EP1521218A2 - Procédé et système pour l'affranchissement numérique rapide - Google Patents

Procédé et système pour l'affranchissement numérique rapide Download PDF

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Publication number
EP1521218A2
EP1521218A2 EP04023374A EP04023374A EP1521218A2 EP 1521218 A2 EP1521218 A2 EP 1521218A2 EP 04023374 A EP04023374 A EP 04023374A EP 04023374 A EP04023374 A EP 04023374A EP 1521218 A2 EP1521218 A2 EP 1521218A2
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EP
European Patent Office
Prior art keywords
print
transport
upstream
downstream
printing
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP04023374A
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German (de)
English (en)
Other versions
EP1521218A3 (fr
EP1521218B1 (fr
Inventor
John W. Sussmeier
Richard F. Stengli
Jerry Leitz
John P. Miller
Anthony E. Yap
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Pitney Bowes Inc
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Pitney Bowes Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US10/675,403 external-priority patent/US6893175B2/en
Priority claimed from US10/675,362 external-priority patent/US6988842B2/en
Application filed by Pitney Bowes Inc filed Critical Pitney Bowes Inc
Publication of EP1521218A2 publication Critical patent/EP1521218A2/fr
Publication of EP1521218A3 publication Critical patent/EP1521218A3/fr
Application granted granted Critical
Publication of EP1521218B1 publication Critical patent/EP1521218B1/fr
Active legal-status Critical Current
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Classifications

    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
    • G07B17/00—Franking apparatus
    • G07B17/00459—Details relating to mailpieces in a franking system
    • G07B17/00508—Printing or attaching on mailpieces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H29/00—Delivering or advancing articles from machines; Advancing articles to or into piles
    • B65H29/12—Delivering or advancing articles from machines; Advancing articles to or into piles by means of the nip between two, or between two sets of, moving tapes or bands or rollers
    • B65H29/125—Delivering or advancing articles from machines; Advancing articles to or into piles by means of the nip between two, or between two sets of, moving tapes or bands or rollers between two sets of rollers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H5/00—Feeding articles separated from piles; Feeding articles to machines
    • B65H5/06—Feeding articles separated from piles; Feeding articles to machines by rollers or balls, e.g. between rollers
    • B65H5/062—Feeding articles separated from piles; Feeding articles to machines by rollers or balls, e.g. between rollers between rollers or balls
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
    • G07B17/00—Franking apparatus
    • G07B17/00459—Details relating to mailpieces in a franking system
    • G07B17/00467—Transporting mailpieces
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
    • G07B17/00—Franking apparatus
    • G07B17/00185—Details internally of apparatus in a franking system, e.g. franking machine at customer or apparatus at post office
    • G07B17/00314—Communication within apparatus, personal computer [PC] system, or server, e.g. between printhead and central unit in a franking machine
    • G07B2017/00322—Communication between components/modules/parts, e.g. printer, printhead, keyboard, conveyor or central unit
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
    • G07B17/00—Franking apparatus
    • G07B17/00459—Details relating to mailpieces in a franking system
    • G07B17/00508—Printing or attaching on mailpieces
    • G07B2017/00516—Details of printing apparatus
    • G07B2017/00524—Printheads
    • G07B2017/00532—Inkjet
    • G—PHYSICS
    • G07—CHECKING-DEVICES
    • G07B—TICKET-ISSUING APPARATUS; FARE-REGISTERING APPARATUS; FRANKING APPARATUS
    • G07B17/00—Franking apparatus
    • G07B17/00459—Details relating to mailpieces in a franking system
    • G07B17/00508—Printing or attaching on mailpieces
    • G07B2017/00516—Details of printing apparatus
    • G07B2017/00556—Ensuring quality of print
    • G07B2017/00564—Ensuring correct position of print on mailpiece

Definitions

  • the present invention rotates to a module for printing postage value, or other information, on an envelope in a high speed mail processing and inserting system.
  • a digital print mechanism is used at high speeds to create the postal indicia for the envelopes.
  • the motion of the envelope is controlled to allow continuous high speed envelope throughput, even if the postage printing device operates at a lower velocity than other parts of the system.
  • inserter systems such as those applicable for use with the present invention, are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mailings where the contents of each mail item are directed to a particular addressee. Also, other organizations, such as direct mailers, use inserts for producing a large volume of generic mailings where the contents of each mail item are substantially identical for each addressee. Examples of such inserter systems are the 8 series, 9 series, and APSTM inserter systems available from Pitney Bowes Inc. of Stamford Connecticut, USA.
