U.S. patent number 3,884,010 [Application Number 05/484,362] was granted by the patent office on 1975-05-20 for apparatus and method for opening and emptying envelopes of various thicknesses.
This patent grant is currently assigned to International Business Machines Corporation. Invention is credited to Gerald Blaine Bardo, Leonard John Zalepa.
United States Patent |
3,884,010 |
Bardo , et al. |
May 20, 1975 |
Apparatus and method for opening and emptying envelopes of various
thicknesses
Abstract
At an entry station, envelopes are extracted from a hopper by a
pivoted hopper vacuum head which tilts up to engage a bottom
envelope, then tilts down to align the leading edge of the envelope
with a reciprocating feed trolley. The reciprocating feed trolley
advances the envelope to a shearing station where a pair of blades
shear the ends of the envelope. Finally, the envelope is advanced
to an exit station where it is loaded on a rotatable drum with vee
pockets integral thereto on four sides thereof. A concave flexible
vacuum head retracts forcing the envelope into the drum vee
pockets. Subsequently, the rotatable drum, envelope and concave
flexible vacuum head rotate clockwise 90.degree., so that the
envelope is now in a vertical position. Then the concave flexible
vacuum head extends from the rotatable drum vee pockets causing the
envelope to fully buckle open allowing the documents, therein, by
gravity, to fall into a document stacker. At this point, the
concave flexible vacuum head rotates 90.degree. in the reverse
direction in order to process the next envelope in sequence. In the
meantime, if the prior envelope was not emptied, as sensed by a
document sensor, the envelope and documents therein are rejected
into a reject receptacle. In the alternative, if as sensed by the
document sensor, the envelope has been emptied, the emptied
envelope will be rejected into a scrap receptacle.
Inventors: |
Bardo; Gerald Blaine (Nichols,
NY), Zalepa; Leonard John (Apalachin, NY) |
Assignee: |
International Business Machines
Corporation (Armonk, NY)
|
Family
ID: |
26218873 |
Appl.
No.: |
05/484,362 |
Filed: |
June 28, 1974 |
Current U.S.
Class: |
53/492; 53/53;
53/381.6; 414/412; 53/381.3; 83/912 |
Current CPC
Class: |
B43M
7/02 (20130101); Y10S 83/912 (20130101) |
Current International
Class: |
B43M
7/00 (20060101); B43M 7/02 (20060101); B65b
009/00 () |
Field of
Search: |
;53/3,381R ;83/912
;214/305 |
References Cited
[Referenced By]
U.S. Patent Documents
|
|
|
3590548 |
July 1971 |
Pierce et al. |
3691726 |
September 1972 |
Stephens et al. |
|
Primary Examiner: McGehee; Travis S.
Attorney, Agent or Firm: Wynn; John G.
Claims
What is claimed is:
1. An apparatus for opening and emptying envelopes of various
thicknesses comprising:
an entry station including means for retaining a plurality of
envelopes containing documents to be emptied, and means for
extracting a single envelope from said retaining means;
a shearing station including means for shearing the ends of an
envelope while said envelope is in a stationary position;
an exit station including rotatable drum means having a plurality
of vee pocket arms thereon and concave flexible vacuum means, said
vacuum means cooperating with said drum means to force an envelope
into the vee pockets of said vee pocket arms while said drum means
is in a load position, said envelope, said drum and said vacuum
means being movable from said load position to an empty position to
properly position said envelope whereupon said vacuum means buckles
open the sides of said envelope allowing documents contained
therein to fall by gravity; and
means for transporting said envelopes, containing documents to be
emptied, from said entry station to said shearing station and from
said shearing station to said exit station.
2. The apparatus according to claim 1 further including as part of
said exit station a document chute having a document stacker
integral therewith for accumulating said documents while said drum
is in said empty position.
3. The apparatus according to claim 2 further including a document
sensor integral with said document chute for sensing whether or not
said documents have entered said document chute within a certain
time interval.
4. The apparatus according to claim 1 further including as part of
said exit station a reject receptacle for receiving by means of a
reject kicker envelopes still containing documents, or a high
probability thereof, as determined by said document sensor, said
reject kicker being operable while said drum is in a reject
position.
5. The apparatus according to claim 1 further including as part of
said exit station a scrap receptacle for receiving by means of an
eject kicker envelopes that have been emptied as determined by said
document sensor, said eject kicker being operable while said drum
is in an eject position.
6. The apparatus according to claim 1 further including an
oscillating shaft having a helical cam rigidly attached thereto,
said helical cam being operable by means of a helical guide rigidly
attached to said transport means and followers causing said
oscillating shaft to rotate counterclockwise as said transport
means move in a forward direction and causing said oscillating
shaft to rotate clockwise as said transport means move in a reverse
direction.
7. The apparatus according to claim 6 in which said oscillating
shaft is rigidly attached to said concave flexible vacuum head and
rotatably mounted in said rotatable drum by bearing means, while in
an extended position, said concave flexible vacuum head being
rotatable in synchronism with said oscillating shaft with said drum
remaining stationary.
8. The apparatus according to claim 7 in which said rotatable drum,
oscillating shaft and concave flexible vacuum head rotate together
when said concave flexible vacuum head is in a retracted
position.
9. The apparatus according to claim 1 in which said transporting
means comprises:
a main frame support having feed guides integral therewith;
a reciprocating feed trolley attached to said main frame
support;
a plurality of anti-back pawls pivotally attached to said feed
guides, said anti-back pawls allowing forward motion of said
envelopes on a forward stroke of said reciprocating feed trolley
and preventing reverse motion of said envelopes on a reverse stroke
of said reciprocating feed trolley; and
a plurality of feed dogs pivotally attached to said reciprocating
feed trolley, said feed dogs on a forward stroke of said
reciprocating feed trolley pushing against the back edge of said
envelopes thereby moving said envelopes forward with said
reciprocating feed trolley, and on reverse stroke of said
reciprocating feed trolley, said feed dogs pivoting to a horizontal
position passing under an envelope following in sequence.
