U.S. patent number 3,817,516 [Application Number 05/365,475] was granted by the patent office on 1974-06-18 for document edging and stack advance system.
This patent grant is currently assigned to Burroughs Corporation. Invention is credited to James R. Hunter, S. James Lazzarotti, Edward A. Wojtowicz.
United States Patent |
3,817,516 |
Lazzarotti , et al. |
June 18, 1974 |
DOCUMENT EDGING AND STACK ADVANCE SYSTEM
Abstract
The present disclosure describes an edging and stack advance
system that is capable of automatically preparing documents such as
letters and the like, that have been loaded onto a conveyor for
subsequent feeding, sorting and/or processing. Significant features
of the system include the use of separate zones for conveyance and
edging, and a plurality of interconnected stack sensing switches.
The latter switches cooperate to establish and maintain a stack
geometry having a degree of looseness which permits reliable edging
and subsequent feeding of the documents. The entire system has been
designed to be relatively uncomplicated and may be manufactured at
low cost.
Inventors: |
Lazzarotti; S. James (Broomall,
PA), Wojtowicz; Edward A. (Bryn Mawr, PA), Hunter; James
R. (Chadds Ford, PA) |
Assignee: |
Burroughs Corporation (Detroit,
MI)
|
Family
ID: |
23439057 |
Appl.
No.: |
05/365,475 |
Filed: |
May 31, 1973 |
Current U.S.
Class: |
271/150; 271/155;
271/250 |
Current CPC
Class: |
B65H
5/021 (20130101); B65H 9/101 (20130101); B65H
7/00 (20130101); B65H 1/025 (20130101) |
Current International
Class: |
B65H
9/00 (20060101); B65H 5/02 (20060101); B65H
7/00 (20060101); B65h 001/02 (); B65h 001/14 ();
B65h 009/00 () |
Field of
Search: |
;271/146-155,126,128-130,48,49,58,59 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Blunk; Evon C.
Assistant Examiner: Miller; James W.
Attorney, Agent or Firm: Varallo; Francis A. Feeney, Jr.;
Edward J. Fiorito; Edward G.
Claims
What is claimed is:
1. A system for stack advance and document edging in preparation
for the feedout of documents by a vacuum feeder mechanism
comprising:
a conveyor zone and an edging zone contiguous to each other and
having a common side registration wall, said edging zone having a
forward wall in proximity to said feeder mechanism,
said conveyor zone having transport means for conveying a stack of
said documents toward said edging zone, said edging zone being
characterized by the absence of said transport means and having
edger bar means operatively connected to agitate said documents in
a vertical plane and to move them in a direction perpendicular to
the motion of said documents in said conveyor zone toward said side
registration wall, the documents in said edging zone being
concurrently pushed forward toward said forward wall by the
documents in the conveyor zone under the influence of said
transport means,
said edging zone further including a plurality of stack sensing
means, at least a pair of said sensing means being positioned
respectively in said forward wall and said side registration wall,
said sensing means being electrically interconnected for
controlling the motion of said transport means and being initially
in an unactuated condition,
the actuation of said forward wall sensing means in response to the
physical contact made therewith by the initial document in said
stack being indicative of the attainment of a proper feedout
position by said stack and causing the termination of motion of
said stack by said transport means, said side registration wall
sensing means being actuated concurrently with said forward wall
sensing means by physical contact of the documents in said edging
zone upon the attainment of said last mentioned position,
the subsequent attraction of each of said documents in turn to said
feeder mechanism as a result of the vacuum forces associated
therewith, and the feedout of documents from said edging zone
creating an incrementally increasing angular separation between the
document in position for feedout and the next succeeding document,
said side registration wall sensing means being responsive to said
increasing angular separation such that upon the attainment of a
predetermined angle, said last mentioned sensing means resumes its
unactuated condition, thereby permitting said transport means to
resume stack motion.
2. A system as defined in claim 1 wherein said conveyor zone
includes a block-like member adapted to be carried by said
transport means for supporting said stack of documents, said
block-like member having its face portion inclined at a
predetermined angle with respect to the vertical such that the
documents standing on edge and leaning thereagainst assume a
substantially like angle.