  • the typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (other sheets, enclosures, and envelopes) enter the inserter system as inputs. Then, a plurality of different modules or workstations in the inserter system work cooperatively to process the sheets until a finished mail piece is produced. The exact configuration of each inserter system depends upon the needs of each particular customer or installation.
  • inserter systems prepare mail pieces by gathering collations of documents on a conveyor. The collations are then transported on the conveyor to an insertion station where they are automatically stuffed into envelopes. After being stuffed with the collations, the envelopes are removed from the insertion station for further processing. Such further processing may include automated closing and sealing the envelope flap, weighing the envelope, applying postage to the envelope, and finally sorting and stacking the envelopes.
  • a typical postage meter used with a conventional high speed mail processing system has a mechanical print head that imprints postage indicia on envelopes being processed.
  • Such conventional postage metering technology is available on Pitney Bowes R150 and R156 mailing machines using model 6500 meters.
  • the mechanical print head is typically comprised of a rotary drum that impresses an ink image on envelopes traveling underneath.
  • throughput speed for meters is limited by considerations such as the meter's ability to calculate postage and update postage meter registers, and the speed at which ink can be applied to the envelopes. In most cases, solutions using mechanical print head technology have been found adequate for providing the desired throughput of approximately five envelopes per second.
  • Another problem is that many existing mechanical print head machines are configured such that once an envelope is in the mailing machine, it is committed to be printed and translated to a downstream module, regardless of downstream conditions. As a result, if there is a paper jam downstream, the existing mailing machine component could cause even more collateral damage to envelopes within the mailing machine. At such high rates, jams and resultant damage may be more severe than at lower speeds. Accordingly, improved control and lowered printing speed, while maintaining high throughput rate in a mechanical print head mailing machine could provide additional advantages.
  • Controlling throughput through the metering portion of a mail producing system is also a significant concern when using non-mechanical print heads.
  • Many current mailing machines use digital printing technology to print postal indicia on envelopes.
  • One form of digital printing that is commonly used for postage metering is thermal inkjet technology.
  • Thermal inkjet technology has been found to be an effective method for generating images at 300 dpi on material translating up to 50 inches per second (ips) and 200 dpi at 80 ips.
  • ips inches per second
  • thermal inkjet technology is recognized as useful, it is difficult to apply to high speed mail production systems that operate on mail pieces that are typically traveling in the range of up to 100 ips in such systems.
  • Ink jet digital print technology is now capable of printing a desired 200 dpi resolution on paper traveling at 80 ips., but has not yet been incorporated in the metering portions of high speed mail production systems.
  • Maintenance may include a "print head wipe” that occurs approximately every 500 prints, and has a duration of approximately 3 seconds.
  • Maintenance also may include a "print head purge” that occurs after approximately every 3000 prints, and has a duration of approximately 14 seconds.
  • the wipe and purge activities would occur every 100 seconds and ten minutes respectively.
  • ScitexTM ink jet printers can run continuously, with no significant interruption. However, such continuous printers can be prohibitively expensive, and it is preferred that less expensive drop-on-demand ink jet print head technology can be used.
  • a routine is Initiated within the postage meter. Once the envelope is committed within the postage meter unit, this routine is carried out without regard to conditions outside the postage meter. The routine decelerates the envelope to a printing velocity. Then, the mechanical print head of the postage meters imprints an indicia on the envelope. After the indicia is printed, the envelope is accelerated back to close to the system velocity, and the envelope is transported out of the meter,
  • envelopes are transported along transport path 100.
  • first serial mechanical mailing machine 101 the first envelope is decelerated for a printing operation by postage meter 104. After printing is complete, the first envelope is carried away from the first serial machine 101 via transport 102 to the second serial mechanical mailing machine 103 .
  • the first envelope is typically decelerated to the print velocity. However, since an indicia has already been printed on the first envelope, no printing operation is performed by the second postage meter 105. The first envelope is then accelerated back to the system velocity and carried out of the serial postage printing arrangement,
  • the motion control of deceleration and acceleration at the second postage meter 105 without performing a print operation is done in order to maintain the displacements of consecutive envelopes in the system. Failure to subject subsequent envelopes to the same displacements may result in one envelope catching up to the other and causing a jam.
  • a second envelope arrives at the first mailing machine 101.