10. Apparatus for automatically opening envelopes of various
thicknesses wherein a completely emptied envelope and the documents
thereof are sorted from an envelope with a high probability of not
being completely emptied comprising:
a hopper for retaining a plurality of envelopes containing
documents to be extracted;
a hopper vacuum head which engages a bottom envelope pulling the
leading edge of said envelope below a hopper exit gate, said exit
gate being integral with the front of said hopper and cooperating
with said vacuum head so that only a single envelope is extracted
from said hopper;
a reciprocating feed trolley being attached to said hopper vacuum
head so that a forward reciprocating motion of said reciprocating
feed trolley advances said envelope in a forward direction;
a shearing means positioned in the path of said advancing envelope
so that when said envelope is stationary at said shearing means,
said shearing means being activated to shear the ends of said
envelope;
a rotatable drum having a plurality of vee pocket arms integral
therewith with vee pockets thereon for receiving said envelopes
while said rotatable drum is in a load position, said reciprocating
feed trolley advancing said envelope to said load position of said
rotatable drum;
a concave flexible vacuum head being in an extended position over
said load position of said rotatable drum, said concave flexible
vacuum head when in a retracting position, forcing said envelope
into said rotatable drum vee pockets and triggering a reverse
trolley stroke which rotates said envelope, said rotatable drum and
said concave flexible vacuum head to an empty position whereupon
said concave flexible vacuum head extends from said rotatable drum
thereby buckling said envelope open allowing documents contained
therein to fall by gravity into a document chute;
a document sensor integral with said document chute for sensing
whether or not said documents have entered said document chute
within a certain time interval;
a reject receptacle for receiving by means of a reject kicker
envelopes still containing documents, or a high probability
thereof, as determined by said document sensor, said reject kicker
being operable while said drum is in a reject position; and
a scrap receptacle for receiving by means of an eject kicker
envelopes that have been emptied as determined by said document
sensor, said eject kicker being operable while said drum is in an
eject position.
11. A method of opening and emptying envelopes of various
thicknesses wherein a completely emptied envelope and the documents
contained therein are sorted from an envelope with a high
probability of not being completely emptied comprising the steps
of:
extracting a bottom envelope with documents contained therein from
a hopper by means of a hopper vacuum head located at an entry
station;
transporting said envelope by means of a reciprocating feed trolley
to a shearing station;
shearing the ends of said envelope while said envelope is in a
stationary position at said shearing station;
transporting said envelope by means of said reciprocating feed
trolley to a loading platform situated over a rotatable drum having
a plurality of vee pocket arms with vee pockets thereon integral
therewith, said loading platform and said rotatable drum being
located at an exit station;
forcing said envelope into said rotatable drum vee pocket by means
of a retracting pockets flexible vacuum head, with vacuum applied,
while said drum is in a load position;
rotating said envelope, said drum and said concave flexible vacuum
head to an empty position;
extending said concave flexible vacuum head buckling open said
envelope whereby said documents contained therein fall by gravity
into a document chute;
sensing the presence or absence of said documents by sensing means
integral with said document chute;
rejecting said envelope by means of a reject kicker into a reject
receptacle after said rotatable drum has rotated to a reject
position only if said sensing means detected the absence of said
documents in said document chute; and
ejecting said envelope by means of an eject kicker into a scrap
receptacle after said drum has been rotated to an eject position
only if said sensing means detected the presence of documents in
said document chute.
12. A method of reliably emptying documents of various thicknesses
from an envelope from which the ends have been sheared comprising
the steps of:
retracting a concave flexible vacuum head, with vacuum being
applied, into contact with said envelope whereupon said envelope is
held in a concave flexed position;
flexing the edges of said envelope in a reverse direction by moving
said envelope into contact with vee pocket arms, said contact being
due to the continued retraction of said concave flexible vacuum
head;
forcing the bottom side of said envelope against a constraining
means to fully insert said envelope into vee pockets of said vee
pocket arms, said vacuum head being flexible to allow the topside
of said envelope to break free and assume a natural curve
contiguous with said concave flexible vacuum head;
rotating said envelope, said vee pocket arms and said concave
flexible vacuum head to a vertical position;
extending said concave flexible vacuum head there by pulling said
envelope slightly out of said vee pockets whereby the bottom side
of said envelope will retain its natural curve giving it strength
to remain bowed while the shape of said concave flexible vacuum
head causes the topside of said envelope to reverse bend until said
envelope is fully buckled open allowing said documents contained
therein to fall out by gravity; and
vibrating said envelope by releasing said vacuum at the instant of
extension of said concave flexible vacuum head at which point said
envelope snaps back fully into said vee pockets thereby overcoming
any static attraction between said documents and said envelope.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to improvements in methods and apparatus for
envelope document emptying, and more particularly, to the automatic
sorting of documents of an envelope, a completely emptied envelope,
and an envelope still containing documents after processing.
2. Description of the Prior Art
In recent years, an increasing number of consumers have been paying
their bills at a central office, rather than at a plurality of
local offices that might be located near the consumer's place of
residence. For example, credit card companies and nationwide retail
outlets, just to name a few, mail out bills, including an envelope
and a stub, which the consumer has to return along with his check
to a central office. Many times the consumer, in addition to the
aforementioned items, will insert a letter in the return envelope
to complain about the correctness of the bill or for various other
reasons. Accordingly, in addition to the tremedous volume of mail
arriving at the central office, the mail in question will vary in
size, condition and mixture of content. At any rate, since the
received mail can number in the thousands per day, it is a time
consuming and costly operation to handle this mail manually at the
central office.
The problem of mail handling of the type herein described has been
around for a long time. Several prior art machines are known in the
art that attempt to extract mail automatically. These prior art
machines have not been satisfactory in all respects, in that some
of them cannot handle mail of various thicknesses and are somewhat
unreliable in their operation, and in addition, there is no means
for checking whether an envelope has been completely emptied. Other
machines extract the mail in a manner which will not insure
reliability, but these machines do have a method of checking
whether the envelope has been emptied. Then there are those
machines which are highly reliable but only do a pg,3 part of the
total job leaving the remainder to be done manually by personnel at
the central office. Herein below, some of these prior art machines
will be described in more detail.
