Method for adjusting at least one means of an inserting apparatus and inserting apparatus

Abstract

A method for adjusting at least one means of an inserting apparatus adjusted for processing envelopes according to at least one predetermined dimension of the envelope is described. A plurality of envelopes is measured, while the envelopes are moved to obtain at least one predetermined dimension of the envelope. Depending on a comparison of the obtained dimension with the adjusted dimension and/or with one or several previously obtained dimensions, at least one means of the inserting apparatus is adjusted for processing the envelopes.

Claims

1. A method for adjusting at least one unit of an inserting apparatus adjusted for processing envelopes according to at least one predetermined dimension of a first envelope, comprising: measuring a plurality of envelopes while the plurality of envelopes is moved to obtain the at least one predetermined dimension of the first envelope to provide an obtained dimension; and depending on a comparison of the obtained dimension with an adjusted dimension and/or with one or several previously obtained dimensions, adjusting the at least one unit of the inserting apparatus for processing the plurality of envelopes; wherein the plurality of envelopes is measured while the plurality of envelopes is fed from an envelope feeder to an inserting area of the inserting apparatus to insert a product into the first envelope.

2. The method according to claim 1, wherein only some of the plurality of envelopes is measured.

3. The method according to claim 1, wherein the at least one unit of the inserting apparatus comprises one or several elements that are configured to operate on the first envelope, wherein adjusting the at least one unit comprises adjusting the element to a predetermined position and/or adjusting a position of the elements relative to one another, wherein the position is selected depending on the comparison.

4. The method according to claim 1, wherein adjusting the at least one unit comprises adjusting a speed at which the plurality of envelopes or the product to be inserted are transported, wherein the speed is selected depending on the comparison.

5. The method according to claim 1, wherein the plurality of envelopes in the inserting apparatus comprise a predetermined orientation, and wherein the at least one unit is adjusted to maintain the predetermined orientation of the plurality of envelopes in the inserting apparatus.

6. The method according to claim 5, wherein the first envelope is orientated centrally with respect to a width of a transport of the inserting apparatus.

7. The method according to claim 5, wherein a tendency is detected from the obtained dimensions whether the at least one predetermined dimension of the first envelope increases or decreases, and wherein, when detecting the tendency, the at least one unit is adjusted to maintain an orientation of the first envelope at a predetermined position.

8. The method according to claim 1, wherein: at least one unit of the inserting apparatus in the inserting area comprises one or several filling aids, one or several envelope guides, an envelope opener, an envelope sealer and/or a product transport, and at least one unit of the inserting apparatus in the envelope feeder comprises an envelope withdrawal and/or an orientation path for the first envelope.

9. The method according to claim 1, wherein a tendency is detected from the obtained dimensions whether the at least one predetermined dimension of the first envelope increases or decreases, wherein detecting the tendency comprises: determining a number of successive envelopes of the plurality of envelopes for which the obtained dimensions continuously increase or decrease; and detecting the tendency when the predetermined number reaches a predetermined threshold.

10. The method according to claim 1, wherein the predetermined dimension of the first envelope comprises at least one of the following: a width of the first envelope perpendicular to a transport direction, a length of the first envelope along the transport direction, a dimension of an envelope flap, a depth of an envelope opening, and a distance of an envelope window from an edge of an envelope body or the envelope flap.

11. The method according to claim 1, wherein measuring the first envelope during its movement further comprises obtaining a further predetermined dimension of the first envelope, and wherein adjusting the at least one unit is further based on a comparison of the obtained further dimension with a further adjusted dimension.

12. An inserting apparatus comprising at least one unit adjusted for processing envelopes according to at least one predetermined dimension of a first envelope, comprising: a measurement path that moves a plurality of envelopes; a sensor assembly that measures the plurality of envelopes to be transported along the measurement path, while the plurality of envelopes is moved to obtain the at least one predetermined dimension of the first envelope to provide an obtained dimension; and at least one controller that generates, depending on a comparison of the obtained dimension with an adjusted dimension and/or with one or several previously obtained dimensions, a control signal that adjusts the at least one unit of the inserting apparatus for processing the plurality of envelopes; wherein the plurality of envelopes is measured while the plurality of envelopes is fed from an envelope feeder via the measurement path to an inserting area of the inserting apparatus to insert a product into the first envelope.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present invention will be detailed subsequently referring to the appended drawings, in which:

(2) FIGS. 1(a)-1(d) are different situations where different dimensions of the envelope change;

(3) FIG. 2 is a schematic illustration of an inserting apparatus having an envelope feed and an inserting area;

(4) FIG. 3 is an example for an orientation path allowing regulation or tracking of an envelope transport within an inserting apparatus;

(5) FIG. 4 is an example for a continuously operating inserter where the envelope and the products to be inserted are moved continuously during the inserting process; and

(6) FIG. 5 is a lateral illustration of the assembly shown in FIG. 4 along the central line 2, 2 of the transport path through the inserting area in FIG. 4.