3. A system as defined in claim 2 further characterized in that
said edging zone includes a plurality of said edger bar means
having their longitudinal axes parallel to the direction of motion
of the documents in the conveyor zone, a retarder strip positioned
between a pair of said edger bar means, said retarder strip being
comprised of a plurality of saw-tooth shaped teeth oriented with
respect to the motion of the stack such that the documents contact
consecutive teeth of the strip as they are pushed toward said
forward wall by the documents in said conveyor zone.
4. A system as defined in claim 3 wherein said edger bar means each
include an elongated portion which is square in cross section, and
a tapered end which first makes contact with the documents
advancing toward said forward wall, said edger bar means being
continuously rotated by drive means in a direction to move said
documents toward said side registration wall.
5. A system as defined in claim 4 further characterized in that the
portion of each of said edger bar means opposite said tapered end
and situated adjacent the front surface of said forward wall is a
pulley, said means for driving said edger bar means including a
friction belt disposed on said pulley, the edged documents
approaching said forward wall contacting said friction belt and
being maintained in, or further edged into, a registered condition
thereby.
6. A system as defined in claim 5 wherein said transport means
comprises a plurality of friction belts mounted on pulleys and
driven by motor means.
7. A system as defined in claim 3 wherein each of said stack
sensing means comprises an actuator finger operatively connected to
an electrical micro-switch, physical contact with said actuator
finger by said documents resulting in the actuation of said
switch.
8. A system as defined in claim 7 further characterized in that the
electrical switch portions of a pair of sensing means are mounted
behind said side registration wall in a vertical plane and in
spaced apart relation, said registration wall having a pair of
slots therein to receive the actuator fingers of said sensing
means, said fingers protruding therethrough to contact the
documents in said stack, and being pivotally mounted to rotate in
the direction of stack movement, thereby actuating the switches
associated respectively therewith.
9. A system as defined in claim 8 wherein each of said pair of side
registration wall sensing means includes a spring member coupled
between its actuator finger and a fixed support to provide more
consistent switch operational cycles.
10. A system as defined in claim 9 wherein the electrical switch
portion of the front wall sensing means is connected in parallel
with a circuit path containing the electrical switch portions of
the pair of side wall sensing means, the series/parallel
arrangement of all the switches being interposed between a source
of electrical power and the motor driving said transport means, the
front wall switch when unactuated being in a closed circuit
condition to permit said motor to be energized, the pair of side
wall switches being connected in an exclusive-or configuration
whereby an electrical circuit path from said source of power to
said motor is established therethrough if, and only if, one of said
switches is actuated, but not if both switches are in an actuated
or unactuated condition.
Description
BACKGROUND OF THE INVENTION
The edging and stack advance system of the present invention has
performed reliably in an actual operative mail sorting machine. In
present day systems, stack advancement is accomplished by utilizing
a single front sensing switch located in the forward wall toward
which the documents to be processed are urged by the conveyor
mechanism. In general, the front switch is usually custom designed
to have a low differential travel, for example, in the order of
0.003 inches. Differential travel may be defined as the switch
actuator movement required from the stop point to the start point
of conveyor movement. The front mounted switch controls a high
performance stepping motor which can advance the entire stack of
documents in response to a single document of minimum thickness
(about 0.008 inches) being fed out of the stack.
The foregoing systems require that the documents in the stack be
maintained in a vertical edge position at all times. The stack is
advanced to correspond with the time allowed for the feed rate
required. If a front stack sensing switch is employed to move the
documents out of the stack, the looseness of the documents, that
is, the stack looseness, is a function of document thickness. In
this system, the consistent looseness control needed for reliable
edging is unpredictable with variable thickness documents.
In contrast to the above mentioned system employing a single front
sensing switch, the present invention contemplates the use of a
plurality of sensing switches. For example, in an actual operative
embodiment of the present invention, a pair of sensing switches
displaced from each other and mounted in a vertical plane in a side
registration wall of the edging zone are employed. Additionally, a
front mounted switch is incorporated.