One such prior art machine automatically removes the contents of
the envelope and assembles them alternately with their respective
empty envelopes so that the contents of each particular envelope
are immediately followed by the empty envelope. The envelope is
slitted edgewise and is subjected to distention of its opposite
sides by a vacuum to cause the contents to drop out by gravity
followed immediately by the dropping of the empty envelope, also by
gravity, into position. In this prior art machine, no mention is
made of the problem of handling the documents. In addition, in this
prior art machine, there is no means to determine whether or not an
envelope has been completely emptied. Due to the distention means
used in the aforementioned machine, it is highly possible that a
document will stick or be sucked by the vacuum of distention means
against the envelope sides.
There are other prior art machines, while having a means for
checking or sensing whether an envelope has been emptied, i.e.,
"thickness checking" these machines still have not addressed the
problem of handling various thicknesses, condition and mixture of
mail as aforementioned. These machines use suction means for
opening the sides of the envelopes and an extracting means to
extract the documents therefrom. It is readily apparent that if a
check or document is sucked by the sucking means against the
envelope sides, that the extracting means might not extract this
check or document. Also, "thickness checking" is a very expensive
method to improve reliability and costs considerably more than an
emptying machine without this feature. In addition, this prior art
machine, in the presence of an envelope which has not been emptied,
will stop operation, thereby slowing down the mail processing
operation.
Machines are known in the art that will handle automatically
special types of mail, i,e., envelopes of the type having a
perforated tear flap. These machines, while being simple in
construction and reliable in operation are only for opening
envelopes with no document extracting being performed.
Consequently, manual handling of the mail is not eliminated with
this type of machine.
OBJECTS OF THE INVENTION
Accordingly, it is an important object of this invention to provide
an improved apparatus and method which will automatically remove
the contents of an envelope with a degree of reliability that has
hitherto not been achieved.
It is another object of the present invention to provide an
improved apparatus and method which would automatically process
mail of various thicknesses, condition and mixture of contents.
It is still another object of the present invention to provide an
improved apparatus and method wherein envelopes which have not been
emptied, or completely emptied, will be rejected automatically
without disturbing the operation of the apparatus.
It is yet another object of the present invention to provide an
improved apparatus and method which will automatically sort the
contents of an envelope, an envelope that has not been emptied or
completely emptied, and a completely emptied envelope in separate
receptacles, with a degree of reliability, and in a manner that has
hitherto not been achieved.
SUMMARY OF THE INVENTION
In accordance with these and other objects, a method and apparatus
is disclosed herein to remove the contents of an envelope
automatically by extracting the envelope from an entry station,
shearing the ends of the envelope at a shearing station, utilizing
a unique drum and vacuum means at an exit station to separate the
sides of the envelope while the envelope is in a vertical position,
allowing the contents of the envelope to fall into a stacker,
sensing the document fall-out at the stacker, rejecting an envelope
that has been completely emptied and ejecting to a scrap receptacle
a completely emptied envelope.
Summarizing in slightly more detail the instant invention, a
hopper, with envelopes contained therein is positioned at an entry
station. A pivoted vacuum head tilts to engage a bottom envelope
from the hopper. The vacuum head then tilts downward aligning the
leading edge of the envelope with an exit gate. The bottom envelope
is subsequently carried forward on a reciprocating feed trolley,
which advances envelopes in a forward direction on a forward stroke
where the envelopes are supported by anti-back pawls. Conversely,
feed dogs pivot under the envelopes on a reverse stroke of
reciprocating feed trolley. Accordingly, an envelope is advanced
forward to a shearing station, where the envelope is positioned
under a pair of blades which shear off the ends of the envelope
while it is in a stationary position. The envelope is then fed
under a concave flexible vacuum head, which is in an extended
position, and located over the vee pockets of a rotatable drum. All
of the aforementioned elements, inter alia, part of the exit
station. The vacuum head then retracts forcing the envelope down
into the vee pockets.
Rigidly attached to the reciprocating feed trolley is a guide means
which rides a helical cam attached to an oscillating shaft.
Accordingly, a forward stroke of the trolley will rotate the
oscillating shaft counterclockwise 90.degree.. Conversely, a
reverse stroke of the trolley will rotate the oscillating shaft
clockwise 90.degree.. The rotatable drum is mounted on the shaft by
bearings and only rotates with the shaft when the concave flexible
vacuum head is in the retracted position, i.e., when forcing an
envelope into the vee pockets. Consequently, a reverse trolley
stroke rotates the envelope, drum and vacuum head clockwise
90.degree. to an empty position. When the 90.degree. rotation is
completed, the vacuum head moves away from the drum buckling the
envelope open. Since the envelope is now in a vertical position,
the contents will fall out by gravity into a document stacker which
senses whether or not documents have been emptied. On a forward
stroke of the trolley, the oscillating shaft rotates the concave
flexible vacuum head counterclockwise 90.degree. back to the load
position, while the drum is stationary.
On the next 90.degree. drum rotation, the first envelope is carried
to the reject position. If no documents were sensed in the previous
position, a reject kicker is activated to remove the envelope from
the drum into a reject receptacle. If documents had been sensed,
the emptied envelope stays on the drum, which rotates on the next
cycle 90.degree. to an eject position, where the emptied envelope
by means of an eject kicker is ejected into an eject
receptacle.
The foregoing and other objects, novel features and advantages of
the invention will be apparent from the following more particular
description of the preferred embodiment as illustrated in the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the apparatus according to the
invention showing the principal elements thereof.
FIG. 1a is a partial sectional view showing the relationship of the
concave flexible vacuum head, the rotatable drum and oscillating
shaft when the concave flexible vacuum head is in a retracted
position.
FIG. 2 is an end view of the apparatus to primarily show the
elements of the exit station.
FIGS. 3a-e show the method of opening and emptying an envelope with
documents contained therein according to the invention.
FIG. 4 is a schematic diagram of the pneumatics employed in the
operation of the invention.
FIG. 5 is a timing diagram showing the interrelationship of the
various elements of the invention during the processing of an
envelope.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following is a brief description of the apparatus of the
instant invention. A more detailed description and operation of the
apparatus according to the invention is described hereinafter under
the heading "Statement of the Operation."