DETAILED DESCRIPTION OF THE INVENTION

(7) In the following description of the embodiments, same or equal elements are provided with the same reference numbers and the mentioned elements are not described multiple times.

(8) The inventive approach solves the above described problems in that during the operation of the inserting apparatus at least one means or unit of the same is adjusted to maintain optimum operation of the apparatus. According to the invention, it is intended to measure a plurality of envelopes while the same are moved, i.e. for example during feeding the envelopes from the envelope feeder to the inserting area of the inserting apparatus. Measuring the plurality of envelopes has the effect that at least one predetermined dimension of the envelope is obtained, for example a width dimension, a length dimension, a dimension of the envelope flap, a depth of the envelope opening or a distance of an envelope window from an envelope edge or from the envelope flap. According to embodiments, it can also be envisaged to obtain several dimensions.

(9) The dimensions obtained in this way are compared to the initially set dimensions and/or to one or several previously obtained dimensions. Depending on this comparison, adjusting of at least one means of the inserting apparatus is performed, for example readjusting the elements of this means to maintain optimum operation of the inserting apparatus.

(10) FIG. 2 shows a schematic illustration of an inserting apparatus 105 comprising an envelope feed 106 and an inserting area 108. The envelope feed 106 comprises, for example, an envelope feeder, a measurement path and an orientation path (not shown in FIG. 2). In the envelope feeder, envelopes having the predetermined dimensions to which the inserting apparatus is adjusted are provided, withdrawn and provided to the inserting area 108 via the measurement path and the optionally provided orientation path. The measurement path is implemented to measure the withdrawn envelopes during a movement along the measurement path, wherein, in embodiments, the measurement path can also be part of the orientation path. According to embodiments, the inserting area comprises filling aids, envelope guides, envelope openers, envelope sealers as well as a product transport to insert the products fed to the inserting area 108 into the envelopes supplied or fed to the inserting area 108. FIG. 2 shows a paper processing plant comprising, in addition to the inserting apparatus 105 consisting of the envelope feed and inserting area, a product feed 110 for providing the products to be inserted, for example in the form of a gathering web with supplement feeders and the like, and an output channel 112 for processing the closed envelopes, for example for sorting the same, wherein the product feed 110 and the output channel 112 are independent means in addition to the inserting apparatus.

(11) According to the invention, an envelope is measured along the measurement path to obtain one or several predetermined dimensions of the envelope. The inserting apparatus 105 was adjusted for the envelopes provided in the envelope feeder, and the measurement along the measurement path serves to detect deviations with respect to one or several predetermined dimensions of the envelope to allow, according to embodiments, resetting or readjustment of the inserting apparatus. More accurately, according to embodiments, it can be envisaged to adjust elements in the envelope feed 106 and/or in the inserting area 108, starting from the detected measurements measured along the measurement path, for example it can be envisaged to adjust the withdrawal from the envelope feeder in dependence on the detected dimension, or to adapt a possibly provided orientation path to ensure, at the input of the inserting area 108, the desired orientation of the envelope with respect to a transport means in the inserting area 108. In the inserting area, for example, the provided envelope transport, the filling aids or opening means for the envelope can be adjusted, adjustment of elements in the envelope sealer or in product transport can also be provided to ensure an optimum effect of the respective elements on the envelope or the product to maintain optimum operation of the inserting apparatus.

(12) Detecting and processing dimensions and generating the necessitated control signals for the respective elements in the envelope feed 106 or in the inserting area 108 can be effected by one or several controls of the inserter (see FIG. 2) or by a central control of a paper-handling plant.

(13) According to embodiments, it is envisaged to detect, by means of the detected measurement values, changes in the dimensions of the envelope, wherein not every successive envelope has to be measured, but it is sufficient, after detecting a dimension of a first envelope, to detect a renewed dimension again only after a predetermined number of further envelopes have passed the measurement path, for example if it is determined that new envelopes have been introduced into the envelope feeder, whose dimensions, due to manufacturing tolerances, might be different to those which have been withdrawn so far. This allows readjusting the inserting apparatus to maintain its optimum operating point.

