GB2195801A - Mail sorting and banding apparatus - Google Patents

Description

GB2195801A 1 SPECIFICATION U.S. Patent 3,935,429, there is certain coded

indicia printed on the computer output form, Sorting and banding apparatus or perforated web as is known in the art. The indicia may include what is known as a zip This invention relates to an apparatus for sort- 70 code break, or coding like a dash which is ing and banding mail according to predeter- significant insofar as being recognizable by the mined postcode or zip code bread data which appropriate sensing devices in the inserting is preprinted on selected documents being machine. When the zip code break code is processed within and through an inserting ma- sensed, the inserting machine is programmed chine. 75 to react accordingly since the zip code corre- In this specification, the term "zip code" sponding to a particular address has changed current in USA is used to refer to a numerical from what was previously processed through coding relating to geographical areas. It will be the machine.

understood that the invention is applicable to Referring now to U.S. Patent No.

analogous codes used in other countries. 80 4,525,788, a conveying device is disclosed is The inserting machine is of the nature de- combination with an inserting machine. In re- scribed in U.S. Patent No. 3 935 429 issued ferring to the above mentioned patent, it may January 27th, 1976 to G. Branecky et a[, enti- be evident that it is possible for an operator tled Process and Apparatus for Controlling to periodically collect by hand a group or a Document Feeding Machines From Indicia Con- 85 batch of mail pieces or envelopes exiting from tained on a Document Fed Therefrom. Other the machine conveyor, and to then manually documents which relate to and explain the op- place a rubber band about the envelopes to eration of the inserting machine are U.S. Pa- form a bundle. However, there is not a suit tent No. 4 020 615, issued May 3rd 1977 to able system yet provided which will identify R. Irvine et a[, entitled Envelope Inserter and 90 the zip code, code break, which corresponds Feeder System and U.S. Patent No. 4 525 to a group of mail pieces of a given zip code 788, issued January 25th 1985 to R. Gottlieb area without having the operator read all of et al for a Scanner Interface Circuit for Univer- the given mail pieces, and then sort them by sal Multistation Document Inserter. These pa- area prior to banding them. It is, therefore, tents explain the nature of operation of the 95 evident that there is a need to make a mail inserting machine in general, and to the extent room operation which utilizes an inserting and necessary for understanding, they are hereby mailing machine much more efficient while re incorporated in the present specification. lieving the typical mailroom clerk or machine

Reference to U.S. Patent No. 3 356 361 operator from what is presently a tedious task issued to T.J. Geisler et a[ for a Sheet Pack- 100 of identifying and manually handling mail of a ing Machine will assist in understanding the given zip code area, and for then manually conveying apparatus to be discussed in the banding that mail.