Referring first to FIG. 1, a plurality of envelopes 10, containing
documents to be extracted, are retained in hopper 12. The following
will describe one envelope and follow it through the machine
cycles. At the beginning of a cycle, reciprocating feed trolley 18
is in the reverse position, i.e., to the left as shown in the
figure. When the start button 74 is depressed (see FIG. 4) hopper
vacuum head 14, which is pivotally attached to reciprocating feed
trolley 18, tilts counterclockwise so that hopper vacuum head 14
engages the front edge of a first bottom envelope contained in
hopper 12. With vacuum applied, hopper vacuum head 14 pulls the
front edge of the first envelope down below hopper gate 15 by
pivoting clockwise, thereby allowing only one envelope at a time to
be extracted. Hopper vacuum head air cylinder 14a is the means by
which hopper vacuum head 14 is tilted. In the Statement of the
Operation this operation will be explained in some detail.
As aforementioned, hopper vacuum head 14 is pivotally attached to
reciprocating feed trolley 18; therefore the first envelope is
carried forward as reciprocating trolley 18 moves forward, i.e., to
the right. The first envelope is carried to the point where it
passes under the first of a plurality of anti-back pawls 20. Since
the anti-back pawls are pivotally attached to feed guides 26, at
the point where the first envelope engages the anti-back pawls, it
passes under the anti-back pawls which pivot counterclockwise
allowing the first envelope to pass under them. Accordingly, after
the first envelope has passed, the anti-back pawls pivot clockwise.
Consequently, when reciprocating feed trolley 18 reverses on a
subsequent cycle, the anti-back pawls will fall (by gravity) behind
the trailing edge of the first envelope thereby restraining the
first envelope from being pulled backwards. Concurrently, hopper
vacuum is turned off (as will be discussed in the Statement of the
Operation) so that the first envelope is released. Also, since
hopper vacuum head 14 is attached to reciprocating feed trolley 18,
hopper vacuum head 14 moves with reciprocating trolley 18 back to
its initial position to repeat the cycle and extract a second
envelope.
After hopper vacuum head 14 engages a second envelope, it tilts
down to clear the front edge of the envelope at which time
reciprocating feed trolley 18 again reciprocates in the forward
direction. At it does, the first envelope which is sitting in front
of feed dogs 22 is pushed forward by the feed dogs from its
immediate position out to the next position.
Feed dogs 22 normally remain in the position as shown in FIG. 1.
These feed dogs are pivotally mounted, so that when reciprocating
feed trolley 18 moves in a forward direction, the toe or front of
the dogs will push against the back edge of the first envelope and
move it along with reciprocating feed trolley 18. When the
reciprocating feed trolley 18 moves in a reverse direction, the toe
of feed dogs 22 strike the envelope back behind, and because the
feed dogs are pivoted, and only depend on the weight of their tails
to hold them in their upright position, they just pivot to a
horizontal position, thereby passing underneath the envelope. After
the feed dogs have passed under the envelope, they pivot back to
their normal position ready to push an envelope forward on the next
cycle.
Consequently, the first feed dogs 22 push the first envelope
forward as reciprocating feed trolley 18 moves forward so that the
first envelope is positioned directly under shearing blades 24. The
envelopes 10, and particularly, the first envelope are kept aligned
and in position by a means of feed guides 26 which are attached to
main frame support 27. At the shearing station, there is another
set of anti-back pawls 20 and a set of feed dogs 22 so that when
reciprocating feed trolley 18 pulls the feed dogs backwards, they
pivot down and under the first envelope, and accordingly, the first
envelope is held in position by the anti-back pawls aforementioned.
Now, when reciprocating feed trolley 18 makes a reverse stroke, the
first envelope is stationary (held by anti-back pawls) and at that
point in time, shearing blades 24 are pushed downward and shear the
ends from this envelope.
At this point in time, the reciprocating feed trolley 18 continues
its leftmost or reverse direction, and hopper vacuum head 14 is now
ready to pivot up and engage a third envelope. On the next forward
motion of reciprocating feed trolley 18, the first, second and
third envelopes all move forward to the next position. At this next
position, there is another set of anti-back pawls and feed dogs.
The cyclic action is repeated once more, this time, of course, as
reciprocating feed trolley 18 reverses to the left, shearing blades
24 shear the edges of the second envelope. Also, hopper vacuum head
14 engages a fourth envelope, and then as reciprocating feed
trolley 18 moves forward again, the first, second, third and fourth
envelopes all move forward in unison. During the prior forward
motion of reciprocating feed trolley, the first envelope has been
pushed forward onto loading platform feed guide 28, which is
positioned over rotatable drum 40. This position of rotatable drum
40 is the load position.
Now that the first envelope is on loading platform feed guide 28,
it is important to describe another function of reciprocating feed
trolley 18 other than transporting a plurality of envelopes 10 to
the load position aforementioned. Still referring to FIG. 1,
rigidly attached to reciprocating feed trolley 18 in a helical
guide support 30 having fixed thereto, a pair followers 31 and
helical guide 32. Followers 31 and helical guide 32 ride on helical
cam 34 which is integral with oscillating shaft 36. Reciprocating
feed air cyclinder 18a is attached to guide support 30 by means of
clevis 33. Accordingly, the linear motion of reciprocating feed
trolley 18 is transformed into a rotational motion of oscillating
shaft 36. Helical cam 34 is spiralled over 90.degree. along the
length of oscillating shaft 36; therefore, as reciprocating feed
trolley 18 moves forward, oscillating shaft 36 rotates
counterclockwise 90.degree., and of course, as reciprocating feed
trolley 18 moves backwards, oscillating shaft 36 rotates clockwise
90.degree.. Accordingly, oscillating shaft 36 continually
oscillates in synchronism with the reciprocating motion of
reciprocating feed trolley 18.
Referring now to FIG. 1a, rotatable drum 40 is mounted on
oscillating shaft 36 by means of rotatable drum bearings 42 and
main frame bearing 43. Consequently, rotatable drum 40 is not
rigidly attached to oscillating shaft 36, thereby permitting free
rotation of oscillating shaft 36 within rotatable drum bearing 42.
But at the end of oscillating shaft 36, vacuum head support
mechanism 44 is rigidly attached to oscillating shaft 36 by means
of taper pin 45. Accordingly, as oscillating shaft 36 rotates,
vacuum head mechanism 44 will oscillate in synchronism therewith.