As will become apparent in the description of the invention
hereinafter, the stack advancement is accomplished primarily by the
two side mounted switches, rather than the front mounted switch,
once feeding is initiated. The system is characterized by slow
response in that the stack is not advanced for every document that
is fed out. Stack thicknesses of approximately 0.5 inches may be
required to be fed out before the conveyor again advances the
stack. The stack geometry is controlled by the side sensing
switches and is substantially vertical in the forward portion of
the edging zone after an initial stack advance. Subsequently,
however, as documents are fed out of the edging zone an angular
separation increases incrementally between the document adjacent
the feeder face and the succeeding documents in the stack. When
this separation angle has attained a predetermined value as sensed
by the side sensing switches, the conveyor is again actuated to
advance the stack and reestablish the aforementioned substantially
vertical condition in the vicinity of the forward wall. Throughout
this range of operation, looseness of the documents is maintained
to a degree which permits reliable edging. The magnitude of the
total travel of the side switches determines the maximum angular
separation, and the travel is chosen to be considerably greater
than that found in systems where only a single front mounted switch
is used. This total travel is composed of a large differential
travel together with an angular over-travel. Such switches need not
be custom designed. In fact, standard low-cost microswitches may be
utilized. Additionally, a readily available low response stepping
motor may be used to drive the conveyor.
SUMMARY OF THE INVENTION
In the present system, the documents to be processed are loaded
into the conveyor zone having conveyor belt transport means. The
side edges of the documents are inclined at a predetermined angle
from the vertical as determined by the face of a stack support
block upon which they rest. The stack support block advances on the
conveyor belts in unison with the stack of documents. The documents
are advanced forward and after leaving the conveyor zone, they are
pushed into the edging zone. A plurality of rotating edger bars in
the latter zone perform both a vertical agitation and horizontal
displacement of the documents to accomplish the edging function.
The bars are driven by a timing belt and pulley system and
continually rotate in a direction that causes the documents through
friction contact between their bottom edges and the bars to be
urged in a direction perpendicular to the stack movement and
against a side registration wall. A retarder strip placed between
two of the bars and having a saw-toothed shape serves to inhibit
stack advancement to the edging zone by tripping the bottom edge of
the mail pieces as they pass over the strip. This causes the
documents on the edger bars to be tipped from an initial backward
leaning position to a more vertical position, thereby enhancing the
capability of the edger bars to perform their function.
A plurality of document sensing switches and associated actuator
fingers that control the stack feeding and orientation of the mail
pieces over the edging mechanism, play an important role in the
edging process. In the present system, three stack sensing switches
are employed -- a front switch and a pair of side sensing switches.
The front sensing switch is positioned to sense the lower front
face of the mail stack as it arrives at the forward wall of the
edging zone, in proximity to the feeder mechanism. A pair of side
switches displaced a predetermined distance from each other and
mounted one above the other in the side registration wall, control
the stack advancement after feed out of the documents from the
edging zone has begun. The side switches monitor respectively the
upper and lower edges of the mail stack.
In the edging zone, the stack in its initial tilted back position,
is operated upon by the rotating edger bars and the retarder strip,
causing it to assume a more vertical position as it approaches and
contacts the forward wall of the edging zone. In approaching the
forward wall, the stack actuates the lower side switch first. Then,
the front switch is actuated by the initial document in the stack
and finally the actuation of the upper side switch takes place.
With the front switch actuated, the electrical circuit conditions
are such that the motor driving the stack conveyor is halted. The
additional actuation of both side switches does not affect this
condition.
An important requirement for successful edging of documents which
may be nonuniform in size and weight is that they be kept as loose
as possible to reduce the interaction of adjacent documents. Such
interaction could inhibit an individual document having its lower
edge above the edger bars from moving to the side registration wall
when the documents on either side of the misregistered document
have already been edged.
A significant advantage of the present invention is that edging is
independent of the stack length. A small portion of the stack in
the edging zone is effectively separated from the main body of
documents in the conveyor zone, and the bulk of the documents do
not interfere with the edging process. Stated another way, the
pressure of the stack is transmitted to the support block, rather
than to the forward part of the edging zone. Thus, the documents to
be edged and situated at the front of the stack are located at a
point of minimum compression, and are therefore in the best
condition to be edged. The present system therefore relieves most
of the stack pressure required to maintain a feeding geometry in
order to enhance edging.