present specification. The present invention is embodied in an

The U.S. Postal Service would prefer that apparatus disclosed for sorting and banding mail such as envelopes be provided in mana- 105 mail according to zip code break data which is geable bundled groups, which are destined for preprinted on selected documents of a plural given zip code areas4 There is presently a ity of documents which are processed in an problem in certain large mailroom facilities of inserting machine. At least one document larger companies such as the insurance indus- bearing zip code break data is stuffed into an try where appropriate clerical personnel have 110 envelope of a batch of successively fed envel to be assigned to bundle groups of mail like opes. There is an apparatus for reading zip envelopes by hand, after the mail has been code break data preprinted on selected docu processed through the appropriate document ments and a device for feeding the plurality of stuffing (inserting machines) and postage indi- the documents past the zip code break data cia applying machine. The volume of mail be- 115 reading apparatus. A conveying apparatus re ing generated is presently substantial, and is ceives a plurality of the envelopes relating to growing larger each year with the increasing a given zip code break data area as they use of computer forms. Computer output transgress from the inserting machine. A first forms, such as those generated by the insur- apparatus which is responsive to the zip code ance industries typically are preprinted with 120 break data reading apparatus indexes the con optical machine readable codes including with veying apparatus When the first envelope of the name, address and zip code address infor- another zip code area arrives at the conveyor mation. The address and code is necessary apparatus. At this point, envelopes designated for reading and identification purposes through for the same zip code area are deposited one a glassine window of a suitable envelope. The 125 on top of another on the conveyor apparatus printed form is typically perforated, and may to form discrete bundles of envelopes which have one perforated panel or document, or are of the same zip code area. A banding many -pages of documents which relate to a apparatus is disposed adjacent to the other particular customer's bill or other related inforend of the conveyor apparatus for receiving mation. Referring to the previously mentioned 130 discrete bundles of the envelopes from the 2 GB2195801A 2 conveyor apparatus. At least one elastic band The inserting machine 14 is in part con- is placed around each of the discrete bundles structed on a frame 18, having an upper, of the envelopes by the banding apparatus. elongate document conveying deck. 20. There The apparatus includes a scanning device is a plurality of insert feeder assemblies which is disposed in the path of envelopes 70 mounted on the deck 20, for example a being fed to the conveyor apparatus for de- feeder 24 which may be loaded with an ap tecting envelopes passing the scanning device. propriate supply of insert or enclosure material And, there is a control device interconnected 26 to be fed downwardly towards the deck between the scanning device and the con- 20 at a predetermined time. The feeder 24, veyor apparatus for indexing the conveyor 75 and each of the other feeders are capable of apparatus when a predetermined number of feeding an enclosure document in an appropri the envelopes has passed the scanning de- ate predetermined sequence towards a con vice. veyor 28. The conveyor 28 has pusher mem- The invention will be better understood from bers attached thereto, which is well known by the following non-limiting description of an 80 those skilled in the art. Referring to Fig. 2, a example thereof given with reference to the portion of the conveyor 28 is shown, having a accompanying drawings in which:- pair of endless chain members 30 and 32, Figure 1 is an overhead isometric view of an each in turn having pusher members attached, example of an inserting, sorting and banding such as a member 34 and 36 respectively.

apparatus according to the present invention. 85 The chain members 30 and 32 are appropri- Figure 2 is an isometric view along the ately rotatably mounted, driven, and sus- same line of sight of Fig. 1 showing only the pended within the frame 18 as will not be essential elements for moving documents and elaborated on in the present specification in selected portions of the mail processing path, view of the referenced prior art.

including portions of the related apparatus for 90 There is a bursting and folding module 38 conveying the different documents processed as seen in Fig. 1, through which a web 40 through the inserting machine. passes for the purpose of separating individual Figure 3 is a plan view of a perforated web panels located between perforations in the having customer address, zip code data and web 40. The bursting and folding module 38 zip code break data printed on selected docu- 95 is considered to be an element of the entire ments of a plurality of documents within the apparatus 10, and is located in an upstream web. location of the apparatus 10 since this is Figure 4 is a partial isometric view of the where the web 40 initially enters the appara- bursting and folding portion of the inserter tus 10. The web 40 has data preprinted on machine, taken along the same viewing direc- 100 selected panels within and comprising the web tion of Fig. 1, with the cover of the bursting 40, which will be described more fully in the machine in a raised, open position. following text. For a clear understanding of Figure 5 is an electro-mechanical schematic the construction and operation of the module view which shows the control system for 38 within which the data is read, reference reading zip code break data, counting envel- 105 may be made to U.S. Patent No. 4,261,497, opes and controlling the conveyor apparatus. entitled BURSTING APPARATUS, issued to F.

Figure 6 is an isometric view taken along Roetter et a[, April 14, 1981. The folding the same lines as Fig. 1, and substantially function performed within the module 38 is enlarged to show a portion of the output end described in U.S. Patent No. 4,261,497, and of the conveyor apparatus with the envelope 110 additionally in U.S. Patent No. 3,495,818 transfer apparatus in position to receive a where a separate folding module is disclosed.

