U.S. patent application number 11/188023 was filed with the patent office on 2007-01-25 for shuttle envelope feeder with suction cup assist.
This patent application is currently assigned to Pitney Bowes Incorporated. Invention is credited to John Kline, Thomas H. Rosenkranz, Boris Rozenfeld.
Application Number | 20070018377 11/188023 |
Document ID | / |
Family ID | 37309587 |
Filed Date | 2007-01-25 |
United States Patent
Application |
20070018377 |
Kind Code |
A1 |
Rozenfeld; Boris ; et
al. |
January 25, 2007 |
Shuttle envelope feeder with suction cup assist
Abstract
An envelope feeder for removing envelopes from an envelope
stack. The envelope feeder comprises a shuttle plate and a suction
cup assembly. The shuttle plate translates between a position under
the envelope stack and another position partially remote from the
envelope stack. The shuttle plate includes an orifice passing
through its surface and an envelope gripping mechanism in
connection with a vacuum valve. The suction cup assembly has a
suction cup connected to a hollow rod that is in connection with
another vacuum valve. An actuator engages the suction cup and moves
the suction cup between an extended position and a retracted
position. The suction cup attaches to an envelope at the bottom of
the envelope stack when it is in the extended position, and pulls
the envelope toward the shuttle plate as it moves to the retracted
position. Then the envelope gripping mechanism retains the
envelope, allowing the shuttle plate to remove the envelope from
the envelope stack.
Inventors: |
Rozenfeld; Boris; (New
Milford, CT) ; Rosenkranz; Thomas H.; (Dover Plains,
NY) ; Kline; John; (Danbury, CT) |
Correspondence
Address: |
PITNEY BOWES INC.;35 WATERVIEW DRIVE
P.O. BOX 3000
MSC 26-22
SHELTON
CT
06484-8000
US
|
Assignee: |
Pitney Bowes Incorporated
Stamford
CT
06926-0700
|
Family ID: |
37309587 |
Appl. No.: |
11/188023 |
Filed: |
July 22, 2005 |
Current U.S.
Class: |
271/99 |
Current CPC
Class: |
B65H 2220/02 20130101;
B65H 2406/342 20130101; B65H 2701/1916 20130101; B65H 3/0858
20130101; B65H 3/0875 20130101; B65H 2406/351 20130101; B65H
2513/514 20130101; B65H 3/085 20130101; B43M 3/04 20130101; B65H
2513/514 20130101 |
Class at
Publication: |
271/099 |
International
Class: |
B65H 3/08 20060101
B65H003/08 |
Claims
1. An envelope feeder in an envelope insertion machine for removing
envelopes from an envelope stack, comprising: a shuttle plate
operable between a first position under said envelope stack and a
second position at least partially remote from the envelope stack,
the shuttle plate having a surface dimensioned for receipt of an
envelope, said surface having a leading edge, the shuttle plate
having a first orifice passing through said surface, the shuttle
plate further having an envelope gripping mechanism extended to the
leading edge and in communication with a shuttle vacuum valve; a
first suction cup having an upper rim and a lower neck with an
opening formed therein, said first opening connecting to a first
hollow rod and said first hollow rod in communication with a first
vacuum valve; a first actuator in cooperative engagement with the
first suction cup for moving the first suction cup between an
extended position that passes through the first orifice in the
shuttle plate to a retracted position where the upper rim is at
least flush with the surface; means for activating the first vacuum
valve at least when the first suction cup is in the extended
position so that the first suction cup attaches to an envelope at
the bottom of the envelope stack and so that the first suction cup
pulls said envelope toward the surface of the shuttle plate as the
first actuator moves from the extended position to the retracted
position; and means for activating the shuttle vacuum valve at
least when said envelope is pulled toward the surface of the
shuttle plate so that the envelope is retained by the envelope
gripping mechanism; thereby allowing the shuttle plate to remove
said envelope from the envelope stack as the shuttle plate moves to
its second position.