  • the second envelope is subjected to the deceleration and acceleration motion profile.
  • the first postage meter 104 may not have had time to reset to print another indicia.
  • the second envelope passes through the first mailing machine 101 without a printing operation.
  • the second envelope is then passed via transport 102 to the second mailing machine 103 where it is again decelerated to the print velocity, This time, mailing machine 103 does perform a printing operation and an indicia is printed on the second envelope by postage meter 105.
  • Mailing machine 103 then accelerates the envelope back to the system velocity, and the second envelope is carried away downstream.
  • serial mailing machines 101 and 103 to alternately take turns printing indicia on every-other envelope.
  • One disadvantage of this serial arrangement is that it remains very sensitive to gaps sizes between consecutive envelopes. Gaps between subsequent envelopes are shortened every time a lead envelope undergoes the printing motion profile. If an error occurs in the processing to make the gap size smaller than expected, envelopes can catch-up to one another, and a paper jam can result. Also, the R150 and R156 mailing machines are a bit too long to have time to carry out printing motion profile before the arrival of the next envelope, and to still have some margin for error in the arrival of a subsequent envelope. As a result, envelopes can be passed off between sets of nips that are not going at the same speed, creating potential for pulling or buckling. Accordingly, a solution with better space utilization and that is less sensitive to gap size variation is desirable.
  • Another problem with existing solution is that the conventional postage meters are inflexible in adjusting to conditions present in upstream or downstream meters. For example, if the downstream module is halted as a result of a jam, the postage meter will continue to operate on whatever envelope is within its control. This often results in an additional jam, and collateral damage, as the postage meter attempts to output the envelope to a stopped downstream module.
  • the present application describes a printing apparatus and method to for use in a continuous high velocity document processing system.
  • they printing system is used in connection with a postage meter for imprinting postal indicia on mail pieces.
  • the print apparatus is preferably located at the downstream end of an inserter device for mass producing mail pieces.
  • a transport path conveys a series of mail pieces at a print velocity.
  • the print heads are preferably available ink jet print heads capable of printing at high resolution on documents traveling at high speed. During normal operation, only one print head is operating at a time. As mail pieces pass the print head at the print velocity, postal indicia are printed on them.
  • the second print head goes into operation without interruption of the document processing flow.
  • the print heads are in series. Thus, when one print head is taken out of service, the other one continues to print on documents in the same transport path. Because the second print head may be at a different location along the transport path, appropriate adjustments to the triggering of the print cycle are required.
  • a parallel print head arrangement may be used.
  • a flipper switch redirects documents to a parallel transport path and a parallel print head, when the first one is out of service.
  • the activation of a second print head may also be triggered when the first print head is subject to a failure that prevents it from being used, Thus, it may not be necessary to halt operation of the mail production process.
  • a motion control scheme is used in the printing module to decelerate a mail piece for slower speed printing, and then returning the mail piece back to the higher system transport speed after printing.
  • different positions of the print heads may require that different portions of the print module transport act to effectuate the necessary print transport motion profile.
  • an upstream print head is in use, an upstream portion of the print module transport may be required to undergo the motion profile to account for the lower print speed.
  • a downstream portion of the print module transport may be required for the motion profile.
  • a system using the present invention transports a first envelope at a nominal transport velocity to the postage printing module.
  • the postage printing module receives the envelope at the nominal transport velocity. Based on predetermined criteria, one or the other of the at least two print heads is selected for printing the indicia on the envelope. If one print head is unavailable because of a failure, or because of a periodic maintenance sequence, then the other one is used.
  • the envelope When the envelope has passed completely into the control of the postage printing module it is decelerated to a predetermined lower print velocity for printing an image of a predetermined length. After the printing is complete the envelope is accelerated back to the transport speed and transported to a downstream module. None of the intervals of deceleration, low print velocity, or acceleration may occur white an envelope in the postage printing module is also in the control of another module.
  • This motion control is carried out by different transport elements in the print module depending on which print head is being used.
  • Transport elements such as rollers, are grouped together to act in unison in order to effectuate the motion control at the appropriate location in relation to the print head.
  • a particular transport element may or may not be in the group performing the motion control.
  • Some transport elements may be in more than one grouping.
  • Deceleration in the motion control profile is activated by a sensor sensing the presence of the envelope at a trigger point. Further sensors at the upstream and downstream modules can be used to verify that no envelopes are under the shared control of the postage printing module and another module.