After the initial advancement of the stack into the edging zone and
the halting of conveyor movement, feedout of the documents in the
forward portion of the edging zone continues by virtue of the
attraction of succeeding documents toward the face of a vacuum feed
chamber. As documents leave the area, a separation angle develops
until the actuator finger of a side switch, for example the upper
switch, is no longer pushed forward and the switch is no longer
actuated. During this time, the stack documents outside the edging
zone, that is, those in the conveyor zone have remained in a
static, tilted-back condition, leaning against the angled support
block face. When either of the side switches is no longer actuated,
the conveyor motor is again energized and more documents from the
main body of the stack are moved into the edging zone, thereby
again halting the conveyor movement. This action of the side
switches provides an adequate range of looseness for proper edging
both in the initial condition where the documents are substantially
vertical in the forward portion of the edging zone, and
subsequently in an angled condition as the documents leave the
zone.
Other features and advantages of the present invention will become
apparent in the detailed description appearing hereinafter.
DESCRIPTION OF THE DRAWING
FIG. 1 is a plan view of the major components of the edging and
stack advance system.
FIG. 2 is a section view taken along the lines 2--2 of FIG. 1 and
providing a detailed view of the drive means for the edger
bars.
FIG. 3 is a section view taken along lines 3--3 of FIG. 1 to better
illustrate the placement of the stack sensing switches with respect
to the document stack.
FIG. 4 is a detailed view of the side stack sensing switches as
they appear mounted on the opposite side of the registration
wall.
FIG. 5 is an electrical schematic depicting the interrelationship
of the sensing switches in their control of the stack conveyor
motor.
FIG. 6 illustrates diagrammatically the initial stack geometry
after the documents have been loaded into the conveyor zone.
FIG. 7 illustrates particularly the geometry of the forward portion
of the stack in the edging zone at the time of halting of conveyor
movement and prior to the commencement of feedout.
FIG. 8 illustrates the angular displacement .theta. in a tilt-back
mode for the forward documents of the edging zone as documents are
fed out therefrom.
FIG. 9 depicts the maximum angle .theta.' (equivalent to its
converse in a forward-tilt mode) permitted in the leading documents
and corresponding to the point of resumption of conveyor
movement.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The basic elements used in the edging and stack advance system of
the present invention are depicted in FIG. 1 and the section views
of FIGS. 2 and 3, derived therefrom. With general reference to FIG.
1, and particular reference to the other Figures where indicated,
the details of the system may be described as follows.
A stack of documents 10 such as mail pieces, which stack may vary
from a few inches to several feet in overall length, is loaded into
the conveyor zone shown in FIG. 3. This zone comprises conveyor
belts 12 disposed on pulleys 13, driven by a motor 14 via shaft 15.
As seen in FIG. 3, the documents are supported by a support block
16 and the angular disposition of the documents is a function of
the sloped upper-face of the block as seen in FIG. 3. In an actual
operative embodiment of the invention, the sloped face of the block
was displaced approximately 30.degree. from the vertical. The
surface of the block contiguous with the conveyor belt is of a
resilient high-friction material 18.
The leading group of letters are the first to leave the belt
surface as the belts start downward in their return excursion to
the opposite end of the conveyor. These letters come to rest within
the edging zone (FIG. 3), and although they are no longer on the
belt they are pushed toward the edger bars 20 by the stack of mail
and the support block 16 still on the conveyor. Three edger bars 20
are depicted in FIGS. 1 and 2. Depending upon the application, a
greater or lesser number of edger bars may be required. Each of the
bars 20 is square in cross section and tapered on the extremity
which first contacts the oncoming documents. This tapered portion
provides a transition ramp from the conveyor to the main body of
the edger bars. Increased edging capability results from this
portion of the bars due to the greater force exerted on the lower
document edge as it is lifted and pushed up the tapered incline.
FIG. 2 indicates the configuration of belts 22a - 22c and pulleys
24a - 24f to continually rotate the edger bars in a direction to
cause the documents to move up and down in a vertical plane and
also horizontally toward the registration wall 26. The main drive
pulley 24f is driven by belt 22c coupled to a source of power, not
shown.
