U.S. patent application number 09/945219 was filed with the patent office on 2003-03-06 for high page count method for mail inserts.
Invention is credited to Stevens, Kenneth A..
Application Number | 20030042666 09/945219 |
Document ID | / |
Family ID | 25482805 |
Filed Date | 2003-03-06 |
United States Patent
Application |
20030042666 |
Kind Code |
A1 |
Stevens, Kenneth A. |
March 6, 2003 |
High page count method for mail inserts
Abstract
The invention is directed to a High Page Count method for mail
inserters. The High Page Count method utilizes multiple source
feeders to deposit source material onto a moving track at a rate
equal to the speed at which the track operates. The High Page Count
method is designed to optimize the mail inserter process by
ensuring that no track position goes unfilled.
Inventors: |
Stevens, Kenneth A.;
(Batavia, IL) |
Correspondence
Address: |
Glenn W. Ohlson
Lee, Mann, Smith, McWilliams Sweeney & Ohlson
P.O. Box 2786
Chicago
IL
60690-2786
US
|
Family ID: |
25482805 |
Appl. No.: |
09/945219 |
Filed: |
August 30, 2001 |
Current U.S.
Class: |
271/9.02 |
Current CPC
Class: |
B65H 2511/526 20130101;
B42C 1/10 20130101; B65H 39/02 20130101; B65H 2511/526 20130101;
B65H 2220/01 20130101 |
Class at
Publication: |
271/9.02 |
International
Class: |
B65H 003/44 |
Claims
1. A method for processing mail inserts, comprising the steps of:
selectively operating two source feed units to compile and deposit
therefrom source material; at least one of the source feed units
being located downstream from an upstream source feed unit;
depositing source material onto a track from the upstream source
feed unit onto a track position; detecting when the upstream source
feed unit is unable to deposit source material onto a track
position; and, depositing source material onto the track from the
downstream source feed unit when the upstream source feed unit
fails to deposit source material onto a track position.
2. The method described in claim 1 including, detecting whether the
downstream source feed unit is prepared to deposit source material;
and, operating the upstream source feed unit to purposely leave an
empty track position when the downstream source feed unit is
prepared to deposit source material.
3. A method for processing mail inserts, comprising the steps of:
selectively operating two source feed units to compile and deposit
therefrom source material; at least one of the source feed units
being located downstream from an upstream source feed unit;
selectively operating a common feeder located upstream from the
upstream source feed unit; depositing common material from the
common feeder onto a track at positions therealong; depositing
source material from the upstream source feed unit onto the track
at positions therealong; detecting when the upstream feed unit is
unable to deposit source material onto a track position; and
depositing source material from the downstream source feed unit
onto the track at positions therealong at which positions the
upstream source feed unit fails to deposit source material
thereat.
4. A method for processing mail inserts, comprising the steps of:
placing two source feed units adjacent the same position along a
track; selectively operating said two source feed units to compile
and deposit therefrom source material; one of the source feed units
being a primary source feed unit the other being a secondary source
feed unit; depositing source material from the primary source feed
unit onto the track at positions therealong; detecting when the
primary source feed unit is unable to deposit source material onto
a track position; and depositing source material from the secondary
source feed unit onto the track at positions at which the primary
source unit has failed to deposit source material thereat.
5. The method described in claim 4 including, detecting when the
secondary source feeder unit is prepared to deposit source
material; and, operating the primary source feed unit to purposely
leave an empty track position when the secondary source feed unit
is prepared to deposit source material.
6. A method for sorting compiled pieces of source material,
comprising the steps of: selectively diverting source material,
compiled from a source feed unit feeding selected track positions,
from said selected track positions into a sorting path for said
source material from the source feed unit; depositing the source
material from the sorting path to an output station; and
distributing the source material from the output station to a
collector.
7. The method described in claim 6 including, selectively operating
a plurality of source feed units to compile source material and
separately diverting and depositing source material corresponding
to each one of said plurality of source feed units.
Description
BACKGROUND OF THE INVENTION
[0001] This invention may be described as an improved method for
optimizing mail inserters to match the document feeder output with
the speed of the track that carries the unique document downstream
where it is grouped with common documents and is inserted into an
envelope.
DESCRIPTION OF RELATED ART
[0002] In a typical mail inserter used for statement processing or
the like, one feeding unit serves as a master document feeder. This
master document feeder is generally the first device on the track
from start to end or from upstream to downstream track positions.