  • the print head is geared to operate in synchronism with the print transport, such that an image will not be distorted if there is a variation in print velocity.
  • the preferred system and method also provide a way to ensure that correct displacement is maintained between subsequent envelopes under the control of the invention in the event of a stop and/or restart of the system resulting from an exception condition, such as an envelope jam.
  • an exception condition such as an envelope jam.
  • the envelope When an envelope is within the print transport during an exception condition, the envelope must be decelerated to a stop, so as not to create further jams or collateral damage.
  • a linear uniform deceleration is preferred to minimize disruption of the desired spacing between mail pieces being processed.
  • deceleration may not occur in the same uniform linear fashion as the rest of the system. Rather, deceleration is preferably controlled to maintain the relative displacement of envelopes in the postage printing module with respect to upstream and downstream modules, Because displacement varies in that module during normal operation, a uniform stopping and starting of the print module to mirror other modules will result in envelope spacing different than originally intended. Such changing in envelope gaps may result in further jams or misprocessing.
  • a controller in the print module controls the displacement of the print module according to a predetermined algorithm.
  • This algorithm relates displacements of the print module with other modules for segments of the motion profile as they would have been executed during normal operation.
  • deceleration and acceleration of the print module is thus controlled as a predetermined function, or set of functions, of the displacements in other transport modules. The appropriate function is determined as a result of the position of the envelope in the print module during the course of the exception condition.
  • This displacement mapping functionality of the preferred embodiment operates cooperatively with the gearing of the print head mechanism to the print transport. In that preferred embodiment, stopping and restarting of the print module may not affect printing of an image on the envelope, even if a printing operation had already begun at the time of the stoppage.
  • Figure 1 depicts a prior art inserter metering system using two mechanical meters in series.
  • Figure 2 is a diagrammatic view of a postage printing module in relation to upstream and downstream modules.
  • Figure 3 is a graphical representation of a print motion control profile for controlling the speed of envelopes in the postage printing module.
  • envelope printing throughput 18,000 to 22,000 mail pieces per hour be achieved.
  • the transport velocity of the inserter system is typically 100 ips or greater.
  • the preferred ink jet printing device to be used for printing a postage indicia is only capable of achieving a desired resolution of 200 dpi at a speed of 80 ips.
  • Such print heads are known to be available from printer manufacturers Canon, Brother and Hewlett-Packard. Accordingly, the present invention will be described primarily in regard to a system whereby the print module 1 is used to decelerate envelopes from 100 ips, to 80 ips for printing, and back to 100 ips for further processing.
  • the present invention includes a postage printing module 1 positioned between an upstream module 2 and a downstream module 3 .
  • Upstream and downstream modules 2 and 3 can be any kinds of modules in an inserter output subsystem.
  • the upstream module 2 could include a device for wetting and sealing an envelope flap.
  • Downstream module 3 could be a module for sorting envelopes into appropriate output bins.
  • Postage printing module 1, upstream module 2, and downstream module 3, all include transport mechanisms for moving envelopes along the processing flow path.
  • the modules use sets of upper and lower rollers 10, 20, 30, 40, 70, and 80 called nips, between which envelopes are driven in the flow direction.
  • rollers 10, 20, 30, 40, 70, and 80 are hard-nip rollers to minimize dither.
  • the transport for module 1 may also be belts, or other known transport mechanisms.
  • Print heads 50 and 60 are preferably located at or near the output end of the print transport portion of the postage printing module 1 (see locations D and E). To satisfy desired readability the print heads 50 and 60 should be capable of printing an indicia at a resolution of 200 dots per inch (dpi). In the preferred embodiment, the print heads 50 and 60 are drop-on-demand ink jet print heads capable of printing 200 dpi on media traveling at 80 ips. Alternatively, the print heads 50 and 60 can be any type of print heads, including those using other digital or mechanical technology, which may benefit from printing at a rate less than the system velocity.
  • print heads 50 or 60 are in use at a given time.
  • one of the print heads, for example 50 will be used to print indicia on the stream of envelopes.
  • print head 60 is brought into service to do the same job.
  • the reserve may then continue operation as the primary print head, and the former primary may become the reserve when the maintenance operation is complete.
  • the primary may be brought back into service when maintenance is complete, and the reserve returned to inactive status. Adjustments to the transport system of print module 1 in support using the two print heads 50 and 60 in this manner are discussed below.
