Inserting apparatus and method with controlled, master cycle speed-dependent actuator operations
First Claim
1. An inserting apparatus operable over a range of master cycle speeds comprising:
- (a) a master drive assembly operative over a master cycle and at variable master cycle speeds;
(b) an encoder operatively coupled to the master drive assembly and adapted to produce an encoder signal indicative of a current master cycle speed at which the master drive assembly is operating;
(c) an insert conveyor assembly driven by a first motor at a variable insert conveyor speed;
(d) an envelope conveyor assembly driven by a second motor at a variable envelope conveyor speed;
(e) a first actuator having a substantially constant activation time lag and disposed in actuating communication with a first peripheral device; and
(f) a motion controller for controlling the insert conveyor assembly speed, the envelope conveyor assembly speed and an activation position of the first actuator based on the encoder signal, the motion controller electrically communicating with the encoder, the first motor, the second motor and the first actuator, wherein, at least once during every master cycle, the motion controller calculates the first actuator activation position and causes the first actuator to be activated at the calculated first actuator activation position.
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Accused Products
Abstract
In an inserting apparatus and method such as the continuous motion type, a motion controller electrically communicates with an encoder, a first motor driving an insert conveyor assembly, a second motor driving an envelope conveyor assembly, and an actuator operatively interfaced with a peripheral device. The motion controller controls insert conveyor assembly speed, envelope conveyor assembly speed, and the rotational position at which the actuator should be activated, based on the encoder signal. Once during every master cycle, the motion controller calculates the actuator activation position, and causes the first actuator to be activated at the calculated first actuator activation position.
12 Citations
44 Claims
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1. An inserting apparatus operable over a range of master cycle speeds comprising:
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(a) a master drive assembly operative over a master cycle and at variable master cycle speeds;
(b) an encoder operatively coupled to the master drive assembly and adapted to produce an encoder signal indicative of a current master cycle speed at which the master drive assembly is operating;
(c) an insert conveyor assembly driven by a first motor at a variable insert conveyor speed;
(d) an envelope conveyor assembly driven by a second motor at a variable envelope conveyor speed;
(e) a first actuator having a substantially constant activation time lag and disposed in actuating communication with a first peripheral device; and
(f) a motion controller for controlling the insert conveyor assembly speed, the envelope conveyor assembly speed and an activation position of the first actuator based on the encoder signal, the motion controller electrically communicating with the encoder, the first motor, the second motor and the first actuator, wherein, at least once during every master cycle, the motion controller calculates the first actuator activation position and causes the first actuator to be activated at the calculated first actuator activation position. - View Dependent Claims (2, 3, 4, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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5. The apparatus according to claim I wherein, during any master cycle, the insert conveyor assembly speed is greater than the envelope conveyor assembly speed.
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16. An inserting apparatus operable over a range of master cycle speeds comprising:
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(a) a master drive assembly operative over a master cycle and at variable master cycle speeds;
(b) an encoder operatively coupled to the master drive assembly and adapted to produce an encoder signal indicative of a current master cycle speed at which the master drive assembly is operating;
(c) an insert conveyor assembly driven by a first motor at a variable insert conveyor speed;
(d) an envelope conveyor assembly driven by a second motor at a variable envelope conveyor speed;
(e) a first actuator having a substantially constant activation time lag and disposed in actuating communication with a first peripheral device; and
(f) a motion controller for controlling the insert conveyor assembly speed, the envelope conveyor assembly speed and an activation position of the first actuator based on the encoder signal, the motion controller electrically communicating with the encoder, the first motor, the second motor and the first actuator; and
(g) a computer program product comprising computer-executable instructions embodied in a computer-readable medium communicating with the motion controller, the computer program product adapted to, at least once during every master cycle, calculate the first actuator activation position and cause the first actuator to be activated at the calculated first actuator activation position.
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31. A method for controlling an inserting apparatus over a range of master cycle speeds, the method comprising the steps of:
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(a) monitoring a master cycle speed at which an inserting apparatus operates over a plurality of master cycles;
(b) determining when a new master cycle has begun;
(c) at least once during every master cycle of operation of the inserting apparatus, performing a first calculation to determine a first cyclical position of the new master cycle at which an actuated device should begin to be activated, wherein the calculation is based on the master cycle speed measured for the new master cycle, a predetermined time duration required for the actuated device to become fully active, and a predetermined cyclical position of the new master cycle at which the actuated device should be fully active; and
(d) at least once during every master cycle of operation of the inserting apparatus, causing the actuated device to begin to be activated when the new master cycle reaches or exceeds the calculated first cyclical position. - View Dependent Claims (32, 33, 34, 35, 37, 38, 39, 40)
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36. A computer program product comprising computer-executable instructions embodied in a computer-readable medium, the computer program product adapted to perform the steps of:
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(a) monitoring a master cycle speed at which an inserting apparatus operates over a plurality of master cycles;
(b) determining when a new master cycle has begun;
(c) at least once during every master cycle of operation of the inserting apparatus, performing a first calculation to determine a first cyclical position of the new master cycle at which an actuated device should begin to be activated, wherein the calculation is based on the master cycle speed measured for the new master cycle, a predetermined time duration required for the actuated device to become fully active, and a predetermined cyclical position of the new master cycle at which the actuated device should be fully active; and
(d) at least once during every master cycle of operation of the inserting apparatus, causing the actuated device to begin to be activated when the new master cycle reaches or exceeds the calculated first cyclical position.
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41. A method for continuously inserting inserts into corresponding envelopes in a controlled manner over a range of master cycle speeds at which an inserting apparatus operates, the method comprising:
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(a) monitoring a master cycle speed at which an inserting apparatus operates over a plurality of master cycles;
(b) determining when a new master cycle has begun;
(c) at least once during every master cycle of operation of the inserting apparatus, performing a first calculation to determine a first cyclical position of the new master cycle at which an actuated device should begin to be activated, wherein the calculation is based on the master cycle speed measured for the new master cycle, a predetermined time duration required for the actuated device to become fully active, and a predetermined cyclical position of the new master cycle at which the actuated device should be fully active;
(d) at least once during every master cycle of operation of the inserting apparatus, causing the actuated device to begin to be activated when the new master cycle reaches or exceeds the calculated first cyclical position, wherein activation of the actuated device assists in an inserting process performed by the inserting apparatus;
(e) feeding an insert along a feed path at an insert feed rate in timed relation with the activation of the actuated device;
(f) feeding an envelope along the feed path at an envelope feed rate in timed relation with the activation of the actuated device, wherein the insert feed rate is greater than the envelope feed rate; and
(g) causing the insert to be inserted into the envelope in timed relation with the activation of the actuated device. - View Dependent Claims (42, 43, 44)
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Specification