(14) Further, embodiments allow detecting a tendency where it is detected from a comparison of a plurality of obtained dimensions measured by the measurement path whether the respective dimension of the envelopes increases or decreases. For example, a number of successive envelopes, for which the obtained dimensions are continuously increasing or decreasing, can be determined, and a tendency is detected when the predetermined number reaches a predetermined threshold.

(15) This will be explained exemplarily based on FIG. 1, where it can be seen in the case of FIG. 1(a) that the envelope E.sub.2 has a smaller width B.sub.2 than the previously transported envelopes E.sub.1. According to the invention, the means of the inserting apparatus 105 are influenced, for example, an orientation path, which has the effect that the envelope E.sub.2 is orientated such that its central line M coincides with the central line Z, so that the filling aids shown in FIG. 1(a) are arranged, also for the envelope E.sub.2, similarly to the envelope E.sub.1, with a distance from the edges R.sub.1 and R.sub.2 of the envelope E.sub.2. Alternatively (if no change of the orientation path is desired or possible) or in inserting apparatuses comprising no orientation path, displacing the filling element 100a, 100b of the filling aid (in the figure towards the right) can be effected instead, for example by half of the distance by which the width B.sub.2 of the envelope E.sub.2 differs from the width B.sub.1 of the envelope E.sub.1, which has the same effect, namely that the filling element 100a no longer abuts on the edge R.sub.1, but that both filling elements, similarly to the envelope E.sub.1, have a distance (less than for envelope E.sub.1) to the edges R.sub.1, R.sub.2 of the envelope E.sub.2, whereby contact of one or several of the filling elements 100a, 100b with the edges is prevented.

(16) In the case illustrated in FIG. 1(b), an orientation of the envelope E.sub.2 can be tracked. Alternatively, the envelope transport can be displaced within the inserting area, so that the same engages at the center M of the envelope E.sub.2.

(17) In the cases shown in FIGS. 1(c) and (d), the speed of the claw 102 or the product transport element 104a, 104b can be changed, so that in the case of FIG. 1(c) the claw 102 is accelerated, for example when a larger envelope opening is determined, so that the same reaches the envelope opening edge also for envelope E.sub.2, similarly to envelope E.sub.1, and can separate the back of the envelope from the front. Accelerating the product transport elements 104a, 104b allows the product to be completely inserted, even with a slightly shorter envelope E.sub.2.

(18) Obviously, the above-described measures can be taken vice versa to compensate changes of the dimensions of the envelopes in another direction than the direction described in FIG. 1, for example with an increase of the width or reduction of the size of the envelope opening or an increase of the envelope length.

(19) The measurement path is implemented to obtain the dimensions of the envelope, for example by optical sensors or ultrasonic sensors, for example a double sheet sensor for detecting the dimension of the envelope opening.

(20) According to embodiments, it can be envisaged that an average from a plurality of measurements is obtained, for example based on 10 subsequent measurements, to compare the same with the adjusted values or one or several previously (earlier) obtained (and cached) averages, wherein adjustment of the means of the inserting apparatus is advantageously performed via several stages or linearly increasing or linearly decreasing to prevent large jumps.

(21) FIG. 3 shows an example of an orientation path allowing regulation or tracking of an envelope transport within the inserting apparatus. The orientation path comprises an adjustable stop 114, against which the envelopes E are moved, as is indicated by the schematically shown drives 116a to 116c. The stop 114 is adjusted in dependence on an envelope width B of the envelope E to be processed, such that the envelopes E are oriented centrally with respect to a subsequent means of the inserting apparatus at the end of the orientation path, for example centrally with respect to an envelope transport moving a feed of the envelope from the orientation path to the inserting area or centrally with respect to an input of the inserting area where the envelope is taken over by an envelope transport of the inserting area. Sensors S1 and S2 are arranged along the orientation path, which can, for example, be optical sensors in the form of light barriers. At the end of the orientation path, the central position of the envelope E is checked, which is indicated by the fact that one of the two light barriers S1 and S2 has to be occupied and the other one has to be free. In this case it is determined that a format width has been adjusted correctly. If no light barrier is occupied, the format is too large. If both light barriers are occupied, the format is too small. These light barriers are displaced center-symmetrically to the displacement axis of the orientation path. At the beginning of processing a job, the format width from the envelope withdrawal is used as the initial value, which is obtained by measuring this envelope when withdrawing the first envelope E of the new job, and the orientation path is adjusted accordingly, so that the envelope is arranged centrally with respect to the subsequent elements of the inserting apparatus. During operation, the envelope width of one or several of the subsequently withdrawn envelopes is measured, wherein either all envelopes are measured or only a predetermined number, for example every fifth, tenth, or hundredth envelope, so that when detecting a deviation or a situation where the envelopes are no longer arranged centrally, resetting or readjustment of the orientation takes place, for example by readjusting the adjustable stop 114, so that a central orientation of the envelope is ensured in this embodiment.