2. The envelope feeder according to claim 1, wherein the first
suction cup and the first actuator are translationally stationary
in relationship to the shuttle plate, and the first orifice is
dimensioned so that the first suction cup resides inside the first
orifice when the suction cup is in the retracted position.
3. The envelope feeder according to claim 1, wherein the first
suction cup and the first actuator are translationally stationary
in relationship to the envelope insertion machine, and the first
orifice is dimensioned so that the first suction cup resides inside
the first orifice when the suction cup is in the retracted position
in a manner so that the first suction cup is not in obstruction
with the movement of the shuttle plate.
4. The envelope feeder according to claim 1, further comprising: a
second orifice passing through said surface of said shuttle plate;
a second suction cup having an upper rim and a lower neck with an
opening formed therein, said opening connecting to a second hollow
rod and said second hollow rod in communication with a second
vacuum valve; a second actuator in cooperative engagement with the
second suction cup for moving the second suction cup between an
extended position that passes through the second orifice in the
shuttle plate to a retracted position where the upper rim is at
least flush with the surface; means for activating the second
vacuum valve at least when the second suction cup is in the
extended position so that the second suction cup attaches to an
envelope at the bottom of the envelope stack and so that the second
suction cup pulls said envelope toward the surface of the shuttle
plate as the second actuator moves from the extended position to
the retracted position.
5. The envelope feeder according to claim 4, wherein the first
suction cup and the first actuator are translationally stationary
in relationship to the shuttle plate, and the first orifice is
dimensioned so that the first suction cup resides inside the first
orifice when it is in the retracted position; and the second
suction cup and the second actuator are translationally stationary
in relationship to the envelope insertion machine, and the second
orifice is dimensioned so that the second suction cup moves within
the second orifice when it is in the retracted position in a manner
so that the second suction cup is not in obstruction with the
movement of the shuttle plate.
6. The envelope feeder according to claim 1, wherein the means for
activating the first vacuum valve includes an input/output control
module in communication with a programmable logical device for
controllably activating the first vacuum valve.
7. The envelope feeder according to claim 6, further comprising a
first air cylinder valve connected to the first actuator, said
first air cylinder valve controllable by said input/output control
module.
8. The envelope feeder according to claim 1, wherein the means for
activating the shuttle vacuum valve includes an input/output
control module in communication with a programmable logical device
for controllably activating the shuttle vacuum valve.
9. The envelope feeder according to claim 4, wherein the means for
activating the second vacuum valve includes an input/output control
module in communication with a programmable logical device for
controllably activating the second vacuum valve.
10. The envelope feeder according to claim 9, further comprising a
second air cylinder valve connected to the second actuator, said
second air cylinder valve controllable by said input/output control
module.
11. A method for an envelope feeder in an envelope insertion
machine to remove an envelope from an envelope stack, said envelope
feeder having a suction cup operable between an extended position
and a retracted position, and a shuttle plate operable between a
first position under the envelope stack and a second position at
least partially remote from said envelope stack, said shuttle plate
having a surface dimensioned for receipt of an envelope, an orifice
passing through the shuttle plate, and an envelope gripping
mechanism in communication with a shuttle vacuum valve, said method
comprising the steps of: placing the shuttle plate in the first
position, moving the suction cup positioned within said orifice
between a retracted position that is at least flush with the
surface of the shuttle plate and an extended position that is in
contact with an envelope at the bottom of the envelope stack, and
controlling the air pressure within the suction cup so that the
suction cup has a lower air pressure than the ambient air pressure
when the suction cup is in the extended position and while it moves
from the extended position to the retracted position; whereby the
envelope at the bottom of the envelope stack is pulled down toward
the surface of the shuttle plate so as to facilitate the
acquisition of said envelope by the envelope gripping
mechanism.
