WO2000017052A1

WO2000017052A1 - Servo motor controlled continuous motion inserting apparatus and method

Info

Publication number: WO2000017052A1
Application number: PCT/US1999/017629
Authority: WO
Inventors: Steve W. Mccay
Original assignee: Bell & Howell Mail And Messaging Technologies
Priority date: 1998-09-24
Filing date: 1999-08-03
Publication date: 2000-03-30
Also published as: AU5254299A

Abstract

A servo motor controlled continuous motion inserting apparatus (1) and method is disclosed. By use of independantly controllable servo motors electronically connected to a single controller (C), a practical continuous motion inserting apparatus that has the ability to alter apparatus synchronization to insert different sized forms into different sized envelopes (E) as well as control the apparatus throughput speed is created.

Description

SERVO MOTOR CONTROLLED CONTINUOUS MOTION INSERTING

APPARATUS AND METHOD

Technical Field

The present invention relates generally to mail processing, and more

particularly to a continuous motion inserting apparatus and method.

Background Art

U.S. Patent Number 3,423,900, to Orsinαer et al.. dated January 28,

1969, and incorporated herein by reference, discloses what is called a

continuous motion inserting machine. As described in the patent, a continuous

motion inserting machine provides a collating-inserting machine operable

without hesitations or dwells, and constructed and arranged to operate in a

continuously flowing manner such that inserts and corresponding envelopes

are brought together and the inserts filled into the envelopes while both are in

continuous movement. This machine is drastically different from the typical

incremental inserter machine in which the envelope is stopped during the entire

step during which the insert is placed inside it. Since there are no periods of

time in which the envelope is stopped in a continuous motion inserting

machine, it is inherently faster and more efficient than incremental inserting

machines. To date, the concepts behind the Orsinger continuous motion inserting

machine have not been widely implemented. This is because of mechanical

and dynamic limitations inherent in its mechanism. The Orsinger inserter, an

awkward, chain and gear operated machine, has a relatively high mass and it

is difficult to change or adjust the synchronization between the inserter and

envelope conveyors to allow for increased flexibility and different modes of

operation.

Accordingly, there is room for improvement within the art.

Disclosure of the Invention

It is an object of the invention to provide a continuous motion inserting

apparatus and method that is an improvement over prior art continuous motion

inserting apparatuses and methods.

It is a further object of the invention to provide an improved continuous

motion inserting apparatus and method that is of a lower mass than prior art

continuous motion inserting apparatuses and methods.

It is yet a further object of the invention to provide an improved

continuous motion inserting machine that is easily able to have the

synchronization between its insert and envelope conveyors adjusted.

These and other objects of the invention are achieved by a continuous

motion inserting apparatus and method, comprising: an envelope conveyorfor

feeding an envelope in a feed direction with its open end trailing during an

insertion step; an insert conveyorfor feeding an insert in the feed direction from

a position upstream of said envelope conveyor during the insertion step; wherein during the insertion step the insert conveyor moves the insert at a

speed greater than the envelope conveyor moves the envelope such that at a

predetermined position the insert is entirely within the envelope; and wherein

the insert and envelope conveyors are driven by first and second servo motor

controlled mechanisms, respectively.

These and other objects of the invention are achieved by a method of

inserting an insert into an open envelope, comprising the steps of: providing a

servo motor controlled envelope conveyor for feeding an envelope in a feed

direction with its open end trailing during an insertion step; providing a servo

motor controlled insert conveyor for feeding an insert in the feed direction from

a position upstream of the envelope conveyor at a speed greater than the

envelope conveyor moves the envelope during the insertion step such that at

a predetermined position the insert is entirely within the envelope.

Some of the objects of the invention having been stated hereinabove,

other objects will become evident as the description proceeds, when taken in

connection with the accompanying drawings as best described hereinbelow.

Brief Description of the Drawings

Figure 1 is a plan view of a continuous motion inserting apparatus

according to the present invention;

Figure 2 is an elevation view of a continuous motion inserting apparatus

according to the present invention; and Figure 3 is an elevation view depicting the envelope presentation,

registration, and opening location of a continuous motion inserting apparatus

according to the present invention.

Best Mode for Carrying Out the Invention

With reference to the above drawings, an improved continuous motion

inserting apparatus and method that meets and achieves all the various objects

of the invention set forth above will now be described.

Figures 1 and 2 show an exemplary embodiment of an improved

continuous motion inserting apparatus 1 according to the present invention.

Continuous motion inserting machine 1 generally comprises insert

conveyor subassembly 10 and envelope conveyor subassembly 50,

respectively. Both conveyor subassemblies are preferably servo motor

controlled mechanisms and operate to continuously feed their respective

products, i.e., inserts and envelopes, respectively, in feed direction F without

stopping for any substantial amount of time. During this feeding process, as

will be described below, the two subassemblies also operate to place the insert

within the envelope.