As will be described hereinbelow, rotatable drum 40 only rotates
when engaged by vacuum head 46 when it is in a retracted position
as shown.
Referring again to FIG. 1, concave flexible vacuum head 46, an
integral part of vacuum head support mechanism 44, is shown in the
extended position (disengaged from rotatable drum 40). As shown in
FIG. 1, and in better detail in FIGS. 3a through 3e, vacuum head 46
is concave and preferably of a flexible material. (More detail on
this aspect of the invention will be discussed in connection with a
description of FIGS. 3a-3e.) Associated with vacuum head support
mechanism 44 is vacuum head air cylinder 46a which allows vacuum
head support mechanism 44 and concave flexible vacuum head 46,
which is integral therewith, to be in an extended position or a
retracted position depending on the operation to be performed. (For
more detail of the operation of vacuum head air cylinder 46a, see
Statement of the Operation.)
Rotatable drum 40 comprises a plurality of vee pockets 50 and a
plurality of envelope backer supports 52. Each vee pocket contains
two pairs of vee pocket arms 51. As discussed hereinbefore, the
first envelope is now in the load position retained by loading
platform feed guide 28 over rotatable drum 40. As reciprocating
feed trolley 18 completes a forward motion and dwells before a
reverse motion begins, vacuum head 46 (as shown in FIG. 1a) is
retracted forcing the first envelope down into vee pockets 50, the
bottom side of the first envelope being restrained by envelope
backer supports 52. As aforementioned, in the retracted position,
vacuum head 46 engages to rotatable drum 40 by means of vacuum head
support mechanism 44 being wedged between the pairs of vee pockets
arms 51 (see FIG. 1a). On the next cycle, reciprocating feed
trolley 18 moves in a reverse direction rotating oscillating shaft
36 clockwise, thereby rotating the first envelope, concave flexible
vacuum head 46 and rotatable drum 40 clockwise to the empty
position.
Referring to FIG. 2, rotatable drum 40 is shown as having reached
the empty position. Vacuum head 46, while in the empty position,
once again extends, thus buckling open the first envelope allowing
the documents contained therein to drop (by gravity) into document
chute 54 (FIG. 2). (The method of buckling open envelopes 10 will
be discussed hereinafter in conjunction with FIGS. 3a-3e.) Document
sensor 56 is integral with document chute 54 to sense whether or
not documents have fallen into document stacker 58.
Referring to FIGS. 1 and 2, concave flexible vacuum head 46 is
still in the extended position and therefore free of rotatable drum
40. Accordingly, as reciprocating feed trolley 18 starts a forward
motion, oscillating shaft 36 rotates counterclockwise carrying
concave flexible vacuum head 46 and its mechanism 44 back up over
rotatable drum 40 as shown. The second envelope is now in the load
position, ready to be forced into rotatable drum 40 on the next
cycle.
Referring to FIG. 2, if documents dropped out of the first envelope
in the correct time frame, the documents are sensed by document
sensor 56 and sensing logic housed in pneumatic control box 70. The
sensed information is stored by the sensing logic to be used for
succeeding cycles. On the next cycle, the first envelope is rotated
to the reject position. The first envelope is not rejected because
documents were sensed by document sensor 56 detecting that the
first envelope is empty. Finally, the first envelope is rotated
from the reject position to the eject position. Since the first
envelope is empty, the system logic activates eject kicker 60 which
will strip it from vee pockets 50 and onto eject chute 62, where it
falls into scrap receptacle 64.
In the alternative, if documents do not fall out of the first
envelope, when it is in the empty position, accordingly, no
documents are sensed by document sensor 56. This information will
be stored by the sensing logic housed in pneumatic control box 70.
Since the first envelope is now suspect, i.e., contain documents or
documents did not fall out in the proper time frame, the first
envelope is rejected, after being rotated to the reject position,
by means of reject kicker 66 into reject receptacle 68.
Also depicted in FIG. 2 is shearing air cylinder 24a which will be
explained in the Statement of the Operation.
The key elements, according to the invention, have been described
in conjunction with FIGS. 1, 1a and 2. Still to be discussed in
conjunction with FIGS. 3a through 3e, is an important feature of
the invention, i.e., the method of buckling opening an envelope
containing documents. The shape of concave flexible vacuum head 46
and the constraining and buckling open of an envelope are important
features which improve the reliability of the instant
invention.
Referring to FIG. 3a, an envelope 10 is shown in the load position.
Concave flexible vacuum head 46, previously described, as being
concave and made of a flexible material, e.g., rubber, plastic,
metal, etc., is in the extended position directly above envelope
10. In FIG. 3b, concave flexible vacuum head 46 is shown starting
its retractive motion. Since vacuum has been applied and vacuum
head 46 is concave and flexible, envelope 10 is held in a flexed
position, as shown. The retraction of vacuum 46 is continued as
shown in FIG. 3c. as shown, the edges of envelope 10 are reverse
flexed by virtue of contact with the top edges of vee pocket arms
51. As aforementioned, rotatable drum 40 is in the load position.
Finally, as shown in FIG. 3d, while rotatable drum 40 is still in
the load position, concave flexible vacuum head 46 continues to
retract forcing the bottom side of envelope 10 against envelope
backer supports 52. When fully inserted into vee pockets 50,
concave flexible vacuum head 46, being flexible, allows the topside
of envelope 10 to break free and assume a natural curve contiguous
with concave flexible vacuum head 46 as shown. As was described
hereinbefore, rotatable drum 40, concave flexible vacuum head 46
and envelope 10 rotates to the empty position as shown in FIGS.
3d-e. Now, in FIG. 3e, concave flexible vacuum head 46 is extended
from vee pockets 50. The bottom side of envelope 10 will have a
natural bend giving it strength to remain bowed while the concave
shape of vacuum head 46 will cause the topside of envelope 10 to
reverse bend until envelope 10 is fully buckled open as shown. The
size of vee pockets 50 is such that envelope 10 will remain opened
and the documents contained therein are free to drop out. Envelope
10 is pulled slightly out of vee pockets 50 by the extraction of
concave flexible vacuum head 46 while vacuum is still being
applied. At this point, the vacuum is released. Thus envelope 10
snaps back into vee pockets 50, thereby vibrating the documents
therein overcoming any static attraction of the documents to the
sides of envelopes 10. This vibrating or jarring effect frees the
documents from the sides of envelope 10 and improves the
reliability of the total operation.