As the master document travels downstream, all other machine
functions will not be allowed to operate unless the master document
is present. For example, without the master, an outer envelope will
not be pulled; without the master, no marketing material will be
pulled; without the master, the postage meter will not fire.
[0003] By definition, the absence of the master document feeder is
an empty track position. In normal operation, it is common
occurrence to have a track outrun the master feeder. This is
especially true if the master feeder is collating multiple pages
together as a set. When the base machine outruns the master feeder,
the feeder is not ready to deposit its material onto the track, and
thus, loses its window of opportunity.
[0004] Obviously, the optimal running state of the machine is
always to maintain a full track with no empty positions. If empty
positions occur, there is a wasted machine cycle, which lessens the
machine's actual output and adds unnecessary wear to the
machine.
[0005] A unique and active solution to optimize the machine's
performance is to provide a means by which the track is to be kept
full by incorporating additional master feeders into the system. A
total of two or more master feeders can be configured in succession
down the track. If an upstream master feeder misses its window of
opportunity and leaves an empty track position, the downstream
feeder can ensure optimal machine operation by filling the empty
position.
SUMMARY OF THE INVENTION
[0006] This invention may be described as an improved method for
optimizing mail output by utilizing more than one source feed unit
to match the speed of the track. By matching the speed of the
track, the source feed units ensure that there is no empty position
on the track, and therefore, allow the mail inserter system to
operate at maximum capacity.
[0007] The High Page Count method can be configured in at least
three different systems. In the first system an upstream source
feed unit deposits the source material onto the track as fast as it
can. Unfortunately, because the track operates at a rate in excess
of what the upstream feeder can deposit source material at, there
will occasionally be an empty track position. In this situation,
the downstream feeder senses the empty track position and deposits
it's source material onto the track, thereby ensuring that no track
position goes unfilled.
[0008] In the second system, the High Page Count method introduces
a common feeder located upstream from the upstream source feed
unit. This common feeder places common material onto the track at a
rate equal to the track speed. As the common material gets to the
upstream source feed unit, the upstream source feed unit will
deposit it's source material onto the track position to accompany
the common material. Again, as the upstream source feeder cannot
match the rate of deposit with the speed of the track there will
occasionally be an empty track position. In this situation, the
downstream source feed unit will sense that the upstream source
feed unit did not deposit source material onto a track position and
will deposit it's source material onto the track, thereby ensuring
that every track position receives source material.
[0009] In the third system, the High Page Count method is
configured such that the source feed units are positioned across
from each other at the same track position. Once again, the primary
source feed unit cannot match the rate of deposit with the speed of
the track and the secondary source feed unit deposits it's source
material when it detects that the primary source feed unit cannot
make a deposit.
[0010] Each of these three systems for the High Page Count method
presents a unique solution for optimizing the mail inserter process
by utilizing multiple source feed unit to match the rate at which
the track operates. Furthermore, each of these three systems can be
configured such that the downstream output stations can be placed
at a right angle to the upstream source feed units thereby creating
a more compact design.
[0011] In each of the three systems for the High Page Count method,
because the source material is being deposited from at least two
source feed units the source material is in a random order on the
track. Therefore, it is a goal of the High Page Count method, at
the downstream section of the operation, to correct the randomness
of the source material placement on the track and reorder the
source material such that all the source material from the primary
source feed unit is sorted into one path, and all of the source
material from the secondary source feed unit is sorted into another
path.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a block diagram of a two source feed unit layout
of the present invention.
[0013] FIG. 2 is a flow chart of the high page count method with a
second source feed unit downstream from the primary source feed
unit.
[0014] FIG. 3 is a block diagram of a common feeder located
upstream from the two source feed units.
[0015] FIG. 4 is a flow chart for the high page count method
wherein a common feeder is located upstream from the two source
feed units.
[0016] FIG. 5 is a block diagram of the source feed units sharing
the same track position.
[0017] FIG. 6 is a flow chart for the high page count method
wherein the two source feed units share the same track
position.
[0018] FIG. 7 is a block diagram of the downstream output
station.
[0019] FIG. 8 is a block diagram of the high page count method in
an alternate embodiment with the downstream output station shown
perpendicular to the upstream source feed units.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] For the purpose of promoting an understanding of the
principles of the invention, references will be made to the
embodiments illustrated in the drawings. It will, nevertheless, be
understood that no limitation of the scope of the invention is
thereby intended, such alterations and further modifications in the
illustrated device, and such further applications of the principles
of the invention illustrated herein being contemplated as would
normally occur to the one skilled in the art to which the invention
relates.