Insert feed conveyor subassembly 10 is most clearly shown in the plan

view of Figure 2. Although it is preferred and described herein that

subassembly 10 comprises side-by-side chain conveyors, it is possible to

employ belt conveyors. Each chain 20 is wrapped around a pair of rotatable

sprockets 25, 25'. To drive each of the side by side conveyors, it is preferred

to fixedly mount an adjacent pair of sprockets 25 on common drive shaft 27 and then connect drive shaft 27 to a servo motor 28 by a mechanical

movement 29, such as a conventional belt and pulley combination. It is also

possible to mount each sprocket 25 on its own axle and then connect each axle

to its own servo motor 27. In either form, however, servo motor(s) 27 will be

connected to a common electronic controller C as will be described below.

Tension sprockets 26 take up any slack in chains 20 and therefore control the

tension in chains 20. Finally, each chain 20 has a plurality of pusher fingers

30, 30', 35, 35", 40, 40' , thereon. These pusherfingers 30, 30', 35, 35', 40, 40'

operate to push an insert I downstream in feed direction F and at a continuous

and constant speed.

Envelope transport conveyor subassemblies 50, 50' are mirror images

of each other and together form the envelope transport conveyor that is used

to transport envelopes E downstream in feed direction F and also at a constant

speed with only momentary stopping during a registration step. From a remote

source, envelopes E are fed to envelope transport conveyor subassemblies 50,

50", via a conventional envelope conveyor (Figure 3) feeding in the direction of

arrow G.

Figure 3 is an elevation view depicting the envelope presentation,

registration, and opening location 100. Location 100 includes a conventional

rotating envelope drum 110, typically and preferably in the form of a rotating

vacuum envelope drum 110 having an envelope gripping member 115 thereon

and positioned below table surface T. Table surface T has a slot therein so

that envelopes may be fed by envelope drum 110 from a position below table surface T to a position above table T so that the envelope can be registered,

opened, and filled.

To register envelope E in area 100, a registration mechanism 200, is

used. Registration mechanism 200, preferably in the form of a front edge ^~

registration system, includes retractable lower portion 210 and stationary upper

portion 220. Stationary upper portion 220 comprises a plurality of spaced apart

vertical plates 220a. Retractable lower portion 210 comprises a moveable front

stop 215 attached to a motor 217 through a suitable mechanical linkage 216.

The mechanical linkage converts the rotary motion of motor 217 in to the

reciprocating motion of stop 215. However, any type of motor and any type of

linkage may be used so long as stop 215 can be moved above or below table

T.

When in its raised position, stop 215 interacts with vertical plates 220a

to form a gate preventing envelopes from passing by. This gate also forms a

front registration element. Therefore, as envelope E is fed into area 200 by

envelope gripping member 115 of envelope drum 110, its leading edge will be

brought into contact with the registration element 210, 220, thereby registering

and squaring the envelope E. The envelope E is momentarily stopped at this

time.

Because, as described above, the envelope is momentarily stopped in

the inserting apparatus according to the invention, it is not a true continuous

inserting apparatus. However, this stop time (dwell) is both short in an absolute

sense as well as in relation to the overall apparatus cycling time. Furthermore, in the inserter apparatus according to the present invention, both the envelope

and insert are in motion during the entire inserting step. In a conventional

incremental inserter, not only is the stop time (dwell) much longer both in

absolute and relative terms, the envelope is stationary during the entire ^~

inserting step. Accordingly, despite the small stop (dwell) time in the inserter

according to the invention, the invention still better approximates the operation

of a true continuous motion inserting apparatus and therefore can be labeled

as such.

Afterthe envelope E is stopped, squared and registered, it is opened by

envelope opening mechanism O. The form of envelope opening mechanism

O plays no part in the invention and may take any form so long as cycling

speeds of the continuous motion inserting apparatus in general are met.

However, typically envelope opening mechanism O will comprise some type of

vertically movable vacuum element that is able to pull apart the walls of the

envelope E.

Finally, after the envelope E is stopped, squared, registered, and

opened, stop 215 is lowered to its position below table T and envelope

transport conveyor subassemblies 50, 50" take over the feeding of the

envelope.

Envelope transport conveyor subassemblies 50, 50" are most clearly

shown in the plan view of Figure 1. Each envelope transport conveyor

subassembly is also preferably a chain mechanism, like those that make up

insert feed conveyor sub-assembly 10. Chains 55, 55" are wrapped around rotatable sprockets 56, 57 and 56', 57', respectively. One of the two sprockets

of each of envelope transport conveyors subassemblies 50, 50' is connected

to a servo motor 59, 59' through a mechanical movement 60, 60', such as a

conventional belt and pulley system. It is also possible to commonly drive ^~

envelope transport conveyor subassemblies 50, 50" by a common motor and

drive (not shown). However, due to spacing and location concerns, it is simpler

and easier to independently drive each envelope conveyor subassembly 50,

50". Like servo motors 27, servo motors 59, 59' are electronically connected

to controller C.