STATEMENT OF THE OPERATION
Details of the operation, according to the invention, are now
described in connection with FIGS. 4 and 5. The essential elements
of the apparatus shown in FIGS. 1 through 3 correspond to those in
the schematic representation of the apparatus as shown in FIG. 4,
and accordingly, are represented by the same reference numbers
depicted in FIGS. 1 through 3. Those elements, not previously
described, are indicated by the designations as shown in the
schematic representation of the invention as depicted in FIG.
4.
The instant invention utilizes pneumatic technology and logic in
order to simplify the logic requirements and also allow logic
functions to be mechanically automated.
The several elements of the invention, as shown in FIGS. 1 through
3, are components well known in the art, except for concave
flexible vacuum head 46 and rotatable drum 40 having a plurality of
vee pockets 50 (see FIG. 1). The significant aspects of the
invention involve the shape of the concave flexible vacuum head 46
and the timing and release of an envelope to be processed. This
timing and the logic involved therewith will be further explained
hereinbelow in the operation of the invention.
Referring now to the schematic representation depicted in FIG. 4,
start valve 72 is shown in the deactivated position and
accordingly, the apparatus of the instant invention is at rest or
stationary. As shown, there is an exhaust to the atmosphere through
start valve 72 from interlock valve 76. The exhaust point on each
valve in FIG. 4 is represented by EX. The source of external air
pressure, i.e., working pressure, is depicted in FIG. 4 by P. The
source of vacuum is represented by VAC. The dotted lines in the
schematic are pilot lines and are utilized solely to active another
valve, e.g., the line between start valve 72 and interlock valve
76. The solid lines in the schematic representation are internal
working air pressure lines or vacuum lines. Accordingly, the air
pressure or vacuum on these lines is used to accomplish mechanical
work, e.g., moving an air cylinder.
When start button 74 is pressed and activates start valve 72,
external pressure is transferred through the valve, activating
interlock valve 76. Interlock valve 76, being in an activated
state, causes internal working air pressure to flow to reverse
sense valve 78. At this point in time, depicted on FIG. 5 as
T.sub.0, reciprocating feed trolley 18 is in the reverse position.
Reciprocating feed trolley air cylinder 18a which provides the
mechanical power to reciprocating feed trolley 18, accordingly, is
in the reverse position, thereby activating reversing sense valve
78 by cam actuated mechanical means as shown in FIG. 4.
Consequently, working air pressure flows through reverse sense
valve 78 through the working air pressure line to hopper vacuum
head air cylinder 14a. Accordingly, this cylinder extends, tilting
or pivoting hopper vacuum head 14 in a position to engage an
envelope as hereinbefore explained in the Description of the
Preferred Embodiment. Vacuum to hopper vacuum head 14 is applied
via hopper head vacuum valve 80, which is shown deactivated in FIG.
4. But at the same time, working air pressure, depicted by the
solid line from reverse sense valve 78, is applied to hopper vacuum
head air cylinder 14a, also, pilot air pressure from the same line
activates hopper head vacuum valve 80, thereby allowing vacuum to
be applied to hopper vacuum head 14. Now hopper vacuum head 14
engages a first bottom envelope.
Referring again to FIG. 5, at a time slightly after T.sub.0, the
first significant operation is that hopper vacuum head 14 moves
from its up position to its down position. This operation is
completed at T.sub.1. For a further explanation of the
aforementioned operation, refer again to FIG. 4.
As shown, a pilot line connected to the same pilot line that
activated hopper head vacuum valve 80 is connected to vacuum head
control valve 82. Valve 82 becomes activated, thereby activating
reciprocating feed control valve 84. (Other operations occur when
vacuum head control valve 82 is activated, which will be discussed
hereinbelow.) Now, reciprocating feed control valve 84 has been
activated allowing external source air pressure to flow to
reciprocating feed trolley air cylinder 18a, starting a forward
motion of reciprocating feed trolley 18 (see FIG. 5). At this point
in time, a working air pressure line, i.e., solid line, off of
reciprocating feed control valve 84 allows working air pressure to
flow to hopper vacuum head air cylinder 14a thereby forcing hopper
vacuum head 14 in a down position, as previously mentioned
hereinabove.
Referring again to FIG. 5, it can be seen that the time for hopper
vacuum head 14 to travel to a down position is short compared to
the time for reciprocating feed trolley 18 to reach its forward
position. This is due to the construction and design of the air
cylinders involved, i.e., hopper vacuum head air cylinder 14a and
reciprocating feed trolley air cylinder 18a. (The construction and
design of the air cylinders are well known in the art and will not
be further explained herein.) To continue, at T.sub.1,
reciprocating feed trolley 18 has barely started its forward
motion. A summary of the operations that have occurred or will
occur are depicted on the horizontal axis of FIG. 5. So, at the
time T.sub.1, recriprocating feed trolley 18 is moving forward
finally reaching its end position at time T.sub.2.
Referring again to FIG. 4, concurrent with activation or
reciprocating feed control valve 84, pilot air pressure is applied
to forward sense valve 86. This valve is activated by cam actuated
mechanical means due to the full-forward position of reciprocating
feed trolley air cylinder 18a. The aforementioned pilot air
pressure is routed through forward sense valve 86 to vacuum head
control valve 82, reversing or deactivating this valve. In turn,
reciprocating feed control valve 84 is deactivated. At the same
time, pilot air pressure from forward sense valve 86 flows to
hopper head vacuum valve 80 deactivating this valve, thereby
turning off the vacuum from hopper vacuum head 14. This operation
is necessary to release the first envelope which has been moving
forward with reciprocating feed trolley 18 (see FIG. 1). As
hereinbefore described, on the first cycle of reciprocating feed
trolley 18, the first envelope is carried forward by means of
hopper vacuum head 14 being attached to reciprocating feed trolley
18. Now since reciprocating feed trolley 18 is about to begin a
reverse cycle, the first envelope is maintained at its forward
position by the release vacuum from hopper vacuum head 14. An
explanation of this operation follows hereinbelow.