[0021] Turning to FIG. 1, there is shown a block diagram of a two
source feed unit layout for System 1 of the present invention.
[0022] System 1 comprises at least two source feeder units 10 and
11. A first source feed unit 10 located at the beginning of a track
12 serves as a primary source feed unit 10. A second source feed
unit 11 is located downstream from the primary source feed unit 10.
Each source feed unit contains source material 17. The source
material 17 represents unique material that is customized for
individual purposes. For example, if the high page count method is
used for compiling billing material the source material 17 would
represent an individuals billing statement, which is unique to a
particular individual. Additionally, each source feed unit 10 and
11 contains a sensor 15 that detects whether the track 12 is empty
or whether the track has already been loaded with source material
17.
[0023] In order to correct the randomness that occurs as a result
of multiple source feed units operating on a single track, each
system described herein contains at least one output station 4A and
4B for each source feed unit 10 and 11, as shown in FIG. 7. Each
output station 4A and 4B contains multiple sorting paths 14A-D,
which allow the mail to be sorted in sequential order. For
instance, the mail that is produced from source material 17, as
shown in FIG. 1, from source feed unit 10 is directed to a
collector, such as bin 5A, at output station 4A. Mail that is
generated using source material 17, as shown in FIG. 1, from source
feed unit 11 is similarly directed to a collector, such as bin 5C,
at output station 4B. Each output station 4A and 4B contains at
least one bin 5, however, an alternate embodiment would contain
multiple collectors, such as bins 5A-D, so that depending on line
speed, economics, and operator speed, in the event of overflow of
one bin 5A a backup bin 5B is present to accept the overflow mail.
The output stations 4A and 4B would know what mail to receive
because each track section 16 is monitored such that the system
knows whether source feed unit 10 or source feed unit 11 deposited
a piece of source material 17 on a particular track section 16.
Furthermore, each output station 4A and 4B contains diverters 19 to
direct the mail from its respective source feed unit 10 and 11 into
the collectors, such as the bins, 5A-D, at the output stations 4A
and 4B. The output stations 4A and 4B of this invention operate
continuously, wherein a downstream track section 7 of the output
stations 4A and 4B moves at a speed that is faster than an upstream
track section 6 at the upstream source feed units 10 and 11.
[0024] Turning to FIG. 2, there is shown a flow chart of the high
page count method with the second source feed unit 11 downstream
from the primary source feed unit 10. The High Page Count method
has the ability to ensure that there are no empty track spaces 16.
The method begins by putting the track 12 in motion. Step 22
determines whether the primary source unit feeder 10 is ready. The
primary source feeder unit 10 is ready when it has compiled all of
the source material 17 that it needs for an individual. If the
response to step 22 is YES, the primary source feed unit 10
deposits its source material 17 onto the track space 16, as is
shown in step 24. After the primary source feeder 10 has deposited
the source material 17 onto the track space, step 26 shows that the
track 12 is advanced one position and the cycle begins again at
step 22 for the primary source feed unit 10. Alternatively, if the
response to step 22 is NO, the primary source feed unit 10 does not
deposit any source material 17 onto the track space 16 and
automatically proceeds to step 26 wherein the track 12 is advanced
one position.
[0025] At the same time the primary source feed unit 10 is running
through its cycle to determine whether it will deposit source
material 17 onto the track space 16, the secondary source feed unit
11 is running through a similar cycle. As is illustrated by step
28, the secondary source feed unit 11 begins its cycle by
determining whether the secondary source feed unit 11 is ready. As
with the primary source feed unit 10, the secondary source feed
unit 11 is ready when it has compiled all of the source material 17
that it needs for an individual. If the response to step 28 is NO,
the secondary source feed unit 11 automatically proceeds to step 34
wherein the secondary source feed unit 11 waits until the track 12
is advanced one position and the secondary source feed unit 11
begins its cycle again with step 28.
[0026] If the response to step 28 is YES, the secondary source feed
unit 11 proceeds to step 30 and determines whether the track space
16 located directly in front of the secondary source unit 11 is
empty. If the response to step 30 is NO, the secondary source feed
unit 11 again automatically proceeds to step 34 wherein the
secondary source feed unit 11 waits unit the track 12 is advanced
one position and the secondary source feed unit 11 begins its cycle
again with step 28.
