopes are conveyed toward the right for delivery to farther equipment. If divert gate has been opened, for instance by a solenoid, an envelope is diverted to lower level 358, as indicated by envelope 388. Guide strip 373 <aids in the proper diversion. Envelope 388 falls onto the floor of lower level 358, as indicated by envelope 388' (FIG.13), in they region between length-stops 374 and 376 and between rear wall 370 and aligner 372'.
Subsequently actuated clockwise rotation of paddles 380 propels envelope 388' toward and into the nip between rolls 382,384 and, thereby, into a spare between spider legs 400.
C~nce an envelope has settled in spider wheels 396 and. is carried in~.tially upwardly thereby, arm 385 pivots upwardly, being lifted by the envelope disposed thereunder, slides along and out of t=he way of the envelope, and thereafter pivot back by gravity. Moreover, the action of arm 385 ensures that a delivered envelope does not bounce or otherwise move out f_.rom its proper location between spidFr leas 400 dur_i.na t.h~ ~_ni.tial. Lpward movement..
Appropriate timings- of actuation of paddles 380 to assure that an env._lope is propelled into a space between legs 400 is obtained by the action of the timina-disc and nhotosensor arrancxernsnt of stacking spider 353. Er_ercri zatio~~
of the clutch to paddles 380 is inhibited at such times when a propelled envelops would impinge upon a spider lea 400.
Spider wheel:5 396,396' carry envelopes to stacking surface 394 and deposit them edge-on. Additionally, trailing edges and tips of spider legs continue to push deposited envelopes side-on°-side onto the accumulating envelope stack 414.
Referring now also particularly to FIG.15, in response to increasing stack pressure, spider wheels 396 move back resiliently (to tine left) by the action of the floating drive suspension arrangement 500, allowing stack 41.4 to increase in thickness. A ohotosensor 706 secured to the floating body of gearbox 502 is partially obstructed by a~
stationary flag 708. The driva of conveyor belt arrangement 406 is energized i.n response to sensing of flag 708 by photosensor 706, a.nd belt arrangement 406 incrementa7.ly moves the accumulated stack 41.4 toward the right. Consenuent stack pressure relief allows spider wheels 396 to follow.
When flag 708 is no longer detected by photosensor 706, the drive of belt arrancrement 406 is deenergized. As a result.
stack pressure is maintained within appropriate limits and orderly stacking is provided, regardless of the thickness of a:n accumulating stack.
In c~e~eral, various photosensors provide signals for tracking of handled envelopes and inserts throughout the apparatus assembly. Interdependent control of various actuations under sut~ervision of main computer 50 (and subsidiary controJ.s and microprocessors) is provided t:hrouahout the in-line rotary inserter device of the invention. The va:r:ic>us sensors particularly also facilitate asynchronous operation in further handling of envelopes that have had inserts inserted therein. Whereas synchronous operation may be utilized, asynchronous handling capability is preferred in view of the advantages offered. It will be understood in this respect that transporting of inserts and envelopes to inserting station 32 is a substantially synchronous operal~ion to the extent that appropriate timing of arrival of mutually associated envelopes and inserts at i.nsertinq station 3~ is essential.
Referring now again to FIGS.1 an~~ 1A, main compute-r 50 is interconnected with subsystems and subunits, also including power s~.yplies, drive motors, pumps and blowers, sensors, detectors, actuators, display stations, control stations, and other electrically operated and electrical sictnal-generating components either directly of via subsidiary or intermediate control and supervisory units_ The latter can include mi<~roprocessors to automatically control and supervs.se the operation of individual units in preprogrammed manner under the overall control of computer 50. For example, sensing of malfunctions, damaged, defective or misaligned items, and consequent diversion and rejection thereof, as well as compensation therefor in subsequent operation, is automatically handled by main computer 50 in preprogrammed manner, as the computer tracks inserts and envelopes individually sequentially and associatively with their associated complementary counterparts.
Moreover, main computer 50 provides auxiliary system control functions, such as, for example, automatic start-un (and shut-down) sequencing of power and particularly of motor power supplies for redu<:ina power surges and consumption (and noise:e. In this respect, computer 50 controls selective powering-up of a z~lurality of rumps fc,r air, vacuum, and water in appropriate sections in accordance ~Tith particular momentary demand, and computer 50 further controls automatic cyclinu of pumps, selective shut-down o' motors consequent to t~_med ina.ctivZties, shut-down of rnalfunctionina subsystems, and the like. Individual malfunction disx>)_s.y and reset. control stat~_ons for individual inserter modules and other subsystems are located :in the vicinity of corresponding units and are :interconnected with computer 50. Whereas central overriding control by computer 50 is provided through displaylcontroi console 52, individual local malfunction display and reset stations are provided i.n appropriately interlocked manner for local operator convenience, to localize malfunctions, wand to direct and assure local attention by operators in case of malfunctions.
In brief recapitulation of the general. overall operation of the in-line rotary inserter device, inserts are fed from a plurality of inserter modules onto a moving pin conveyor whereupon one or more inserts are accumul<3ted in insert stack packages that are conveyed. to an inserting station. Envelopes are fed to the inserting stat~_on, are inserted therein. w~.th insert stack packages, and are transported farther through sealing and turnover modules.
Sealed and turned--over envelopes are stacked. in at 1_east one accumulator. Prior to being stacked, sealed and turned-r>ve.r envelopes can be <:~orxveyed through a postage meter rnod.ul_r foz~
appropriate meterincx (franking).
While the invention has been particularly shown anc.1 described with reference to preferred embodiments thereof, it will be, understood by those skilled in the art that various chancres arid modifications in form and details may be made therein withaut departing from the spirit and scope of the invention.