(22) Based on FIG. 3, an example of a means of an inserting apparatus is described which can be operated on to compensate variations or changes of a dimension, in the described case the width of an envelope E, by readjusting the orientation path.

(23) However, the present invention is not limited to such an implementation, but, as mentioned above, in other areas of the inserting apparatus it is also possible to operate on the elements cooperating with the envelopes/products to compensate a change of the envelope dimensions.

(24) In the following, an example of a continuously operating inserter will be discussed based on FIG. 4, wherein during the inserting process, the envelope and the products to be inserted are moved continuously, wherein the products are moved faster than the envelope, so that introducing the products into the envelope is accomplished due to the speed excess. According to this inserting principle, neither the products nor the envelopes are stopped during the inserting process.

(25) FIG. 4 is a schematic illustration of such an inserter in a top view. The inserter comprises an envelope transport 130 having, according to embodiments, a suction belt 132. The envelope transport 300 moves the envelopes E.sub.1 and E.sub.2 along an inserting path starting, for example, at the position where the envelope E.sub.1 and the product G.sub.1 are initially arranged in an overlapping manner, and ending when the products are arranged completely within the envelope E.sub.1. FIG. 1 shows a further envelope E.sub.3 which has already left the inserting path and which includes the products G.sub.3. Further, the products G.sub.4 are illustrated which are moved from the left side in FIG. 1 in the direction of the inserter, for example by means of a product feed, to be then introduced into an envelope which is fed to the inserting area subsequent to envelope E.sub.1. The envelope E.sub.1 is at the beginning of the inserting path and the products G.sub.1 have already passed the flap F.sub.1, so that the leading edge of the product is inside the envelope E.sub.1. Due to the different speeds at which the envelope and the products are moved, the products are introduced into the envelope along the inserting path. The product G.sub.2 is already inside the envelope E.sub.2 for the most part and the trailing edge of the product has already passed the edge of the flap F.sub.2. The envelope E.sub.3 is already filled, i.e. a leading edge of the product has already reached the bottom of the envelope.

(26) The inserter further comprises a product transport 140 comprising the plurality of product transport elements 104a, 104b, which have been discussed above based on FIG. 1. According to embodiments, this can be shifting elements engaging products G.sub.1 to G.sub.4 to move these products at a speed that is higher than the speed at which the envelope transport 130 operates. The products and the envelopes are moved in the same transport direction F, and the openings of the envelopes are arranged perpendicularly or laterally to the transport direction F so that the movement of the envelopes and the products along the same direction F (in an overlapping manner) results in the insertion of the products into the envelopes. The product transport elements 104a, 104b are arranged with respect to the trailing edges of the product at positions symmetrically to the center of the product. The product transport 140 is longer than the envelope transport 100, wherein the product transport 140 can be provided to effect expelling of the filled envelopes from the inserting path.

(27) Further, the inserter includes the filling aid 150 having a first conveyor 152 which again comprises a first driven roller 154 and a second roller 156, on which a chain or a belt 158 extends. A plurality of filling elements 100a, for example so-called filling fingers, are arranged along the chain 158 at predetermined positions. The first conveyor 152 is arranged such that the filling elements 100a are moved along the conveying direction F on one side of the conveyor, which opposes the envelope transport 100, and are moved in the opposite direction on the side facing away from the transport 130. This means that the filling elements 100a are moved along the inserting path and moved back from the end of the inserting path to the beginning of the same. The filling aid 150 further includes a second transport 162, further comprising again a driven roller 164, a further roller 166 and a chain or a belt 168 extending around the rollers. The filling elements 100b are arranged along the chain 168 to be movable similarly to the filling elements 100a. The filling elements 100a, 100b are provided to be inserted into the envelopes E.sub.1 and E.sub.2 at a predetermined distance. They serve to guide the product during filling, according to the presented embodiment, to prevent collisions of the products with the edges of the envelopes.