12. A method for an envelope feeder in an envelope insertion
machine to remove an envelope from an envelope stack, said envelope
feeder having a first suction cup operable between an extended
position and a retracted position, a second suction cup operable
between an extended position and a retracted position, and a
shuttle plate operable between a first position under the envelope
stack and a second position at least partially remote from said
envelope stack, said shuttle plate having a surface dimensioned for
receipt of an envelope, a first and a second orifice each passing
through the shuttle plate, and an envelope gripping mechanism in
communication with a shuttle vacuum valve, said method comprising
the steps of: placing the shuttle plate in the first position,
moving the first suction cup positioned within said first orifice
between a retracted position that is at least flush with the
surface of the shuttle plate and an extended position that is in
contact with an envelope at the bottom of the envelope stack, and
controlling the air pressure within the first suction cup so that
the first suction cup has a lower air pressure than the ambient air
pressure when the first suction cup is in the extended position and
while it moves from the extended position to the retracted
position; moving the second suction cup positioned within said
second orifice between a retracted position that is at least flush
with the surface of the shuttle plate and an extended position that
is in contact with an envelope at the bottom of the envelope stack,
and controlling the air pressure within the second suction cup so
that the second suction cup has a lower air pressure than the
ambient air pressure when the second suction cup is in the extended
position and while it moves from the extended position to the
retracted position; whereby the envelope at the bottom of the
envelope stack is pulled down toward the surface of the shuttle
plate so as to facilitate the acquisition of said envelope by the
envelop gripping mechanism.
Description
TECHNICAL FIELD
[0001] This invention generally relates to machines that operate at
a very high speed to insert sheets of paper or other items into
envelopes. More particularly, it relates to a shuttle envelope
feeder that transports the envelopes to be inserted.
BACKGROUND ART
[0002] Machines for automatically inserting items such as sheets of
paper into envelopes are known in the art. A state-of-the-art mail
inserting machine such as the Pitney Bowes Flowmaster.TM. FX14 can
perform 12,000 insertions per hour when properly maintained and
adjusted.
[0003] A typical high-speed inserting machine comprises several
modules. A first module transports an elongate horizontal queue of
envelopes to an envelope stack. An envelope feeder located at the
bottom of the envelope stack delivers the envelopes one by one to
an envelope insertion station. A second module delivers individual
groups of stacked sheets to the envelope insertion station. A third
module, the envelope insertion station, includes clamps carried by
an elongate sprocket chain that sequentially receives envelopes
from the envelope feeder and pulls them past an envelope
flap-opening structure and a sheet inserting structure where the
envelopes are opened and inserted with stacked sheets. The
envelopes are then pulled past an envelope closing structure and an
envelope sealing structure before been ejected to a collection
station. envelope closing structure and an envelope sealing
structure before been ejected to a collection station.
[0004] FIG. 1 schematically shows an arrangement of a prior art
envelope feeder. The envelope feeder comprises a shuttle plate 150
that moves back and forth (direction shown as doted arrow line 152)
to transport envelopes 140 to be grasped by clamps 190 on an
elongate sprocket chain 160 of the insertion station. The shuttle
plate has a recessed area in which a vacuum gripping mechanism 180
is arranged. The negative pressure form the vacuum gripping
mechanism 180 pulls the part of the envelope directly above the
recessed area toward the recessed area so as to temporarily secure
the envelope to the upper surface of the shuttle plate. When the
shuttle moves toward the sprocket chain 160, a stripper bar 170
located above the recessed area separates the secured bottom
envelope from the envelope stack and allows it to move forward with
the shuttle.
[0005] The vacuum envelope feeder of the above arrangement works
well when envelopes are substantially flat. If, however, some of
the envelopes are significantly curled or bent, the shuttle vacuum
may not have sufficient suction to pull down these envelopes,
causing a failure in the shuttle feed.
[0006] Some methods have been proposed in order to solve the above
problem. One is to add pressure to the top of the envelope stack to
help flatten the envelopes. This method is somewhat ineffective,
because an improperly applied stack pressure can also cause a
failure in the shuttle feed or multiple envelope feedings.
[0007] Another method uses a thumper to add stack pressure when the
shuttle vacuum is turned on. When the shuttle moves forward, the
thumper retracts and the shuttle vacuum holds the curled envelope.
The disadvantages of this method are that the thumper disturbs the
stack and the flow of envelopes from the envelope transport module,
and it requires constant mechanical adjustment.