  • rollers 10, 20, 30, and 40 for postage printing module 1 are driven by motors 11 , 21, 31 , and 41.
  • rollers 70 and 80 are driven by electric motors 12 and 13 respectively.
  • Motors 11, 21, 31, 41, 12, and 13 are preferably independently controllable servo motors.
  • Motors 12 and 13 in upstream and downstream modules 2 and 3 drive rollers 70 and 80 at a constant velocity, preferably at the desired nominal velocity for envelopes traveling in the system.
  • upstream and downstream modules 2 and 3 will transport envelopes at 100 ips in the flow direction.
  • the transports for module 1 may be driven in any known manner.
  • the rollers 10, 20, 30, and 40 could be all geared to a single driving mechanism.
  • the arrangement of separate control is preferred because it allows for more flexibility in controlling motion within the print module 1.
  • Motors 11, 21, 31, and 41 drive rollers 10, 20, 30, and 40 in the postage printing module 1 at varying speeds in order to provide lower velocity printing capabilities.
  • Postage printing module motors 11, 21, 31, and 41 are controlled by controller 14 which in turn receives sensor signals. Signals may be provided to the controller 14 from upstream sensor 15, downstream sensor 18, and trigger sensors 16 and 17. Sensors 15 and 18 are preferably used to detect the trailing edges of consecutive envelopes passing through the postage printing module 1, and to verify that the printing motion control adjustment only occurs while a single envelope under the control of the set of rollers performing the velocity change.
  • Trigger sensor 16 determines that an envelope to be printed with an indicia is in the appropriate position to trigger the beginning of the print motion control scheme for print head 50, as described further below.
  • trigger sensor 17 may be used for triggering the motion control scheme for print head 60.
  • Sensors 15, 16, 17 and 18 are preferably photo sensors that are capable of detecting leading and trailing edges of envelopes. While four photo sensors are depicted in the embodiment of Fig. 2, the system can be operated with as few as one photo sensor at an upstream location. The upstream single photo sensor would generate a signal upon deteting the presence of a lead or trail edge of an envelope. Subsequent to sensing the envelope, encoder pulses from the servo motors (11, 21, 31, 41 ) transporting the envelope could be counted, and the corresponding displacement can be accurately determined. Thus the controller 14 could trigger an action based on the sensing of an envelope edge, and then counting a predetermined quantity of pulses from the motor encoders. The preferred positioning of the sensors, and the utilization of signals received from the sensors are discussed in more detail below.
  • the location of the output of the transport for upstream module 2 is location A.
  • the location for the input to the print transport of postage printing module 1 is location B.
  • An intermediary transport roller 20 is located at point C.
  • Transports 30 and 40 for print heads 50 and 60 are located at points D and E.
  • Point E is also the output of the print transport mechanism for postage printing module 1 .
  • the input for the transport of downstream module 3 is location F.
  • the modules may also include other rollers, or other types of transports, at other locations.
  • consecutive distances between rollers 10, 20, 30, and 40 must be less than the shortest length envelope expected to be conveyed.
  • the rollers 10, 20 , 30 , and 40 will preferably be spaced not more than 6.25" apart, so that an envelope can be handed off between sets of rollers without giving up control transporting the envelope at any time.
  • the preferred embodiment is also designed to handle an envelope 10.375 inches long.
  • Upstream sensor 15 is preferably located at or near location B, while downstream sensor 16 is preferably located at or near location E.
  • Trigger sensors 17 and 18 are preferably located upstream from print heads 50 and 60 by a sufficient distance to permit deceleration of the print transport from the nominal transport velocity to the print velocity upon the detection of a lead envelope edge.
  • the trigger sensors 17 and 18 may be located any distance upstream from the minimum deceleration point, even as far upstream as upstream sensor 15, so long as the motion control profile determined by controller 14 is adjusted accordingly.
  • Controller 14 controls the motors 11, 21, 31, and 41 in accordance with a print motion control profile in order to achieve the goals of (1) reducing the speed of an envelope so that the lower velocity print heads 50 and 60 can print an indicia, (2) controlling the motion of the envelopes so that consecutive envelopes do not interfere with each other, and (3) allowing the printing duties to be shared between print heads 50 and 60 located at different positions along the transport path.
  • the preferred motion control profile further allows that multiple envelopes may be handled within the print module 1 at a given time, and not interfere with one another, even when they are at different velocities, and without creating mismatches between print module 1 and the upstream and downstream modules 2 and 3.