batch of envelopes prior to banding them. - Referring back to Fig. 1, the web 40 is Figure 7 is an enlarged longitudinal view of supplied from a pile 42 which leads to a web the output end of the conveyor apparatus as advancing apparatus 44. Referring to Fig. 3, taken along the lines of 7-7 from Fig. 1. 115 there is shown a portion of the web 40 with Figure 8 is a detailed fragmentary view of a the previously referred to panels located be- mail separator member, and its mounting to tween perforations. For example, there is a an endless conveyor member, as viewed panel 46 located between a perforation 49 along the same lines as Fig. 6. and 49', the panel 46 being typical of an ad- Figure 9 is an end view taken along the 120 dress bearing document which has data for lines of 9-9 from Fig. 8 of the member OMR processing (OPTICAL MACHINE READA shown in Fig. 8. BLE) including the customers name and ad- Referring to Fig. 1, there is shown an appa- dress. There is an indicia 48 located in the ratus for sorting and banding mail, the appara- panel 46, which is representative of indicia tus generally denoted as 10. There is an in- 125 discussed in the previously referenced U.S.

serting machine 14 which is generally that as Patent No. 3,935,429. A dash 50 is provided, disclosed and discussed in the reference pa- which indicates a zip code break. A second tents previously noted in the background of address bearing document 52 has dash 54, the present invention such as U.S. Patent No. representing another zip code break. The web 4,020,615. 130 40 is provided with a series of suitable 3 GB2195801A 3 sprocket holes 56 and 58, which are opera- A turntable apparatus 88 is located immedi- tively engaged with various web advancing de- ately downstream of the inserting machine 14, vices well known to those skilled in the art. to receive each envelope from the insertion The web 40 is processed within the burster and document track leading from the envelope and folding module 38, and reference is made 70 feeder 86. There is a pair of gripper members to Fig. 4 where a greenhouse cover 60 has 94 which are operatively opened and shut been opened from a closed position (see Fig. upon receiving each envelope, and for then 1) to expose a portion of the instrumentalities swinging the clamped envelope (in the present of the module 38. In particular, it is pointed case, the envelope 76) through a 180' angle out that there is a web advancing apparatus 75 to be then released by the gripper members 62, which will not be explained in detail within 94 for further conveyance along a feed path the present specification in view of the previ- 96. There is a cyclicable apparatus (not ously mentioned patent references. The web shown) connectively engaged with the drive is advanced according to instructions in- apparatus of the inserting machine 14 so that cluded within the data (previously described) 80 one 180 turn of the turntable apparatus 88 provided within the preprinted indicia 48 and occurs for each separate, filled envelope.

read by a first scanning device 64. A second There is a framework 98 which supports a scanning device 68 scans the web 40 for the plurality of mail processing elements posi dash 50, which is representative of a zip code tioned along the entire path 96. A suitable break (refer to Fig. 3) which is the operative 85 power driven roller 100, advances the envel signal to an electronic control device 70 of ope 76 towards an envelope moistening de the inserting machine that a zip code break vice 102. Such moistening device is disclosed has been sensed. in U.S. Patent No. 2,970,536, issued to J. W.

Generally, the electronic control device 70 is Bach on February 7, 1961 for POSTAGE best seen in Figs. 1 and 5. The device 70 is 90 METER MACHINES. Reference may be made the electronic memory and information control to the same reference patent where a postage apparatus which is utilized for controlling the meter and base is described.