For actually moving the envelopes again, each envelope transport

conveyor chain 55, 55" is provided with a plurality of opening fingers 65, 66, 67,

65', 66', 67' that work together in opposing pairs. Each opening finger may be

similarly constructed from suitably formed sheet metal or plastic in an

elongated channel-shaped cross-section having its forward end shaped and

constructed, i.e., tapered, to facilitate entry into the mouth of an envelope.

Finally, opening fingers 65, 66, 67, 65', 66", 67' continuously travel along the

paths defined by chains 55, 55' in the direction of arrows H and at a constant

speed.

After the envelope is presented for insertion and momentarily stopped

after registration, a pair of opposing opening fingers will swing around

sprockets 56, 56', and begin to enter the gap of the mouth of the presented and

opened envelope along the envelope's opposite edges. As the opening fingers

continue to be moved in feed direction F, they will continue entering the envelope until fully inside. By that point, the opening fingers will have complete

control of the envelope, feeding it downstream again as the opening fingers 65,

65', 66, 66', 67, 67' move downstream. Though the envelope was momentarily

stopped from being fed, as described above, this time period is small in ^~

absolute terms as well as in relation to the inserter cycle speed that it results

in a minimal delay, unlike the substantial delays incurred in prior art non-

continuous (incremental) motion inserting apparatuses.

Within the engaged envelope, opening fingers provide, in effect, an

insert receiving funnel opening rearward. To facilitate reception of inserts into

the funnel thus provided, the fingers are desirably provided on their lower rear

portions with flanges which may extend into close proximity of each other over

the envelope flap (to hold the flap open).

As each envelope E is thus readied in the filling zone, inserts I are thrust

by insert feed conveyor subassembly 10 through the opening fingers and into

the envelopes E. The speed of insert feed conveyor subassembly 10 is set to

a speed faster than that by which envelopes E are fed downstream in direction

F by the envelope transport conveyor subassemblies 50, 50'. Thus, inserts I

will completely be inserted into envelopes E. As can be seen by this

description, in the continuous motion inserter apparatus according to the

invention the envelope is moved in a downstream direction as the envelope is

being filled, i.e., during the insertion step. Other than during the short moment

during the registration step, the envelope is continuously moving downstream

and is not stationary. The fact that the continuous motion inserter according to the invention

provides for the use of servo motors to drive each the insert and envelope

conveyors represents a large step forward in this technology.

In prior art continuous feeding apparatuses, such as described above ^~

and in U.S. Patent No. 3,423,900, to Orsinger et al.. since all of the drive

components are mechanically linked to each other, such as by chains and

gears, the apparatus will not be able to have the synchronization between the

envelope and insert conveyors easily changed. Being able to easily change

this synchronization is important to a more efficient use of the continuous

motion inserting apparatus. In particular, for different sized (e.g. length) forms,

the location at which the insert is placed into the envelope will be different.

Similarly, for different thickness inserts, different operating speeds will be

required so as to prevent jams. In prior art continuous motion inserting

apparatuses such as described in Orsinger, changing the synchronization

between insert and envelope conveyors requires difficult and time consuming

processes. For example, gear ratios need to be changed and that can only be

done by the replacement of one sized gear with another sized gear. This may

require taking apart large portions of the continuous motion inserting apparatus

to gain access to these components. Such taking apart is time consuming.

Other issues such as belt slippage and gear teeth mis-meshing can result in

a mechanical system that easily goes out of synchronization. It is probably for

these reasons that the Orsinger continuous motion inserter has not been

implemented in working embodiments despite its advance in the art. The continuous motion inserter according to the invention overcomes all

these deficiencies to prior art continuous motion inserter and therefore allows

for the practical implementation and use of continuous inserting theory. What

allows for the implementation of the continuous motion inserting theory, i.e.,

keeping both the insert and envelope in motion for as long as possible and with

as little stop (dwell) time as possible, in practical applications in the apparatus

according to the invention and not in Orsinger is the use of independently

controllable drive sources to drive each of the mechanical conveyors in the

invention. As described above, the preferred type of independent drive

sources comprises independently controllable servo motors. Because

continuous motion inserting apparatus 1 uses independently driven servo

motors, the apparatus will be of lower mass and inertia. Accordingly, lower

power servo motors can be used and less power consumed during apparatus

operation. Also, the low mass/inertia allows for some stopping motion to be

introduced in the registration step, without any degradation in apparatus

throughput or reliability.