Reciprocating feed trolley air cylinder 18a is moving to the left
or the reverse direction (FIG. 4). As hereinbefore described,
working air pressure has been applied to reciprocating feed trolley
air cylinder 18a. This air pressure is tapped and a pilot line is
routed to shearing sense valve 88. This valve is shown
schematically at a position which corresponds to the middle of the
stroke of reciprocating feed trolley air cylinder 18a in FIG. 4.
Shearing sense valve 88 is activated on the reverse and forward
stroke of reciprocating feed trolley air cylinder 18a by cam
actuated mechanical means. But pilot air pressure is applied to
this valve only on a reverse stroke of reciprocating feed trolley
air cylinder 18a. Accordingly, pilot air pressure is transferred
through shearing sense valve 88 only on a reverse stroke of
reciprocating feed trolley air cylinder 18a. Also, the first
envelope is now stationary, as previously mentioned, at the
shearing station. When shearing sense valve 88 is activated, pilot
air pressure flows to shearing valve 90, thereby activating this
valve allowing external source air pressure to flow to shearing air
cylinder 24a. This air pressure causes shearing blades 24 to move
downward shearing the end of the first envelope. In the meantime,
reciprocating feed trolley air cylinder 18a continues its rearward
movement passing by shearing sense valve 88 which, again, becomes
deactivated. Accordingly, pilot air pressure to shearing valve 90
is removed and due to shearing valve spring 92, returns to a
deactivated condition. This operation allows external air pressure
to be applied to shearing air cylinder 24a, thereby retracting
shearing blades 24.
Describing the above with respect to the timing diagram of FIG. 5,
it will be seen that reciprocating feed trolley 18 has reached its
forward position at time T.sub.2. Forward sense valve 86 is
activated and stays activated during a dwell period of
reciprocating feed trolley 18. At time T.sub.2, reciprocating feed
trolley 18 starts its reverse motion, and slightly thereafter,
forward sense valve 86 is deactivated at a time slightly before
T.sub.3. At time T.sub.3, shearing blades 24 move from a dwell
position to a shearing position, as aforementioned. Slightly prior
to reaching its reverse position, reciprocating feed trolley 18, by
cam actuated mechanical means, activates reverse sense valve 78.
Reciprocating feed trolley 18 continues its reverse movement which
is completed at time T.sub.4. During the period slightly after time
T.sub.3, shearing blades 24 shear the ends of the first envelope.
There is a slight dwell period, and after pilot air pressure is
removed from shearing valve 90, this valve returns to a deactivated
state by means of shearing valve spring 92 (see FIG. 4).
Accordingly, shearing blades 24 return to a dwell or up position by
time T.sub.4.
When reciprocating feed trolley air cylinder 18a reaches its full
reverse position, the operations herein described before, are
repeated, i.e., a second envelope starts its forward progression
and will follow the same sequence as did the first envelope.
Accordingly, it will suffice to follow the progress of the first
envelope to fully understand the system logic and timing employed
in the instant invention as depicted in FIGS. 4 and 5.
Consequently, reciprocating feed trolley 18, after a dwell period,
moves forward at a time T.sub.6 as shown in FIG. 5. The first
envelope, as depicted in FIG. 5, and described hereinbefore in the
detailed description is carried forward and positioned over
rotatable drum 40.
At a time slightly before T.sub.7, forward sense valve 86 is
activated in response to the cam mechanism on reciprocating feed
trolley air cylinder 18a. As shown in FIG. 4, a pilot air line from
forward sense valve 86 activates vacuum head control valve 82 which
allows external working air pressure to be applied to vacuum head
air cylinder 46a. Accordingly, the aforementioned working air
pressure causes concave flexible vacuum head 46 to retract,
thereby, forcing the first envelope into vee pockets 50 which are
integral with rotatable drum 40 (see FIGS. 1 and 2).
Now describing this operation with respect to the timing diagram,
the first envelope has moved forward with the forward motion of
reciprocating feed trolley 18 to a load position over rotatable
drum 40. As shown in FIG. 5, this operation occurs between times
T.sub.6 and T.sub.7. At T.sub.6, concave flexible vacuum head 46 is
in an extended position. There is a dwell period and as described
hereinbefore, concave flexible vacuum head 46 is retracted, thereby
forcing the first envelope into vee pockets 50 at a time T.sub.8.
As seen from FIG. 5, slightly before concave flexible vacuum head
46 starts retracting, vacuum is applied at a time slightly before
T.sub.7.
Referring to FIGS. 4 and 5 concurrently, it can be seen that
slightly before T.sub.7, forward sense valve 86 is activated.
Accordingly, pilot air pressure from that valve flows also to
concave flexible vacuum head valve 94. This valve is activated
causing vacuum to be applied to concave flexible vacuum head 46 as
previously indicated.
After the above operations have taken place, up to a time T.sub.8,
as depicted in FIG. 5, rotatable drum 40 is in a dwell state.
Slightly after time T.sub.8, as reciprocating feed trolley 18 moves
in a reverse direction, oscillating shaft 36 is rotated thereby,
(see also Description of the Preferred Embodiment) during the time
period T.sub.9 to T.sub.10. Consequently, rotatable drum 40 is
rotated to an empty position during the period T.sub.9 to T.sub.10.
Accordingly, rotatable drum 40, the first envelope and concave
flexible vacuum head 46 with vacuum applied, are rotated to the
empty position.