The tapered ends of the edger bars 20 begin the edging process as
soon as the bottom edge of the mail pieces come into contact with
its surface. As a result, some of the documents are driven to the
side registration wall 26 while they also continue advancing onto
the edger bars. Since the mail stack is still leaning against the
support block 16, a portion of the letters will not have been edged
due to the resisting frictional forces that are evident because of
the higher normal forces present between adjacent letters.
The documents continue to advance on the rotating edger bars 20 so
that their bottom edges contact the saw-tooth shaped teeth of the
retarder strip 28 as seen clearly in FIG. 3. Sloped or leaning
letters generate higher normal forces between adjacent mail pieces
and this prevents a letter situated between two edged letters from
effectively being registered due to the resisting frictional forces
between the letters. The edges of the documents are tripped by the
retarder strip 28 such that the vertical agitation provided by the
edger bars 20 permits those letters 10 temporarily restrained by
the retarder strip to assume a more vertical geometry than those in
the remainder of the stack. As the letters continue to advance
toward the forward wall 30 of the edging zone, their bottom edges
contact the surface of belt 22a which drives the edger bars 20. The
high frictional surface of the latter belt helps to maintain the
mail pieces in their edged condition and urges them toward the side
registration wall 26 in preparation for their subsequent feed out
from the edging zone.
A brief explanation of feeder operation is pertinent at this time.
It should be understood that a variety of feeder mechanisms are
well known and that the following description of a particular
feeder is presented merely for purposes of example. It should not
be construed as limiting the present invention. The leading
document in the forward end of the edging zone is drawn against the
feeder control fingers 32 by virtue of the high air flow entering
the feeder vacuum chamber 34 through lines 33. The control fingers
32 intermesh the moving feeder belts 36 and extend above the
surface thereof. The latter belts are driven by drive pulley 37
through the action of belt 38 coupled to a drive source, not shown.
The document is thereby prevented from contacting the feeder belts
36 until feed out of the document is desired. The latter is
accomplished by retracting the control fingers 32 and allowing the
documents to contact the moving belts 36.
As the stack of documents 10 is advanced by the conveyor system,
the leading document contacts the forward wall 30 of the edging
zone, thereby depressing the actuator finger 40 and actuating the
front switch 42. A return spring 39 assures more positive switch
operation. Concurrently, the leading documents are driven against
the side registration wall 26 by the edger bars 20 and push both
actuator fingers 44 and 46 as seen in FIG. 3 toward the forward
wall 30, thereby actuating respectively both side switches 48 and
50. The mounting of the side switches 48 and 50 on a bracket 41
behind registration wall 26, and the projection of the actuator
fingers 44 and 46 through respective slots 43 and 43' in the wall,
are clearly shown in FIG. 4. Springs 45 and 45' are coupled
respectively between the fingers 44, 46 and posts 47, 47'. The
movement of fingers 44, 46 forward toward the forward wall 30 (FIG.
3) in an arc about pivot points 49, 49' extends the respective
springs, which are designed to become fully extended with a small
force of about one ounce applied thereto. The purpose of springs
45, 45' is to provide a more reliable return motion of the actuator
when it is being pushed by the oncoming documents. Moreover, the
springs permit the fingers to rotate in the opposite direction as
documents exit the edging zone, in minimum time. It an automatic
mode, this permits more consistent earlier initiation of conveyor
motion.
The actuation of all the sensing switches is indicative of the
proper positioning of the documents for feeding purposes. The
corresponding electrical condition is such that power is removed
from the stack conveyor motor 14, thereby halting the advance of
the stack. The electrical schematic of FIG. 5 indicates the circuit
interconnections of the front switch 42, the upper side switch 48,
lower side switch 50, and the conveyor drive motor 14, for the
condition that none of the switches is actuated. That is, no
documents are in contact with switch actuator 40, 44 and 46.
Consideration of the various switch combinations possible during
the actuation of one or more of the switches, reveals that the
motor 14 will be energized by an electrical power source applied to
terminals 51--51', and conveyor motion initiated under all switch
conditions except where the front switch 42 alone is actuated, or
where all three switches 42, 48 and 50 are actuated concurrently.