Each of the independently controllable servo motors will be electronically

connected to a common controller, such as in the form of a conventional

microprocessor controlled computer. Data provided to this controller, whether

in the form of look-up tables or directly entered data, will be used to control the

synchronization of the various servo motors within the continuous motion

inserter according to the invention. This synchronization allows for the start

and stop times of each servo motor to be controlled as well as their speeds. By adjusting these speeds, not only can the continuous motion inserter insert

different sized inserts into different sized envelopes, it can also control

apparatus throughput speed. Control of apparatus throughput speed is

especially important with larger inserts that require more positive control in ^~

order to prevent jamming.

Through a user interface 300 of some type, the inserter operator (or the

inserter itself) will be able to vary the synchronization by merely making

selections either from a keyboard or other conventional input device or sensor.

The controller will then do the rest and no mechanical adjustments or changes

will have to be made to the continuous motion inserter. This allows for

instantaneous changes in apparatus configuration, a highly beneficial result.

Finally, while as described above the instant invention is not a true

continuous motion inserting apparatus in as much as the envelope does

momentarily stop during the registration step, but not during the insertion step,

this time period in which the apparatus stops is small in absolute terms and in

relation to the overall cycle speed that is has no practical effect on the inserting

process and renders the inserting apparatus according to the invention a better

approximation to a true continuous motion inserting apparatus than would be

a conventional incremental inserter. Further, as described above, the low

mass/inertia of the apparatus allows the small periods of stop time to be

introduced without any degradation of apparatus throughput speed or reliability,

thus still achieving the objects of the invention set forth above. The above description is given with reference to a continuous motion

inserting apparatus and method. However, it will be understood that various

details of the invention may be changed without departing from the scope of

the invention. Furthermore, the foregoing description is for purpose of ^~

illustration only, and not for purpose of limitation, as the invention is defined by

the following, appended claims.

It will be understood that various details of the invention may be

changed without departing from the scope of the invention. Furthermore, the

foregoing description is for the purpose of illustration only, and not for the

purpose of limitation, as the invention is defined by the following, appended

claims.

Claims

CLAIMSWhat is claimed is:

1. A continuous motion inserting apparatus, comprising:

(a) an envelope conveyor for feeding an envelope in a feed direction

with its open end trailing during an insertion step;

(b) an insert conveyor for feeding an insert in said feed direction

from a position upstream of said envelope conveyor during said

insertion step;

(c) wherein during said insertion step said insert conveyor moves

said insert at a speed greater than said envelope conveyor

moves said envelope such that at a predetermined position said

insert is entirely within said envelope; and

(d) wherein said insert and envelope conveyors are driven by first

and second servo motor controlled mechanisms, respectively.

2. The apparatus according to claim 1 , wherein said first servo

motor controlled mechanism is driven by a first servo motor and said second

servo motor controlled mechanism is driven by second and third servo motors.

3. The apparatus according to claim 2, wherein said first, second,

and third servo motors are controlled by a single motion control system.

4. The apparatus according to claim 3, wherein said single motion

control system comprises an electronic controller.

5. The apparatus according to claim 4, wherein said electronic

controller comprises a microprocessor-based computer.

6. The apparatus according to claim 5, wherein:

(a) said first, second, and third servo motors are operated in

synchronization by said computer; and

(b) said synchronization can be adjusted by modifying data in said

computer.

7. The apparatus according to claim 6, wherein different said

synchronizations allow for the insertion of different sized forms into different

sized envelopes.

8. The apparatus according to claim 1 , wherein both said envelope

and insert are in motion during the entire said insertion step.

9. A method of inserting an insert into an open envelope, comprising

the steps of:

(a) providing a servo motor controlled envelope conveyor for feeding

an envelope in a feed direction with its open end trailing during

an insertion step; and

(b) providing a servo motor controlled insert conveyor for feeding an

insert in said feed direction from a position upstream of said

envelope conveyor at a speed greater than said envelope

conveyor moves said envelope during said insertion step such

that at a predetermined position said insert is entirely within said

envelope.

10. The method according to claim 9, wherein: (a) said step of providing a servo motor controlled insert conveyor further comprises providing a first servo motor; and

(b) said step of providing a servo motor controlled envelope

conveyor further comprises providing second and third servo

motors.

11. The method according to claim 10, further comprising the step of

controlling said first, second, and third servo motors by use of a single

controller.

12. The method according to claim 11 , further comprising the step of

controlling the synchronization of said first, second, and third servo motors by

adjusting data within said single motion controller.

13. The method according to claim 9, wherein both said envelope and

insert are in motion during the entire said insertion step.