(28) In the shown embodiment, the filling elements 100a, 100b are merely provided to effect guidance of the goods to be introduced; the transport of the envelope is performed by means of the envelope transport 130. In other embodiments, the inserter might not comprise any transport 130; instead the envelopes are moved along the inserting path by the filling elements 100a, 100b.

(29) In the shown embodiment, the filling elements 100a, 100b have a bottom part 170a, 170b, a top part 172a, 172b and a vertical element 174a, 174b connecting the top and bottom parts of the filling elements 100a, 100b. The bottom and top elements can be movable with respect to each other, depending on the thickness of the products to be inserted.

(30) The inserter further comprise several separating claws 180 engaging a trailing edge of the envelope opening to keep the envelope open along the filling path, i.e. to separate the two opposite sides, the front and the back of the envelope to prevent collisions between products and the upper side of the envelope.

(31) FIG. 5 shows a lateral illustration of the assembly shown in FIG. 4 along the central line 2, 2 of the transport path through the inserting area. FIG. 5 shows further details of the envelope transport, the product transport and a transport for the claws 180, each comprising belts extending around pairs of rollers which are spaced apart. Further, a pair of blowing nozzles 190 is shown, arranged at the beginning of the inserting path to direct blowing air in the direction of an envelope that has just been received in order to support opening of the envelope.

(32) In the inserter shown based on FIGS. 4 and 5, the envelope feed can be arranged below the envelope transport 130. Along the envelope feed, the above-described orientation path can be provided which passes the envelopes to a feed transport with a desired orientation, which passes the orientated envelopes to the envelope transport 130. In such a case, the orientation path is readjusted to maintain the central orientation of the supplied envelopes.

(33) In other embodiments, merely the measurement path can be provided in the envelope feed and instead of an orientation path, it can be envisaged to operate on the different elements in the inserting area or also on elements in the envelope feeder to compensate a deviation of the dimensions of the envelope due to manufacturing tolerances.

(34) As has already been described above, for example the filling elements 100a, 100b can be adjusted to each other with respect to their distance from one another, wherein advantageously the entire assembly 150, or more accurately the belt drives 152, 162 on both sides of the envelope transport 130 are movable with respect to one another, to change the distance between the filling elements 100a, 100b when a deviation of the envelope width necessitating readjustment is detected. Further, it can be envisaged that the transport 130 is implemented to be displaceable transversally to the transport direction F to readjust the same, so that the same is aligned with the center of the transported envelope or fed envelope. If it is determined that a length of the envelopes deviates in the transport direction F, the product transport 140 can be accelerated or decelerated to ensure complete filling of the envelope with the product. If it is determined that an envelope opening comprises a dimension along the conveying direction F that deviates from the adjusted deviation by a predetermined amount, the drive of the claw 180 can be accelerated or decelerated to ensure that the claw engages the top of the envelope when taking over the envelope in the transport area, to keep the same open along the filling path. Further, it can be envisaged to modify a position of the blow air nozzle 190 along the conveying direction F, to ensure that the output blowing air reaches the envelope such that opening of the same is supported, in particular when the length of the envelope deviates from the adjusted length along the conveying direction F.

(35) It should be noted that also a plurality of dimensions of the envelope can be detected in order to perform one or several of the above-stated operations in response to respective deviations.

(36) Embodiments of the invention have been explained based on an inserting principle, as was discussed in FIGS. 4 and 5, but which are not limited to this inserting principle. Rather, the inventive approach can be applied to any type of inserting apparatus, i.e. also to inserting apparatuses operating in the start/stop operation, where an envelope has to be applied to the inserting position in a predetermined orientation at the time of inserting, which can, however, vary depending on deviations of the dimensions. Here, too, maintaining the desired orientation during deviations from the predetermined dimensions can be obtained in a manner similar to that discussed above, for example by operating on an envelope transport. The inventive approach can also be applied to inserting apparatuses moving the envelope and the product to be inserted towards each other.

(37) While some aspects have been described in the context of an apparatus, it is obvious that these aspects also represent a description of the respective method, so that a block or a member of an apparatus can also be seen as a respective method step or as a feature of a method step. Analogously, aspects that have been described in the context of a method step or as a method step also represent a description of a respective block or details or features of a respective apparatus.

(38) While this invention has been described in terms of several advantageous embodiments, there are alterations, permutations, and equivalents which fall within the scope of this invention. It should also be noted that there are many alternative ways of implementing the methods and compositions of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, permutations, and equivalents as fall within the true spirit and scope of the present invention.