entire operation of the apparatus 10. In the present apparatus there is a postage Each panel is burst from the web 40 during meter 104, which receives the envelope 76 the course of operation of the bursting and 95 from a pair of driven conveying rollers 106. It folding module 38, and, immediately, each se- will be understood by those skilled in the art, parated panel is folded in a folding apparatus that the meter 104 cycles once in engage 72 preparatory to being placed on the deck ment with an impression roller 105 for each by a pair of conveying rollers, which are envelope or mail piece being printed, and located on-the output side of the bursting 100 therefore delivers a printed meter indicia 108 apparatus 72 (not shown but understood by representing the weight of the envelope 76. A those skilled in the art to belong to the burst- suitably driven pair of conveying rollers 110 ing apparatus 72). causes the envelope 76 to continue along its In the prior description, it was previously feed path from the meter 104 towards a mentioned that the conveyor 28 is used to 105 scanning device 112 (a scanning device is al convey the appropriately dispensed documents ternatively defined as a sensing device within along the deck 20, and that appropriate feed- the present specification) which senses the ar ers such as Z4 may add additional enclosures rival of each envelope. The device 112 is in to the pile of documents such as a pile 74 communication with an adjustable piece coun seen in Fig. 2. The pile 74 is positioned for 110 ter 114 which is operatively connected to an deposit (otherwise known as stuffing) within electronic control device 116 (refer to Figs. 1 an envelope 76, as is typical for each cycle of and 5). The control device 116 will be de the inserting machine 14 where one envelope scribed in more detail in the latter portion of is involved in receiving one or more docu- the present specification where its specific ments or enclosures from a group of docu- 115 functions are defined as they directly control ments. The pile 74 is accumulated so that the indexing of a conveyor apparatus 118 located address of the customer (for example) is on at the intermediate output end of the appara- top of the pile, such that an address 78 such tus 10. The function of the control device as is shown on the panel 48 (refer to Fig. 3) 116 and the piece counter 114 is to allow an is positioned to be visible through a window 120 operator to select a desired number of mail aperture 80 on each mating envelope. The op- pieces to be counted as those pieces pass eration continues, as is seen in Fig. 2 where a through the scanning device 112. The piece ram 82 is utilized to deposit the pile 74, into counter 114 therefore enables programming of the envelope 76, the envelope 76 having been the conveyor apparatus 118 in order to cycle fed downwardly from a batch of envelopes 84 125 forward one pitch (to index one pitch) when within an envelope feeder 86. Here again, ref- the selected number of mail pieces matches erence is made to the patents cited within the an actual mail piece count made by the scann present specification where the details of ing device 112.

feeding envelopes and depositing enclosures The conveyor apparatus 118 is constructed thereto is defined. 130 on a frame 122, and has a pair of endless 4 GB2195801A 4 members consisting of a chain member 124 to remain substantially neatly aligned with the and a chain member 126 (refer to Fig. 2). conveyor 118 indexes forward. There is a Members 124 and 126 are both rotatably sus- separator member 166, shown deflected at a pended on suitable chain sprockets, part of skewed angle (there is a pair of members 166 which is shown in Fig. 2. There is a sprocket 70 as will be understood). A top corner 169 of 128 and a sprocket 130, both of which are the members 166 is engaged with a fixed, appropriately connected to a shaft 132 which substantially curved member 172, having ro is rotatably supported and journalled in the - tated in a direction 170 opposite to a direc frame 122. There is an equivalent shaft 132' tion of movement 173 of the conveyor chain and pair of sprockets 130' located at the 75 members. as those members advance towards downstream end of the conveyor 118, which the output end 155, of the apparatus 118.

is seen in Fig. 6. There is a sprocket 134 Referring to Figs. 8 and 9, a greatly en- connected to one end of the shaft 132, and a larged view of a separator member such as suitable slip clutch and drive member 136 is the member 156, in Fig. 7 is shown. In Fig.

adapted to the sprocket 134. A driving 80 8, there is a trolley member 174 which is sprocket (not shown) is mounted on an output connected to an end 176 and 178 of the shaft 137 of a d.c. drive motor 138. The chain member 126. (There is a similar mem sprocket 134 is suitable engaged with one ber attached and aligned with the chain mem side of the mechanical, torque limiting slip ber 124). There are suitable connecting pins clutch-device 136, which acts as a drag brake- 85 180, which engage the respective receiving in the apparatus. Therefore, when the motor holes in the trolley 174, and the links of the 138 is energized, the conveyor 118 indexes chain 126. There is a bracket 182, which is forward one pitch. One index of the conveyor generally U-shaped, and which fits outside of 118 is s _fficient to provide an empty com- an edge 184 and 186 of the member 156, partment on the conveyor 118 which will seri- 90 such that an ear 188 and 190 receive a pin ally receive and stack a new batch of envel- 192 for connectively engaging the member ope being conveyed along the feed path 96. 156 which is fastened to the bracket 182 by There is a sensing device 142 which deter- a rivet 192 and 19X. A torsion spring 194 mines the position of the compartments within suitably urges the member 156 against an end the conveyor 118 (see Fig. 1). Referring back 95 196 of the bracket 182, which acts as a limit to Fig. 2, each chain member 124 and 126 stop for the member 156. It will be evident has a plurality of spaced apart separator mem- that all the separator members are similarly bers, such as a member 144 and a member attached to their respective mounts and 146, each being connected to the chain mem- chains, and further that the springs such as ber 124 and 126 respectively. The members 100 the torsion spring 194 are sufficiently strong 144 and 146 are generally perpendicular with enough to yield only when engaging positive respect to the frame 122, and conveyor 118, obstacle such as a person's limb, hand, or the but are resiliently mounted to the chains for curved member 172 which is designed to re pivotable movement when the stack of envel- ceive and deflect those separator members.