[0008] What is needed is a vacuum shuttle feeder that is capable of
feeding curled envelopes without failure. Preferably, the operation
of such feeder will not interfere with existing configuration of
the envelope stack or envelope flow. In addition, the feeder should
be operative over a wide range of envelope dimensions.
SUMMARY OF THE INVENTION
[0009] The invention provides an envelope feeder in an envelope
insertion machine for removing envelopes from an envelope stack.
The envelope feeder comprises a shuttle plate and a suction cup
assembly.
[0010] The shuttle plate is operable between a first position under
the envelope stack and a second position at least partially remote
from the envelope stack. The shuttle plate has an orifice passing
through its upper surface, and an envelope gripping mechanism that
is in communication with a shuttle vacuum valve.
[0011] The suction cup assembly comprises a suction cup that has an
upper rim and a lower neck with an opening formed therein, the
opening is connected to a hollow rod. The rod, in turn, is in
communication with a suction cup vacuum valve. An actuator engages
the suction cup and moves the suction cup between an extended
position that passes through the orifice in the shuttle plate to a
retracted position that the upper rim of the suction cup is at
least flush with the upper surface of the shuttle plate.
[0012] The suction cup vacuum valve is activated at least when the
suction cup is in the extended position so that the suction cup
attaches to an envelope at the bottom of the envelope stack. The
suction cup pulls the envelope toward the upper surface of the
shuttle plate as the actuator moves from the extended position to
the retracted position.
[0013] The shuttle vacuum valve is activated at least when the
envelope is pulled toward the upper surface of the shuttle plate.
By doing so, the envelope is retained by the envelope gripping
mechanism, allowing the shuttle plate to remove the envelope from
the envelope stack as the shuttle plate moves to its second
position.
[0014] The invention further provides a method for an
above-described envelope feeder in an envelope insertion machine to
remove an envelope from an envelope stack. The method comprising
the steps of: placing the shuttle plate in the first position,
moving the suction cup between the retracted position that is at
least flush with the upper surface of the shuttle plate and the
extended position that is in contact with an envelope at the bottom
of the envelope stack, and controlling the air pressure within the
suction cup so that the suction cup has a lower air pressure than
the ambient air pressure when the suction cup is in the extended
position and while it moves from the extended position to the
retracted position.
[0015] In accordance with the method, the envelope at the bottom of
the envelope stack is pulled down toward the upper surface of the
shuttle plate so as to facilitate the acquisition of said envelope
by the envelope gripping mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects, features and advantages of the
invention will become apparent from a consideration of the
subsequent detailed description presented in connection with
accompanying drawings, in which:
[0017] FIG. 1 is a schematic illustration of a prior art shuttle
feeder part of an envelope insertion station.
[0018] FIG. 2A is a schematic top view of a shuttle envelope feeder
with vacuum suction assist, according to a first embodiment of the
invention.
[0019] FIG. 2B is a schematic cross-sectional view of a shuttle
envelope feeder with vacuum suction assist, taken along line 2B in
FIG. 2A, according to the first embodiment of the invention.
[0020] FIG. 3 is a block diagram of the shuttle envelope feeder
with vacuum suction cup assist, including valves and controlling
mechanism, according to the first embodiment of the invention.
[0021] FIG. 4 is a three-dimensional view of the shuttle envelope
feeder, according to the first embodiment of the invention.
[0022] FIG. 5 is a three-dimensional view of the shuttle envelope
feeder, according to a second embodiment of the invention.
[0023] FIG. 6 is a three-dimensional view of the shuttle envelope
feeder, according to a third embodiment of the invention.