  • print motion control profile Depending on which of the print heads 50 or 60 is in use, different groupings of transport rollers (10, 20, 30, 40) in print module 1 will be used to perform the print motion control profile to decelerate envelopes to the print velocity and to return them to the transport velocity.
  • a preferred embodiment of a print motion control profile for use with the present invention is depicted in FIG. 3, and described further below.
  • the present invention enables the speed adjustment motion profile to begin and end at different locations in the print module 1.
  • transport rollers 10, 20, and 30 will be used to perform the speed adjustment, while roller 40 will remain at the constant transport velocity.
  • roller 10 When print head 60 is in use, roller 10 operates at constant velocity, as if it were part of the upstream module 2 . Meanwhile, rollers 20 , 30 , and 40 are grouped together to perform the motion profile.
  • the groupings of the rollers will only remain in place so long as the rollers are needed as part of the group.
  • Upstream members of the groups will return immediately to the transport velocity as soon as an envelope being printed passes from its control. For example, if print head 50 is in use, rollers 10, 20, and 30 will operate in unison as the envelope comes under the control of the group, However, the envelope may pass out of the control of roller 10, even while the printing operation, and corresponding transport motion control, are being carried out. When this happens, roller 10 leaves the uniformly controlled group and immediate accelerates back to transport velocity. Similarly, roller 20 would return immediately to the transport velocity when the envelope leaves its control. In this manner, the upstream rollers are more quickly ready to receive envelopes from upstream sources, even as print speed adjustments are still underway.
  • roller 30 (and motor 31) become a master for slave rollers 10 and 20 when an envelope comes under the complete control of the group.
  • roller 30 When the envelopes leave rollers 10 and 20, they cease to be slaved to roller 30 and may be slaved to the roller 70 for upstream module 2.
  • roller 40 was never part of the velocity adjustment grouping, and may be slaved to roller 80 of downstream module 3.
  • the master roller for the velocity adjustment control group is roller 40.
  • rollers 20 and 30 will be slaved to the master 40.
  • roller 10 may be continuously slaved to roller 70 of upstream module 2.
  • the envelope passes through the control group, and out of the control of rollers 20 and 30, they are preferably released from the master 40 and return to the transport velocity. In returning to the transport velocity, they may in turn be slaved to upstream roller 70.
  • controller 14 is programmed to designate the appropriate individually controllable rollers and motors as masters and slaves based on positions of envelopes sensed by the sensors. Concurrently, the controller 14 is also providing the appropriate motion profile for the control group to allow reduced velocity printing.
  • Initiation of the slaving of rollers and the print motion adjustment may be triggered by the controller when an envelope reaches a predetermined displacement downstream from sensor 15.
  • the predetermined displacement is based on the distance between the trip photocell 15 and the print head 50, the deceleration rate, the indicia offset, upstream module velocity, print velocity, and settle time (before printing begins).
  • the locations of the edges of envelopes may be detected based on the positioning of photocells at the exact locations. Alternatively, positions may be calculated by measuring encoder pulses from the servo motors, and adding the envelopes positional displacement from a known location of a previously tripped upstream sensor.
  • Fig. 3 is an exemplary motion profile of master rollers 30 or 40 at locations D and E, depending on which of the print heads 50 or 60 is in use. Based on the criteria discussed above, rollers slaved to the master rollers will also perform portions of motion profile. Notations provide the translation distances of envelopes within the velocity adjustment control group of rollers for different intervals.
  • the depicted profile is based on a system that is printing on envelopes 10.375" inches in length, that requires a maximum length printed indicia of 5".
  • the nominal transport velocity is 100 ips, and the print velocity is 80 ips.
  • the accelerations for adjusting speeds are 8.0 G's, or 3091 in/s 2 .
  • the throughput rate is 22,000 mailpieces per hour. At the nominal transport speed the period between envelopes is 164 ms.
  • the print heads 50 and 60 are preferably located just downstream of nip roller sets 30 and 40. This location allows greater control at the print head location, and also minimizes the opportunity for errors relating to an envelope tail kick. Tail kick occurs when the trail edge of an envelope is not adequately constrained and comes into contact with a print head, thereby causing print head damage and failure.
  • a lead edge of a first envelope reaches the output of the upstream module 2, at location A.
  • the lead edge of the first envelope is at the most upstream roller of the velocity adjustment control group (location B or C).