opes is dumped into a hopper 150, located at 105 There is a speed control device 198 (refer the output end of the conveyor 118. to Fig. 5) which is operatively connected to a The separator members are spaced apart, motor control apparatus 200. An operator of sufficiently enough to allow the width of an the apparatus 10 may vary the speed of the average mail piece to easily enter a compart- conveying apparatus 118 during the indexing ment 152, which is located immediately adja- 110 to that of the output speed of the inserting cent to the output end of the feed path 96. machine. The need for varying the conveyor The sensing device 142 is looking for a sep- 118 speed may exist when there is a heavy arator member when the conveyor is indexing load being conveyed by the conveyor appara forward with compartments filled with mail, tus 118. The slip clutch device 136 has a and when a separator membe such as a 115 limiting torque transmission, and must there member 154 (refer to Fig. 5) is aligned with fore be compensated for by an increase in the scanning path of the device 142, the mo- speed of the conveyor 118, when the con tor 138 stops driving the conveyor 118. veyor 118 is carrying heavy stacks of envel- Referring to Figs. 6 and 7, there is shown a opes. For example, if each compartment is portion of an output end 155 of the conveyor 120 loaded with 10 envelopes having 1 or 2 en apparatus 118, which shows a shaft 132% closures each, the weight is only perhaps 10 supporting a pair of sprockets 130% and the ounces per compartment, times the number of chain members 124 and 126. A separator compartments being advances forward. If the member 156 is shown in its generally verti compartments are filled with say 20 envel cally oriented position, and there is a stack of 125 opes, which are each 3/W thick, the weight envelopes 1H aligned with an edge 160 of of each envelope may approach 16 ounces, the member 156 (there is a pair of members and therefore will be 20 pounds per compart- 156). There is a bridge support frame 162, ment. The failure to maintain speed by the having a suitably mounted brush 164. The conveyor 118 will be compensated for by brush 164 causes the stack of envelopes 158 130 providing a slight increase of speed in adjust- GB2195801A 5 ment of the device 198. ery may be made directly to the USPS. Alter- Referring to Fig. 7, the hopper 150 is seen natively, the stack 201, and all following having a stack of envelopes 201 therein. The banded stacks may then be simply deposited stack 201 was previously dumped off of the directly into a suitable mail bag or other ap output end 155 of the conveyor 118 during 70 propriate receptacle. It is pointed out that an indexing motion of the conveyor 118. Re- either one or two bands may be applied to ferring to Fig. 6, the hopper 150 is seen each stack of envelopes, and that the arm along with guiding members which assist the assembly 2 10 may only have to travel to a stacks of envelopes such as the stack 201 in substantially upright position, from which the the descent to the pocket 150. For example, 75 bundled stack of envelopes may be released.

there is a guide 202, which is suitably fas- In addition, it is hereby pointed out that this tened to the bridge support frame 162, and a function occurs as a result of structure which flared member 204, which helps in deflecting is not disclosed and is not part of the present the stack of envelopes downwardly towards invention.

the hopper 150. A guide 20.6 is positioned 80 Therefore, having briefly described the vari- according to the width of the stack 201. A ous parts and functions of the present inven platform 208 is fixedly mounted to the frame tion, the operation of the invention will now 122 of the apparatus 118 to provide an in- be described.