[0024] FIG. 7 is a block diagram of the shuttle envelope feeder
with vacuum suction cup assist, including valves and controlling
mechanism, according to the third embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring to FIG. 2A, a shuttle envelope feeder 200,
according to the present invention comprises a shuttle plate 150
operable between a first position under an envelope stack and a
second position that is at least partially remote from the envelope
stack. The shuttle plate 150 has a surface 252 dimensioned for
receipt of an envelope. The surface 252 has a leading edge 254. The
shuttle plate 150 has an orifice 240 passing through the surface
252. The shuttle plate 150 further has a recessed area 280 formed
in its surface 252 in proximity to the orifice 240 and extending at
one end to the leading edge 254 of the surface 252. The recessed
area 280 has at least one orifice 181 passing therethrough and in
communication with a shuttle vacuum valve 256 (seen in FIG. 3) to
form a vacuum gripping mechanism 180.
[0026] Referring now to FIG. 2B, the vacuum envelope feeder further
comprises a suction cup 230 having an upper rim 232 and a lower
neck 234. The lower neck 234 has an opening formed therein, which
is connected to a hollow rod 233, the rod, in turn, is in
communication with a suction cup vacuum valve 238 (seen in FIG.
3).
[0027] The suction cup 230 is thus in cooperative engagement with
an actuator or air cylinder 236, which, in turn, is in
communication with an air cylinder valve 262 (seen in FIG. 3). The
actuator 236 moves the rod 233 and thus the suction cup 230 between
an extended position that passes the suction cup through the
orifice 240 in the shuttle plate 150 and a retracted position so
that the suction cup resides inside the orifice and the upper rim
232 of the suction cup 230 is at least flush with the surface 252.
The orifice 240 is dimensioned so that the suction cup 230 and/or
the hollow rod 233 is not in contact with the orifice and not in
obstruction with the movement of the shuttle plate.
[0028] Referring further to FIG. 3, the vacuum envelope feeder also
comprises a controlling mechanism including a computer 300 (or
other programmable logical device) that coordinates an input/output
control module 310 by monitoring the shuttle position via an
up/down counter 320 in communication with an encoder 330 equipped
with a position sensor 331 via a position circuit. The position
circuit may consist of an up/down counter 320 in communication with
an encoder 330 equipped with a position sensor 331 or an input port
that allows the computer to directly read position of the shuttle
plate from an absolute encoder or positional resolver.
[0029] With the shuttle plate 150 at the first position and the
trailing edge of the previous envelope off of the suction cup 230,
the actuator 236 moves the cup 230 toward the extended position and
the suction cup vacuum valve 238 is activated (vacuum ON). Once the
suction cup 230 reaches the extended position, a small time delay
is used to insure that the suction cup 230 attaches to an envelope
at the bottom of the envelope stack. The actuator then pulls the
suction cup 230 toward the retracted position.
[0030] Once the suction cup 230 reaches the retracted position, the
shuttle vacuum valve 256 is activated to allow the envelope
gripping mechanism 180 to acquire the envelope. The suction cup
vacuum valve can be deactivated (turned OFF) immediately after
envelope is acquired. The shuttle plate 150 then moves toward the
second position with the envelope going under a stripper bar 170 so
that it is separated from the remaining envelopes in the envelope
stack. After clamps 190 (see FIG. 1) on the mail insertion station
have grasped the envelope, the shuttle feeder returns to its
initial position, ready to acquire the next envelope.
[0031] The computer 300 stores parameters such as the real-time
shuttle position acquired via a position circuit with an position
encoder or resolver 330 having a position sensor 331, envelope
width, the distance D between the leading edge 254 of the shuttle
plate and the center of the suction cup 230, air valve latencies,
air cylinder latencies and system latencies. Based on the
parameters pre-stored in the computer and acquired by the computer,
the computer calculates a time sequence for actuating the suction
cup and activating/deactivating the suction cup vacuum valve for
the input/output control module 310 to coordinate the operation of
the valves. The specific computer programming and controlling
procedures of vacuum and air valves according to such specific
parameters is known to people of ordinary skills in the art.
First Embodiment of the Invention
[0032] In a first embodiment of the invention as shown in FIG. 4,
the shuttle plate 150 comprises an orifice 240 passing through the
surface 252. The shuttle plate 150 and the actuator 236 that
supports the suction cup 230 are mounted rigidly on a frame 392.