[0027] If the response to step 30, however, is YES, the secondary
source feed unit 11 will deposit its source material 17 onto the
empty track space 16 located directly in front of the secondary
source feed unit 11. After the secondary source feed unit 11
deposits its source material 17 the secondary source feed unit 11
then proceeds to step 34 wherein the secondary source feed unit 11
waits for the track 12 to advance one position and the secondary
source feed unit 11 begins its cycle again with step 28.
[0028] Turning to FIG. 3 there is shown a block diagram of a common
feeder 13 located upstream from the two source feed units 10 and 11
for System 2 of the present invention.
[0029] System 2 comprises a common feeder 13 located upstream from
at least two source feeder units 10 and 11. The common feeder 13
contains common material 18. Common material 18 represents material
that must be included in every piece of mailing. For instance, if
the High Page Count method is used for sending out billing
statements, the common material may be a standard form that
accompanies every billing statement. The common feeder 13 is
located at the beginning of the track 12. The first source feed
unit 10 is located downstream from the common feeder 13 and
upstream from the secondary source feed unit 11. The first source
feed unit 10 serves as the primary source feed unit. The second
source feeder unit 11 is located downstream from both the primary
source feed unit 10 and the common feeder 13. Each source feed unit
10 and 11 contains source material 17 and the central processing
unit of the system (CPU) monitors source feed units 10 and 11 to
verify whether the primary and secondary source feed units 10 and
11 have deposited the source material 17 onto the track space 16 on
track 12.
[0030] The process whereby the High Page Count method operates with
a common feeder 13 is similar to the process where there are
multiple source feed units 10 and 11. However, the source feed
units 10 and 11 will not have a step that will ask whether the
track space 16 is empty. When the High Page Count method runs with
a common feeder 13 the only time a track space 16 will be empty is
when it initially reaches the common feeder 13. The common feeder
13 then deposits its common material 18 onto the track 12, and the
track 12 is advance one position. When the track space 16 gets to
the source feed units 10 and 11 the track space 16 has already been
filled with common material 18. Therefore, instead of determining
whether the track space 16 is empty, the source feed units 10 and
111 are reprogrammed to determine whether the track space 16 has
source material 17.
[0031] Turning to FIG. 4, there is shown a flow chart for the High
Page Count method of FIG. 3 wherein a common feeder 13 is located
upstream from the two source feed units 10 and 11.
[0032] The cycle for System 2 begins by putting the track 12 in
motion and the common feeder 13 deposits common source material 18
onto the track 12.
[0033] Step 112 determines whether the primary source unit feeder
10 is ready. The primary source feed unit 10 is ready when it has
compiled all of the source material 17 that it needs for an
individual. If the response to step 112 is YES, the primary source
feed unit 10 deposits its source material 17 onto the track space
16, as is shown in step 114. After the primary source feed unit 10
has deposited the source material 17 onto the track space 16, step
116 shows that the track 12 is advanced one position and the cycle
begins again at step 112 for the primary source feed unit 10.
Alternatively, if the response to step 112 is NO, the primary
source feed unit 10 does not deposit any source material 17 onto
the track space 16 and automatically proceeds to step 112 wherein
the track 12 is advanced one position.
[0034] At the same time the primary source feed unit 10 is running
through its cycle depositing source material 17 onto the track
space 16, the secondary source feed unit 11 is running through a
similar cycle. As is illustrated by step 120, the secondary source
feed unit 11 begins its cycle by determining whether the secondary
source feed unit 11 is ready. As with the primary source feed unit
10, the secondary source feed unit is ready when it has compiled
all of the source material 17 that it needs for an individual. If
the response to step 120 is NO, the secondary source feed unit 11
automatically proceeds to step 126 wherein the secondary source
feed unit 11 waits until the track 12 is advanced one position and
the secondary source feed unit 11 begins its cycle again with step
120.
[0035] If the response to step 120 is YES, the secondary source
feed unit 11 proceeds to step 122 and determines whether the track
space 16 located directly in front of the secondary source unit 11
is empty. If the response to step 122 is NO, the secondary source
feed unit 11 again automatically proceeds to step 126 wherein the
secondary source feed unit 11 waits unit the track 12 is advanced
one position and the secondary source feed unit 11 begins its cycle
again with step 120.
[0036] If the response to step 122 is YES, the secondary source
feed unit will deposit its source material 17 onto the empty track
space 16 located directly in front of the secondary source feed
unit 11. After the secondary source feed unit 11 deposits its
source material 17 the secondary source feed unit 11 then proceeds
to step 126 wherein the secondary source feed unit 11 waits for the
track 12 to advance one position and the secondary source feed unit
11 begins its cycle again with step 120.