clined registration surface for accepting each stack of envelopes. 85 Operation of the Invention Referring to Fig. 2, it will be evident that Referring back to Fig. 1 and the apparatus the stack of envelopes 201 has been located 10, the web 40 enters the bursting and fold and registered within the hopper 150 by the ing Module 38 where the panel 46 (refer to various guides described heretofore, in prepa- Fig. 3) is burst from the remainder of the web ration for further processing. 90 40. If there were an associated plurality of The next operation to be performed on the panels or billing statements accompanying the stack 200 entails banding. Basically, there is panel 46, such as pages 1, 2 and so forth, an oscillating arm assembly 210 pivotably lo- those panels would have been burst from the cated within a banding apparatus 212. There web 40 in advance of the panel 46. Each of is a frame 214 (see Fig. 1 and Fig. 2) which 95 the associated panels, including the panel 46 is suitably constructed to rigidly support the is then scanned by the scanning devices 64 apparatus 212. The arm assembly 210 is and 68 referred to in the preceding specifica seen through some protective transparent tion and in Fig. 4. The indicia 48 and the covers of the banding apparatus, including a dash 50, if present, are read by the associ fixed cover 216 and a pivotable cover 218, 100 ated scanners 64 and 68, respectively, and which provides operator access to the band- the information is stored in the referenced ing apparatus 212. In Fig. 1, we see that the electronic control apparatus, for controlling stack of envelopes is moved along an arcuate and monitoring related functions, as is de path 220, and at an intermediate position of scribed in the referenced prior art within the travel is temporarily positioned for application 105 specification. The panel 46 has the dash 50, of a rubber band 222. The stack 201 is tem- and will therefore communicate this data (zip porarily gripped by a plurality of appropriate code break) with subsequent movement of the gripper devices 226 which are operatively panel 46 and its associated documents connected to the arm assembly 210 and con- through the inserting machine 14.

trolled by an electronic control apparatus 228. 110 When the panel 46 and related panels arrive The control apparatus 228 will not be de- at the conveying device 28, all documents are scribed in detail within the present specifica- in the position shown and represented in Fig.

tion, since it is not relevant to the major 2 having been accumulated in the pile 74, and thrust of the present invention. It will suffice moved to the downstream end of the insert to mention that the arm assembly 210 is a 115 ing machine 14. The pile 74 is deposited cyclicable mechanical device which is utilized within the envelope 76, and the envelope 74 in the manner not unlike a robot arm to firmly is subsequently conveyed to the turntable grip a batch of envelopes, such as the stack apparatus 88. It will be understood that there 201, and to present the batch 200 to a rubis a second pile of enclosures in spaced rela ber band application apparatus generally de- 120 tionship upstream with respect to the pile 74, noted as 230. The apparatus 230 initially ap- and so forth, each pile being identified with a plies the rubber band 222 around the widest particular zip code area, which may be the dimension of the envelope stack 201, while same, or be different as will be recognized by the arm assembly 210 is positioned in a sub- the scanner 68. The envelope 76 with the stantially vertical position 232. The banding 125 predetermined amount of contents (the panel apparatus 230 may then apply another other 46 and related panels) then is advanced di rubber band as is required. The arm assembly rectly to the mailing machine and associated 210 then continues rotating along the arcuate postage meter 104, The envelope 76 then path 220, to deliver the banded stack of en- continues advancing along the feed path 96 to velopes to a conveyor 236, from which deliv- 130 the conveying rollers 110, having had suitable 6 GB2195801A 6 postage applied, and is thereafter sensed as switch 248 is engaged, the OR gate 242 en having arrived thereat by the scanning device ables the latch 244 through aconnector 251 112. It is pointed out that there is a plurality to energize the relay 246 through the connec of similar scanning devices (not shown) lo- tors 245 and 247, thereby causing the subse cated along within the feed path 96 of the 70 quent energization of the d. c. motor 138. Dur inserting machine 14. Each scanner will detect ing the course of indexing of the conveyor the passage of the appropriate corresponding 118, the separator member following the sep documents. The pile 74 is sensed as having arator member 154 is detected by the sensing arrived at the stuffing station for example, and device 142, and the motor 138 is de-ener- the envelope 76 as having been positioned at 75 gized.