  • Sensors 15 and 16 can provide signals to controller 14 to prevent initiation of a change in velocity white an envelope is under the control of more than one module, or more than one control group.
  • the first envelope is under the sole control of the control group of roller for print module 1, and the control group may slow down to allow the slower velocity printing.
  • Controller 14 can begin the necessary deceleration by sensing the lead edge of the first envelope with the trigger sensor 16, 17.
  • the deceleration can begin as a result of upstream sensor 15 detecting the position of the tail end of the first envelope.
  • the three nips of the control group of the print module 1 initiate a predetermined deceleration to reach the desired print velocity, in this case 80 ips.
  • the control group master roller then operates at 80 ips to transport the envelope a predetermined distance while an indicia is printed on it. In this exemplary embodiment the print distance is five inches.
  • the envelope is accelerated back to the transport speed. Slaved control group rollers upstream of the master roller, preferably return to the transport velocity of 100 ips prior to completion of the motion control profile of Fig. 3, once the envelope has passed out of their control.
  • the lead edge of the first envelope reaches the first nip downstream of the master nip.
  • the first envelope is no longer under the exclusive control of the control group and variations in the print transport speed are not permissible.
  • envelopes can be slowed for lower speed printing, but without having subsequent envelopes collide.
  • the nominal distance between envelopes for the example described would be about 6.025 inches before entering the print module 1 .
  • the minimum distance between envelopes is reduced to 4.49 inches.
  • the nominal distance is restored as the subsequent envelope has the same motion profile performed on it, and the prior envelope travels away at the nominal travel velocity of 100 ips. Accordingly, the throughput of the system remains intact.
  • the exemplary motion profile described above complies with requirements necessary for a successful reduced velocity print operation.
  • the velocity adjustment control group of nip in print module 1 must have total control of the envelope.
  • the envelope cannot reside between nip rollers at location A or F during execution of the print motion control profile.
  • the rate at which the print heads 50 and 60 print the indicia can be electronically or mechanically geared to the speed of the print transport in the print module 1. In such case, under circumstances where the print transport is operating outside of nominal conditions, a correct size and resolution print image can be generated.
  • controller 14, print head 50 or 60, and the master roller servomotor 31 or 41 are geared to the same velocity and timing signals to provide that the transport and printing are always in synchronism.
  • Another preferred embodiment of the present invention addresses a problem that occurs when the print module 1 is forced to deviate from the motion control profile depicted in Fig. 3.
  • a problem that occurs when the print module 1 is forced to deviate from the motion control profile depicted in Fig. 3.
  • upstream and downstream modules typically come to a halt in accordance with a uniform rapid linear deceleration profile.
  • the postage printing modules have no mechanism for halting envelopes that are committed within the postage meter.
  • additional paper jams and damaged envelopes commonly occur as the postage printing module forces envelopes against a halted downstream module.
  • the print module 1 will also decelerate to a stop upon the occurrence of an exception event.
  • exception events may include detection of jams, detection that mail pieces are out of order, or detection of equipment malfunctions.
  • the print head 50 or 60 is geared to the master motor 31 or 41, then an envelope can be stopped anywhere in the print module 1 upon the occurrence of an exception event without damaging the envelopes, and without compromising the image to be printed on the envelope.
  • print module 1 can be accelerated back to the velocities in accordance with the motion profile depicted in Fig. 3.
  • a uniform linear deceleration and acceleration during an exception condition is preferred for the upstream and downstream modules 2 and 3.
  • a deceleration and acceleration having that same uniform linear profile may cause problems in print module 1. For example, if the print transport was about to reach point 203 in the motion profile of Fig. 3 when the exception condition occurred, the control group of the print transport could decelerate down to zero velocity in a linear fashion the same as modules 2 and 3.
  • the envelope in the print module 1 will be closer to the downstream module than it would have been if the normal motion profile had been executed. This is because during the uniform deceleration, the print module 1 has essentially skipped a portion of the motion profile.
  • the present invention maintains the expected displacements between consecutive documents by controlling the transport of envelopes in print module 1 as a function of the displacement positions of upstream and/or downstream modules 2 and 3.
  • the variations in velocity that result from the stoppage and starting in an exception condition should not affect the relative spacing of the envelopes.
  • the velocity variables will be eliminated, and positions of the transports expressed in terms of variable displacements and known constants.