[0037] Turning to FIG. 5 there is shown a block diagram of the
source feed units 10 and 11 sharing the same track position for
System 3 of the present invention.
[0038] System 3 comprises two source feed units 10 and 11 located
across from each other at the same track space 16 on track 12.
Unlike the previously described arrangements of the High Page Count
method where the source feed units do not share the same track
position, this arrangement requires a greater level of timing to
ensure that the source feed units 10 and 11 do not collide the
source material 17 when they are placed onto the track 12. In this
system, as in the other two systems, source feed unit 10 operates
as the primary source feed unit, and source feed unit 11 operates
as the secondary source feed unit. Both source feed units 10 and 11
contain source material 17 and the CPU of the system monitors
source feed units 10 and 11 to verify whether the primary and
secondary source feed units 10 and 11 have deposited the source
material 17 onto the track space 16 on track 12.
[0039] Turning to FIG. 6 there is shown a flow chart for the High
Page Count method of FIG. 5 having said two source feed units 10
and 11 sharing the same track space 16 on track 12. The method for
System 3 begins at step 50 by putting the track 12 in motion and
beginning a cycle. Step 56 determines if the primary source feed
unit 10 is ready to deposit its source material 17 onto the track
12. If the answer to step 56 is YES, the primary source feed unit
10 proceeds to step 58 whereby the primary source feed unit 10
determines whether the track 12 is empty. If the response to step
58 is YES, the primary source feed unit 10 deposits its source feed
material 17 onto the track 12 and automatically renews its cycle by
proceeding directly back to step 52. If the response to step 58 is
NO, indicating that the track 12 is full, the primary source feed
unit 10 also proceeds automatically to step 52. If at step 56 the
response is that the primary source feed unit 10 is not ready to
deposit its source material 17 onto the track 12, the system
proceeds to step 70 wherein the secondary source feed unit 11 is
queried as to whether it is ready. If the response to step 70 is
NO, the system automatically returns to the beginning of the cycle
at step 52. On the other hand, if the response at step 70 is YES,
indicating that the secondary source feed unit 11 is ready to
deposit its source material 17 onto the track 12, the system
proceeds to step 72 wherein the secondary source feed unit 11
determines if the track 12 is empty.
[0040] At step 72, if the track 12 is full this would indicate that
the primary source unit 10 has fully performed its cycle and has
deposited its source material 17 onto the track. In this case, the
secondary source feed unit 11 returns to the beginning of the cycle
at step 52. If the primary source feed unit 10 has not deposited
its source material 17 and the response to step 72 is YES,
indicating that the track 12 is empty, the secondary source feed
unit 11 proceeds to step 74 wherein the secondary source feed unit
11 deposits its source material 17 onto the track 12.
[0041] In an alternate embodiment of the High Page Count method,
the two source feed units 10 and 11, or more than two, can be
programmed such that they perform a true load balancing between
such two or more units. This load balancing system can be performed
in either an "intelligent" or "non-intelligent" manner.
[0042] In the "non-intelligent" load balancing system, for example,
the primary source feed unit 10 ensures that the secondary source
feed unit 11 has a turn by purposely not filling the track space
16. In this manner, the material is used up more equally. In a
system using multiple feeders, each feeder would pause feeding the
same number of times that there are feeders on the system.
[0043] In the "intelligent" load balancing system, the primary
source feed unit 10 must check the secondary source feed unit 11 to
determine whether the secondary source feed unit 11 is ready. If
the secondary source feed unit 11 is ready, the primary source feed
unit 10 is allowed to leave an empty track position 16. This mode
is considered "intelligent" load balancing because
inter-communications are required and a test for downstream
readiness must be performed.
[0044] As is shown in FIG. 8, in an alternate to the embodiment of
the High Page Count shown in FIG. 7, method the downstream section
with output stations 4A and 4B is placed perpendicular to the
upstream source output units 10 and 11. The benefit of this
perpendicular setup is that it reduces operator foot traffic.
Therefore, in the embodiment shown in FIG. 8, the operator is able
to cover more of the unit in fewer steps.
[0045] Various features of the invention have been particularly
shown and described in connection with the illustrated embodiments
of the invention. However, it must be understood that these
particular products, and their method of manufacture, do not limit
but merely illustrate, and that the invention is to be given its
fullest interpretation within the terms of the appended claims.
* * * * *