the feeder 86. In addition, sensing devices ar- Referring now to Fig. 1, a more detailed I ranged along the feed path 96 detect the arri- explanation of the counting and advancing val of the envelope 76 prior to arrival at the apparatus will be made. A compartment 250 meter 104. The intelligence of the apparatus is shown advancing towards the output end 10 is designed to maintain the particular appa- 80 155 of the conveyor apparatus 118, having ratus of each respective element of the appa- 20 envelopes therein. A compartment 252 ratus 10 cognizant of the presence or absence has 15 envelopes, and is of the same zip of the documents which have been scanned code area as the compartment 250. A com or read for the indicia such as the indicia 48 partment 254 has a stack of 20 envelopes located thereon. Therefore, when new indicia 85 with a new zip code, and a compartment 256 (such as the dash 54) including a new zip has a stack of 20 envelopes. The operator code area, or a zip code break is recognized, has set the number 20 into the adjustable the count of envelopes at the control device piece counting device as was previously de- 116 is immediately restarted. It is pointed out scribed. The conveyor apparatus 118 is con- that there may be as few as one, or many 90 tinuing to receive batches of 20 envelopes in envelopes in a given zip code area, all of each compartment, and indexes according to which will be received by the conveyor 118. the electronic counting controls provided in The machine operator is in control of part the device 116 previously described. The con- of the operator of the machine insofar as pro- trol device 116 constitutes an apparatus gramming the control device 116 to cause the 95 which interfaces the scanning device 112 and conveyor 118 to index forward after a predetthe conveying apparatus 118 for indexing the ermined count of mail pieces are seen by the apparatus 118 when a predetermined number scanning device 112. The operator will dial in of envelopes (such as 20) has passed the a desired count number through a control scanning device 112. The control device 116 knob 238 connected to the counter 114. A 100 matches the number of envelopes passing the count, such as 20 (refer to Fig. 5) may be scanning device 112 against the predeter entered which means that when the electronic mined number set into the piece counter 114, control device 70 signals through a connector and then enables the indexing of the conveyor 239 to and AND gate 240 at the same time 118. It will be evident that the index occurs that the scanning device 112 has detected 105 whether or not a zip code break is recognized mail pieces and caused the counter 114 to because of the set number 20.

have counted 20 pieces through a connector There is an additional feature included with 241, a signal will be given to an OR gate 242 the control device wherein an indicator lamp through a connector 243 and through a con- 260 is illuminated whenever less than a pre nector 241" to enable a latch 244 through a 110 determined minimum number of envelopes has connector 245 to further enable a relay 246 been deposited within a compartment of the through a connector 247, and thereby ener- conveyor 11 B. For example, if the adjustable gize the d.c. motor 138 through a connector piece counter 114 has been programmed to 249 and 249'. The conveyor 118 then in- count 20 pieces of a run, and a compartment dexes forward one pitch, which is defined by 115 only fills to 19, or less pieces, the indicator the sensing device 142, detecting the separa- lamp 260 would illuminate. If a signal comes tor member 154. During each index, or ad- from the counter 114 to an AND gate 264, vance, it will be recognized that a new separ- through a connector 265m at the same time ator member representing one pitch or index that a signal comes from the AND gate 240 cycle, will be detected for each corresponding 120 through a connector 267, the lamp 260 is indexing motion of the conveyor 118. The illuminated. The machine operator would at speed control device 198 is directly linked this point, manually distribute the smaller num through the connector 249' and a connector ber of mail pieces (19) into the preceding bins 249" to the motor 138, to enable the previ- containing 20 pieces.

ously discussed operator speed control of the 125 Therefore, having briefly described the pre- conveyor apparatus 118. sent invention in terms of a sorting and band- Whenever a manual switch 248 is de- ing apparatus, the advantages will be recog- pressed by the machine operator, the conveynized for use of the apparatus in conjunction ing apparatus 118 cycles forward to enable with an inserting machine, or other article con clearance of the stacker. Therefore, when 130 veying apparatus.

7 GB2195801A 7 It will be seen that the embodiment dis- indexing said conveyor means when a predet- closed and illustrated has the following advan- ermined number of said envelopes has passed tages:- said scanning means.

it provides an automatic system for sorting 3. Apparatus as set forth in claim 2 mail into groups having given zip code break 70 wherein said control means comprises:

data which is preprinted on selected docu- A. manually settable means for entering a ments of a plurality of documents; it enables number into said control means representative counting mail pieces into predetermined numof the maximum number of envelopes of a bers by groups which are suitable for handling given thickness which can be deposited one by the Postal Authorities; it provides an appa- 75 on top of another on said conveyor means, ratus for separating groups of mail pieces by and an apparatus which indexes upon matching a B. second means for indexing said conveyor number set into a control device by a machine means when the number of envelopes de operator; it enables banding the mail piece tected by said scanning means matches said groups by applying a rubber band in at least 80 predetermined number.