This latter condition is the one mentioned hereinbefore. The former
condition, wherein the front switch 42 is actuated and both side
switches 48 and 50 remain unactuated can occur under conditions of
imperfect edging where a vertical gap appears along the
registration wall 26 which encompasses the actuator fingers 44 and
46 of both side switches 48 and 50. The side switches therefore
sense this abnormal condition which would create excessive stack
tightness and halt the stack advance. The function of the front
switch 42 is to permit advancement of the stack after the stack
conveyor is first loaded, even though the side switches are not
actuated.
Assuming that the documents have arrived in the edging zone, that
all three switches are actuated and that conveyor motion has been
halted, the subsequent motion of the conveyor is dependent upon
either switch 48 or switch 50 reverting to the unactuated
condition. This further assumes that the front switch remains
generally in an actuated condition as a result of the sequential
drawing of the documents from the stack and their being held
against the forward wall 30 and feeder fingers 32, as a result of
the vacuum force exerted by the feeder mechanism. The two side
switches 48 and 50 therefore perform an exclusive-or logic
function, that is, the conveyor motor will be energized, if and
only if, one of the switches is actuated but not if both are in an
actuated or unactuated condition. As documents are fed out of the
edging zone while the conveyor motion is halted, a condition is
reached in the angular displacement of documents in this zone which
causes either one of the side switches 48 or 50 to revert to its
unactuated condition. Conveyor motion is resumed and more documents
in the main body of the stack are moved from the conveyor zone into
the edging zone.
The actual operation of the system is best explained in connection
with the diagrammatic illustration of FIGS. 6-9 inclusive which
nevertheless should be considered in connection with the structural
details of FIGS. 1-5 inclusive described hereinbefore.
In FIG. 6, the documents 10 are shown loaded onto the conveyor
belts 12 at an angle .alpha. which is determined by the face of the
support block 16. No support means at the front of the leading
document is needed because the belts have an adequate frictional
coefficient to prevent the stack from collapsing or even increasing
the initial angular condition. The support block 16 absorbs the
stack compression force.
As the documents are moved forward by the conveyor belts 12, they
are forced off the belt, leaving the conveyor zone for the edging
zone. At this point, the documents contact the edger bars 20 and
are agitated in a substantially vertical plane perpendicular to the
stack advance direction. The coefficient of friction of the edger
bars is lower than that of the conveyor belts and would normally
not permit the stack to advance without an increase in angle
.alpha. or indeed a collapse of the stack. However, the retarder
strip 28, positioned between the edger bars permits the stack to
continue toward the forward wall 30 without collapse. The vertical
teeth of the retarder 28, extending above the edger bars,
interweave between documents to prevent forward movement of the
bottom edges of the documents, and initially to permit the stack to
maintain the angle .alpha. in the edging zone. Since the leading
edges of the retarder teeth are sloped, sufficient force from the
conveyor belts during stack advance drives the document in the
edging zone over the retarder teeth to permit them to arrive at the
forward wall 30. At this point the documents assume a substantially
vertical configuration as seen in FIG. 7.
As the stack advances and reaches the feeder, all three stack
sensing switches 42, 48 and 50 (FIG. 3) will have been actuated and
advancement is halted. This condition is illustrated in FIG. 7. The
leading document 10a is attracted to the feeder by the air flow
associated therewith and the remaining documents in the edging zone
each has an increasing component of angularity proceeding from the
initial document 10a whose angularity is zero toward the last
document in the edging zone, designated 10b, which has an
angularity substantially the same as that possessed by the
documents now stored in the conveyor zone and awaiting the edging
function.
FIG. 8 represents the condition wherein several of the documents in
the edging zone have been fed out. An angular separation,
represented by the angle .theta., increases incrementally as the
documents leave the zone. Actually, an exiting document creates a
void between the lower edge of the succeeding document and the
forward wall equal to the document thickness. The lower edge of the
succeeding document translates forward and the upper edge then
rotates to contact the feeder control fingers 32 (FIG. 1). That is,
the document waiting to be fed out of the edging area, is pulled to
a vertical position by the vacuum forces exerted by the feeder.