Claims (6)

CLAIMS:

1. A rotary feeder module for feeding sheet inserts and having a thickness detector for measuring the thickness of moving inserts, comprising:
a gripper drum disc for transporting said inserts thereupon, said gripper drum disc having an axis of rotation and a periphery;
a detector caliper assembly including an arm having a first and a second end, said arm having at said first end a follower roller and at said second end a magnet, said arm being pivotally mounted and spring-loaded so that said follower roller spring-loadedly rides upon and along said periphery and upon moving inserts transported upon said periphery of said gripper drum disc; and means for sensing the field of said magnet, said means for sensing including a stationary Hall sensor to provide a measure of relative displacement between said sensor and said magnet and thereby a measure of the radius of said periphery from said axis of rotation;
wherein said means for sensing provides reference signals corresponding to zero thickness of said inserts in the absence of inserts upon said gripper drum disc, said means for sensing providing thickness signals corresponding to the thickness of said inserts in reference to said reference signals when said inserts are transported upon said gripper drum disc interposed between said follower roller and said periphery.

2. The rotary feeder module according to claim 1, wherein said gripper drum disc includes an anvil adjustably mounted upon a face thereof, said anvil having a peripheral surface that is adjusted to a constant radial distance from said axis of rotation.

3. The rotary feeder module according to claim 1, wherein said means for sensing includes:
means for storing reference signals provided by said Hall sensor in absence of inserts upon said gripper drum disc;
means for comparing stored reference signals with presence signals obtained in presence of inserts upon said gripper drum disc; and means for providing difference signals between the reference and the presence signals to provide an accurate measure of the thickness of inserts transported upon said periphery regardless of eccentricity thereof about said axis of rotation.

4. A method of dispensing inserts by a rotary insert feeder module including detecting thickness of moving inserts and, comprising the steps of:
revolving a gripper drum disc about an axis, said gripper drum disc having a periphery;
rolling a follower roller upon said periphery, said follower roller being comprised of a follower roller assembly that includes a pivotable arm, said follower roller being disposed at a first end of said pivotable arm and being spring loaded toward said periphery, said pivotable arm having a magnet disposed at a second end of said pivotable arm;
sensing position of said magnet with respect to and by a stationary Hall sensor;
transporting inserts upon said periphery and interposing and spring-loadedly nipping the moving inserts between said periphery and said follower roller; and providing signals corresponding to insert thickness as a measure of the displacement of said magnet while said step of transporting inserts is being effected.

5. The method according to claim 4, wherein said gripper drum disc includes an anvil adjustably mounted on a face thereof, said anvil having a peripheral surface, the method including pre-adjusting said anvil so that said peripheral surface is disposed at a constant radial distance from said axis.

6. The method according to claim 4, wherein the step of sensing includes:
storing reference signals provided by said Hall sensor in the absence of inserts upon said peripheral, comparing stored reference signals with presence signals obtained in the presence of inserts upon said of periphery; and providing difference signals between the reference and the presence signals as a measure of the thickness of inserts during the step of transporting inserts upon said periphery regardless of eccentricity thereof about said axis.