one direction which captures all of the mail 4. Apparatus as set forth in claim 3 pieces into a manageable package (one can wherein said control means further comprises also apply a second rubbber band to the mail means for detecting and indicating when less piece group so as to ensure integrity of that than a predetermined minimum number of en mail group during handling); and it provides a 85 velopes has been deposited on said conveyor conveying apparatus which has upstanding and said conveyor has been indexed by said pusher members which yield after having de- first indexing means.

livered a batch of mail to the banding device. 5. Apparatus as set forth in any one of claim 1-4 wherein said conveyor means corn

Claims (1)

1. CLAIMS 90 prises:-

   1. Apparatus for sorting and banding mail A. a pair of endless members, according to zip code break data preprinted B. guide means for causing said endless on selected documents of a plurality of docu- members to move in a substantially horizontal ments which are fed seriatim through an inpath, and serting machine in which at least one docu- 95 C. a plurality of separator members con- ment is placed in an envelope of a batch of nected to said endless members in generally successively fed envelopes, said sorting and perpendicular relationship thereto for defining banding apparatus comprising: individual compartments into which said envel- A. means for reading zip code break data opes are deposited one on top of another to preprinted on said selected documents, 100 form said discrete bundles.

   B. means for feeding said plurality of docu- 6. Apparatus as set forth in claim 5 ments including said selected documents seri- wherein said banding means comprises:

   atim past said zip code break data reading A. envelope transfer means for receiving means, bundles of envelopes from said conveyor C. conveying means for receiving a plurality 105 means and for gripping said bundles and of said envelopes seriatim from said inserting transferring them to a banding position, and machine, B. means at said banding position for placD. first means responsive to said zip code ing at least one rubber band around said bun- break data reading means for indexing said die of envelopes while it is gripped by said conveyor means when the first envelope of 110 transfer means.

   another zip code area arrives at said conveyor 7. Apparatus as set forth in claim 6 means to cause envelopes designated for the wherein said transfer means comprises:

   same zip code area to be deposited one on A. an elongate arm having an envelope bun- top of another on said conveyor means to dle holding hopper mounted on an end of said form discrete bundles of envelopes thereof, 115 arm, and and B. means mounting the other end of said E. banding means disposed adjacent the arm for oscillating movement of said arm from other end of said conveyor means for receiv- an envelope receiving position in which said ing discrete bundles of envelopes from said hopper is adjacent the downstream end of conveyor means and for placing at least one 120 said conveyor means with respect to said en elastic band around each of said discrete velope banding position.

   bundles of said envelopes. 8. Apparatus as set forth in claim 7 2. Apparatus as set forth in claim 1 further wherein said conveyor means further corn- including: prises:

   A. scanning means disposed in the path of 125 A. means connecting said separator mem- envelopes being fed to said conveyor means bers to said endless members for limited rela for detecting envelopes passing said scanning tive rotation with respect thereto, means, and B. resilient means normally urging said sep- B. control means interconnected between arators members to said perpendicular rela- said scanning means and said conveyor for 130 tionship, and 8 GB2195801A 8 C. means for causing said separator'mem- bers to rotate in a direction opposite to the direction of movement of said conveyor means after said bundle of envelopes has been transferred from said conveyor means to said hopper of said transfer means so that said separator members do not interfere with said hopper as said separator members and said endless members reverse directions at said downstream end of said conveyor means.

   9. Apparatus for sorting and bandling mail substantailly as herein described with refer ence to and as illustrated in the accompanying drawings.

   10. Any novel combination or sub-combi- nation disclosed and/or illustrated herein.

   Published 1988 at ThePatent Office, State House, 66/71 High Holborn, London WC1R 4TP. Further copies may be obtained from The Patent Office, Sales Branch, St Mary Cray, Orpington, Kent BR5 3RD.

   Printed by Burgess & Son (Abingdon) Ltd. Con. 1/87.