The next operation is to buckle the sides of the first envelope
open. This operation commences slightly after time T.sub.10 and is
completed at time T.sub.11, as shown in FIG. 5. Also, reciprocating
feed trolley 18 is in a reverse position, and as aforementioned,
reverse sense valve 78 is activated by mechanical cam means,
thereby applying pilot air pressure to vacuum head control valve
82. Consequently, vacuum head control valve 82 is activated,
thereby extending concave flexible vacuum head 46 by means of
applying working air pressure to vacuum head air cylinder 46a. As
concave flexible vacuum head 46 is being extended, at time
T.sub.11, vacuum shut-off sense valve 96 is activated by mechanical
means, thereby deactivating vacuum head valve 94, thus, releasing
vacuum from concave flexible vacuum head 46. As can be seen from
FIG. 5, vacuum shut-off sense valve 96 is activated for a short
time, slightly after T.sub.11. The time is such that as concave
flexible vacuum head 46 is being extended, the first envelope is
pulled slightly out of vee pockets 50 (see FIG. 3). Now, when
vacuum is released, the first envelope snaps back fully into vee
pockets 50, causing a vibrating action. The documents in the first
envelope will normally fall by gravity. If for such reasons, as
creased documents, static forces between the first envelope and the
documents therein, the documents do not fall, the vibrating action
will tend to release the documents restrained, thus, improving the
reliability of document fallout. The document fallout takes place
within a time period T.sub.11 to T.sub.12 as shown in FIG. 5.
Refer to FIGS. 4 and 5 concurrently for an understanding of the
operations occurring just prior to T.sub.11 and during the period
T.sub.11 to T.sub.13. First, if the documents have fallen out of
the first envelope, then, as shown in FIG. 4, document sense valve
98, by means of document sensor 56, is activated. External source
pilot air then flows to document sense interlock valve 100.
Document sense interlock valve 100 is activated only during a
period of time at which an envelope is in the empty position. So,
from FIGS. 4 and 5, during the reverse dwell period of
reciprocating feed trolley 18, and at time T.sub.11, document sense
interlock valve 100 is in the activated or enabling state.
Consequently, since documents have been sensed, pilot air pressure
from document sense valve 98 is transferred through document
interlock valve 100. Therefore, any time a document is sensed,
document sense memory valve 110 is activated. There is no external
air pressure to document sense memory valve 110. Accordingly, this
valve is conditioned to the fact that it has been activated and
that documents have been sensed but no information is transferred
through the valve at this point in time.
Referring to FIG. 5, at time T.sub.12, reciprocating feed trolley
18 is in a forward dwell position about to start a reverse cycle.
As aforementioned, shearing valve 90 is activated at T.sub.13 and
as shown in FIG. 4, pilot air pressure flows to document sense
memory valve 110. This pilot air pressure is transferred through
document sense memory valve 110 to reject memory valve 112, thereby
activating this valve. At this point in time, reject memory valve
112 simply stores the information that documents have fallen out of
the first envelope. The activating of reject memory valve 112
disables reject kicker 66 in order that the first envelope will not
be rejected on the next cycle. Referring again to FIG. 5, after a
forward dwell period, reciprocating feed trolley 18 starts a
reverse cycle. Accordingly, rotatable drum 40 with the first
envelope attached, rotates to the reject position, concurrent with
times T.sub.13 to T.sub.14 . Since the first envelope contains no
documents, reject kicker 66 is disabled or in a dwell state.
Therefore, the reject operation, which would ordinarily occur
during the period T.sub.14 through T.sub.15 does not occur. So at
T.sub.14, reciprocating feed trolley 18 reaches its reverse
position, dwells, and then starts a forward motion at T.sub.15.
When this occurs, forward sense valve 86 is activated. Referring to
FIG. 4, it can be seen that pilot air pressure flows to reject
memory valve 112, deactivating this valve, thus destroying the
memory therein. The information stored, i.e., documents have
fallen, is not needed since the point where the first envelope
could have been rejected has been passed.
Between the period T.sub.16 to T.sub.17, rotatable drum 40 rotates
the first envelope to the eject position. Reciprocating feed
trolley 18 has just started a reverse cycle and as aforementioned
vacuum head control valve 82 is activated at the end of this cycle,
(see FIG. 4). Accordingly, working air pressure flows to eject
kicker 60, thereby ejecting the first envelope. This operation
occurs during a reverse dwell period of reciprocating feed trolley
18 during the time interval T.sub.17 to T.sub.18, as shown in FIG.
5. Eject kicker 60 is reset or returned to a dwell state on a
forward cycle of reciprocating feed trolley 18 as shown in FIGS. 4
and 5.
In the alternative, if documents have not been sensed during the
period T.sub.11 to T.sub.13 (see FIG. 5). As aforementioned, the
first envelope, now containing documents, is rotated to the reject
position during the period T.sub.13 to T.sub.14. As herinbefore
noted at this point in time, reject memory valve 112 has not been
activated, reciprocating feed trolley 18 is in a reverse dwell
position, and vacuum head control valve 82 has been activated. As
depicted in FIG. 4, working air pressure flows through reject
memory valve 112 while it is in a deactivated state, thereby
extending reject kicker 66 and rejecting the first envelope. This
operation is shown in FIG. 5 by the dash-dot line during the period
T.sub.14 through T.sub.15. When reciprocating feed trolley 18 is in
a forward dwell position (prior to T.sub.16), reject kicker 66 is
reset or changed to a dwell state by working air pressure from
vacuum head control valve 82 when this valve is in a deactivated
state.
Referring again to FIG. 4, as document information is being
transferred from document sensed memory valve 110 to reject memory
valve 112, during a shearing cycle, as previously explained, the
same pilot line from shearing valve 90 that fed document sense
memory valve 110, also resets document sense interlock valve 100 by
means of reset delay variable orifice 114. The previous reset
operation is necessary in order to ready the apparatus for the
second envelope which is following in sequence. The delay of the
pilot air pressure to document sense interlock valve 100, by means
of reset delay variable orifice 114, is necessary in order not to
deactivate or reset document sense interlock valve 100 at the same
time that information is being transferred to document sense memory
valve 110. So by delaying the deactivation of document sense
interlock valve 100, slightly, it allows time for the transfer of
the aforementioned information to take place.
Finally, to turn the apparatus off, stop button 116 is depressed
activating stop valve 118. This action deactivates interlock valve
76 by means of external source pilot air pressure thereby
eliminating working air pressure to reverse sense valve 78.
Accordingly, when reciprocating feed trolley air cylinder 18a moves
to a reverse position, the apparatus ceases to operate since there
is no air pressure to start the next sequence.
While the invention has been shown and described with reference to
preferred embodiments thereof, it will be appreciated by those of
skill in the art that variations in form may be made therein
without departing from the spirit and scope of the invention.
* * * * *