  • the desired displacements of the print module 1 must be describable in terms of the position of upstream or downstream modules. Also, the descriptions must be expressed in terms of the displacement relationships that would have resulted from the distinct segments in the motion profile.
  • print module 1 must decelerate more quickly than upstream module 2 in order that the shortening of the gap between envelopes in those modules be preserved. To derive the appropriate displacement relationship for this segment of the print module 1 motion, the following symbols are defined:
  • controller 14 of print module 1 can adjust the displacement of print module 1 when an envelope is present at a location where it normally would undergo the deceleration portion of the motion profile.
  • the appropriate displacement relationship may change white the print module 1 is decelerating to a stop.
  • an envelope that is slightly upstream of trigger sensor 16 or 17, and traveling at the transport velocity, may begin to stop in accordance with the displacement relationship described in equation [1], above.
  • the envelope may reach the trigger position marked sensor 16 or 17 .
  • controller 14 will switch the displacement relationship to that described in equation [4] above.
  • displacement may be controlled in accordance equation [5] above.
  • the print head may begin printing a portion of the image on the envelope before it stops.
  • the geared print head will also resume printing at the appropriate geared speed.
  • a final segment of the motion profile is the acceleration of the envelope from the print velocity, back to the transport velocity.
  • the displacement mapping relationship for this segment can be derived in the same way as for equation [4] above.
  • a difference in the result being that this acceleration segment is causing an envelope in the print module 1 to increase its distance from a subsequent envelope in upstream module 2 .
  • Displacement information for respective print, upstream, and downstream modules 1, 2, and 3 may typically be monitored via encoders in motors 11, 21, 31 , and 41 .
  • the encoders register the mechanical movement of the module transports and report the displacements to controller 14 for appropriate use by controller 14 to maintain correct displacement mapping between the modules.
  • Fig. 2 depicts an exemplary serial arrangement of two print heads, whereby one may be taken out of service while the other undergoes a maintenance cycle
  • An alternative embodiment could utilize a parallel arrangement. Under this parallel arrangement, a flipper gate would be activated when the active print head is taken out of service. The flipper gate would redirect envelopes to a second parallel transport where the back-up print head prints indicia on envelopes.
  • An exemplary parallel path system that would be suitable for use in this manner is depicted in co-pending European Patent Publication number 1391849, published February 25, 2004 and entitled PARALLEL PROCESSING HIGH SPEED PRINTING SYSTEM FOR AN INSERTING SYSTEM.
  • documents being processed are envelopes. It should be understood that the present invention may be applicable for any kind of document on which printing is desired. Also a package or a parcel to which a printed image is applied as part of a processing system should also be considered to fall within the scope of the term "document" as used in this application,

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Computer Security & Cryptography (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Accessory Devices And Overall Control Thereof (AREA)
  • Delivering By Means Of Belts And Rollers (AREA)
  • Devices For Checking Fares Or Tickets At Control Points (AREA)
  • Ink Jet (AREA)
EP04023374.4A 2003-09-30 2004-09-30 Procédé et système pour l'affranchissement numérique rapide Active EP1521218B1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US675362 2003-09-30
US10/675,403 US6893175B2 (en) 2003-09-30 2003-09-30 Method and system for high speed digital metering
US675403 2003-09-30
US10/675,362 US6988842B2 (en) 2003-09-30 2003-09-30 Method and apparatus for continuous high speed digital metering using multiple print heads

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EP1521218A2 true EP1521218A2 (fr) 2005-04-06
EP1521218A3 EP1521218A3 (fr) 2006-08-02
EP1521218B1 EP1521218B1 (fr) 2013-07-31

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Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0724234A2 (fr) 1995-01-30 1996-07-31 Neopost Limited Appareil d'affranchissement et système de transport de courrier pour cela
US20020040354A1 (en) 2000-09-29 2002-04-04 Neopost Industrie High-rate franking machine

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6322069B1 (en) * 1999-03-12 2001-11-27 Xerox Corporation Interpaper spacing control in a media handling system
US6783290B2 (en) * 2002-08-05 2004-08-31 Pitney Bowes Inc. Method and system for high speed digital metering using low velocity print technology

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0724234A2 (fr) 1995-01-30 1996-07-31 Neopost Limited Appareil d'affranchissement et système de transport de courrier pour cela
US20020040354A1 (en) 2000-09-29 2002-04-04 Neopost Industrie High-rate franking machine

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EP1521218B1 (fr) 2013-07-31

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