Each succeeding document is subject to the same motion. It should
be noted that only the documents lying in the space between the
last tooth 28a of the retarder strip 28 and the front wall 30 are
not inhibited by the retarder teeth and are therefore attracted by
the feeder vacuum.
As feeding continues and the angle .theta. increases, the number of
documents in the edging zone decreases. This condition causes
increased looseness, and the relaxation of pressure between
adjacent documents promotes even more effective edging.
FIG. 9 illustrates the condition existing just prior to the
commencement of the next cycle of conveyor motion. The exiting of a
number of documents from the edging zone has caused a separation
angle .theta.' to develop, which has a maximum predetermined value.
Concurrent with such development, the actuator finger 44 associated
with switch 48 which had been moved forward by the advancing
documents, has moved incrementally backward toward its initial
position as the documents are fed out. The angle .theta.' which is
somewhat smaller than the initial bias angle .alpha. allows switch
48 to achieve its original unactuated condition, and as will be
apparent from the electrical schematic of FIG. 5, an electrical
circuit path is established to supply power to motor 14 and
reestablish conveyor motion.
It should be noted that as documents are fed out of the edging zone
and angle .theta. increases, the time to pull succeeding documents
to the feeder face increases. A momentary angular void exists
between the feeder and the document about to be pulled forward by
the feeder vacuum. With small angles of .theta. and documents of
minimal thickness, actuator 40 of the front switch 42 may extend
somewhat during the transient period immediately following feed
out, but this extension is insufficient to cause conveyor movement.
On the other hand, as .theta. becomes larger and with thicker
documents, it is possible that a momentary return of switch 42 to
its unactuated condition can occur, with some stack advancement. It
must be emphasized, however, that the latter advancement is minimal
compared to the total stack advancement effected by the side
sensing switches.
FIGS. 6 through 9 assume that the stack in the edging zone is in a
normal tilt-back mode. It has been observed in an actual operating
system that under certain circumstances, related to the initial
loading of documents onto the conveyor, or as a result of a high
feed-out rate, the documents in the edging area will assume a
forward-tilt geometry. Thus, compared with FIG. 9, an illustration
of the latter would depict the top edges of the documents leaning
toward the forward wall 30, and the formation of a displacement
angle, equal but converse to .theta.', that is, measured between
the forward wall 30 and the bottom edge of the next document
waiting to be attracted to the feeder. In this case, the actuation
finger 46 associated with lower side wall switch 50, FIG. 3, will
have moved to its original position and switch 50 is no longer
actuated. Upper side wall switch 48 remains actuated. Under these
conditions, switch 50 effects the resumption of conveyor
motion.
The function of the stack zones may be summarized as follows. The
documents in the edging zone are edged in preparation for feeding,
whereas those in the conveyor zone are stored in an angular
geometry determined by the face of the support block 16. In the
edging zone, which accommodates a very small portion of the stack
(only about 3 inches in an actual operative embodiment) the edger
bars 20 move the documents in a plane perpendicular to the
direction of stack advance. The bars do not advance the stack, but
permit the documents in the edging zone to be advanced forward when
required by the pushing action of the documents in the conveyor
zone. The documents in the edging zone are supported in varying
stages of angularity by the documents in the conveyor zone as well
as the retarder strip 28. The documents in the conveyor zone
however, are stored in a mode of angularity which remains unchanged
while they are present in this zone. These documents are supported
by the support block 16 as well as by the friction of the conveyor
belts 12 themselves.
It should be apparent from the foregoing description and mode of
operation that there is taught an improved system wherein optimum
edging is maintained at all times through a zone stack arrangement
that effectively relieves stack pressure against the documents
being edged, and a plurality of stack sensing switches adapted to
sense the geometry of the documents being edged and to advance the
entire stack upon the attainment of predetermined angular
conditions. These concepts have proved highly satisfactory in an
actual operative mail handling system, resulting in reliable
feeding with minimal numbers of double-fed documents. It should be
understood, however, that changes and modifications of the
mechanisms described herein may be necessary to suit particular
requirements. Such changes and modifications, insofar as they do
not depart from the spirit of the invention, are intended to be
covered by the following claims.
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