The frame moves from a first position to a second position by a
rolling mechanism 394 on a horizontal bar 396. The orifice 240 is
dimensioned larger than the outer dimension of the suction cup 230
so as to allow the suction cup to reside inside the orifice when
the suction cup is in the retracted position.
Second Embodiment of the Invention
[0033] In a second embodiment of the invention as shown in FIG. 5,
the shuttle plate 150 comprises an orifice 440 passing through the
surface 252. The shuttle plate 150 and the actuator 436 that
supports the suction cup 430 are mounted on two separate frames 392
and 498, respectively. The shuttle plate 150 mounted on the frame
392 moves from a first position to a second position by a rolling
mechanism 394 on a horizontal bar 396. Frame 498 is stationary in
relationship to the insertion station. The orifice 440 is in an
elongated shape and is dimensioned larger than the outer dimension
of the suction cup 430. The suction cup 430 resides inside the
orifice when it is in the retracted position, and the suction cup
is not in obstruction with the movement of the shuttle plate.
Third and Preferred Embodiment of the Invention
[0034] In a third and preferred embodiment of the invention as
shown in FIG. 6, the shuttle plate 150 comprises a first orifice
240 and a second orifice 440, both passing through the surface 252.
The shuttle plate 150 and a first actuator 236 that supports a
first suction cup 230 are mounted rigidly on a frame 392. A second
actuator 436 that supports a second suction cup 430 is mounted on a
frame 498. Frame 392 moves from a first position to a second
position by a rolling mechanism 394 on a horizontal bar 396. Frame
498 is stationary in relationship to the mail insertion
station.
[0035] The first orifice 240 is dimensioned larger than the outer
dimension of the first suction cup 230 so as to allow the first
suction cup to reside inside the orifice when the first suction cup
is in the retracted position. The second orifice 440 is in
elongated shape and is dimensioned larger than the outer dimension
of the second suction cup 430. The second suction cup 430 resides
inside the second orifice 440 when the second suction cup is in the
retracted position, and the second suction cup is not in
obstruction with the movement of the shuttle plate.
[0036] As shown in FIG. 7, the first suction cup 230 is connected
via a hollow rod to a first suction cup vacuum valve 238. A first
actuator or air cylinder 236 that moves the first suction cup is in
communication with a first air cylinder valve 262. The second
suction cup 430 is connected via a hollow rod to a second suction
cup vacuum valve 438. A second actuator or air cylinder 436 that
moves the second suction cup is in communication with a second air
cylinder valve 462.
[0037] A computer 300 (or other programmable logical device) stores
parameters such as the real-time shuttle position acquired via a
up/down counter 320 in communication with a position encoder 330
having a position sensor 331, envelope width, the distance D
between the leading edge 254 of the shuttle plate 150 to the center
of the first suction cup 230, air valve latencies, air cylinder
latencies and system latencies. Based on the parameters pre-stored
in the computer and acquired by the computer, the computer
calculates a time sequence for actuating the suction cups and
activating/deactivating the suction cup vacuum valves for the
input/output control module 310' to coordinate the operation of the
valves.
Alternative Embodiments of the Invention
[0038] The vacuum suction mechanism of present invention may be
replaced by other 15 mechanisms that temporarily acquire envelope
through a moving part that is in corporation with the shuttle
plate. Examples include a receiving member in place of the suction
cup that is charged with static electrons. The static electrons
attract the envelope at the bottom of the envelope stack when the
receiving member is in close proximity of the envelope. Thereby
temporarily secure the envelope onto the receiving member.
[0039] In summary, the present invention relates to a shuttle
envelope feeder with a vacuum suction cup assist mechanism. The
present invention has the advantage of acquiring cupped or bent
envelopes in an envelope stack in a very repeatable fashion. The
suction cup controlling mechanism is separable from the controlling
mechanism of the shuttle plate. One or more suction cups can be
individually enabled or disabled according to the conditions of the
envelopes in the envelope stack.
[0040] Although the invention has been described and illustrated
with respect to exemplary embodiments thereof, the foregoing and
various other additions and omissions may be made therein without
departing from the spirit and scope of the present invention.
* * * * *