PATENT DOCUMENT

Abstract:
A system and method for personalizing cards and other secure identification documents. The card personalization system and method provide improved data integrity, system reliability, and system performance. Improvements to card handling and processing within the modules, improved card transfer between modules, improvements to control of the modules, and other improvements are set forth, all of which contribute, individually and collectively, to achieving these goals.

Full Description:
PRIOR APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 60/352,648, filed Jan. 28, 2002. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a system and method for producing and personalizing identity documents. In particular, this invention relates to a system and method for producing and personalizing data bearing plastic cards such as financial (e.g. credit and debit) cards, drivers&#39; licenses, national identification cards, and other cards which are personalized with information unique to the card holder and/or with other card or document information. 
       BACKGROUND OF THE INVENTION 
       [0003]    Card personalization systems and methods used in producing personalized cards and other personalized identity documents have been employed by institutions that issue such documents. Identity documents which are often personalized by such systems and methods includes plastic and composite cards, such as financial (e.g. credit and debit) cards, drivers&#39; licenses, national identification cards, and other cards and documents which are personalized with information unique to the intended document holder. 
         [0004]    Card personalization systems and methods can be designed for small scale, individual card personalization and production. In these systems, a single card to be personalized is input into a personalization machine, which typically includes one or two personalization/production capabilities, such as printing and laminating. 
         [0005]    For large volume, batch production of cards, institutions often utilize systems that employ multiple processing stations or modules to process multiple cards at the same time to reduce the overall per card processing time. Examples of such systems includes the DataCard 9000 series available from DataCard Corporation of Minneapolis, Minn., the system disclosed in U.S. Pat. No. 4,825,054, and the system disclosed in U.S. Pat. No. 5,266,781 and its progeny. Common to each of these types of systems is an input with the ability to hold a relatively large number of cards that are to be personalized/produced, a plurality of personalization/production stations through which each card is directed to perform a personalization/production operation, and an output that holds the personalized cards. Personalization and production operations that are typically performed on the cards include the programming of data onto a magnetic stripe of the card, monochromatic and/or color printing, programming an integrated circuit chip in the card, embossing, and applying various topcoat and protective layers. A controller is typically employed to transfer data information and instructions for operating the input, the personalization/production stations, and the output. 
         [0006]    In batch card personalization and production systems, such as the DataCard 9000 series, data integrity (e.g. ensuring that the correct data is placed onto the proper card), and system reliability and performance are important. Any improvements in these areas, including improvements in the personalization process and the modules used to implement the process, will improve the utility of batch card personalization and production systems. 
         [0007]    The present invention, as described hereinbelow, provides improvements upon one or more of the above described existing and previous card personalization systems. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention provides a system for personalizing cards and other secure identification documents. Further, the present invention provides methods of personalizing cards and secure documents. One object of the present invention is to provide a card personalization system with improved data integrity, reliability, and performance. 
         [0009]    In one embodiment of the present invention, a card personalization system includes an input at one end of the system that holds a supply of cards and inputs the cards for personalization by the system. The input delivers each of the cards to a plurality of card processing modules arranged in sequence, where one module is downstream from a previous module. An output is disposed at an end of the card personalization system, and collects cards that have been personalized by the card processing modules. Together the input, plurality of processing modules, and output define a card track, which enables each card to advance through the system. A controller is operatively connected to and in communication with the input, each of the processing modules, and the output. Processing and data information is transferred to and from the controller to the input, processing modules, and output. 
         [0010]    In one embodiment, the system is arranged and configured to operate such that at least one of the modules exits a processed card before accepting entry of another card to be processed by the module. Preferably, the system is arranged and configured to operate such that a card can be output to the next module after the module completes its personalization, provided the next module is ready to receive the card (i.e. the next module has already processed its card and exited the card), and once the card exits the module, the module is ready to receive another card from the adjacent upstream module. 
         [0011]    More preferably, each module in the system operates such that entry of a card into a module occurs only after a processed card has exited the module, or when no card is in the module, where card transfer by the plurality of modules in the system is configured in a cascading arrangement. 
         [0012]    In one embodiment, the processing modules are supported on a mounting mechanism. The mounting mechanism includes common support structures to enable secure connection and proper alignment of the modules. 
         [0013]    In one embodiment, each of the processing modules includes status indicators incorporated therein and in communication with the controller. A status indicator is also incorporated into an operator station of the system. The status indicators provide the disposition and operation status of each of the modules. 
         [0014]    In one embodiment, the controller that is used to control operation of the system provides a networking system. The networking system resides in the controller, wherein configurative adjustments may be made at the controller for each card processing module connected within the system. 
         [0015]    In one embodiment, the plurality of processing modules include, but are not limited to, a magnetic stripe module, an embossing module, a smart card programming module, a printer module, a laser module, a graphics module, and a cleaning module. 
         [0016]    In one embodiment, a method for personalizing cards includes picking a card from an input, placing the card in a card track, and inputting the card to a first processing module. The card is transferred along the card track to additional processing modules arranged in sequence. The card is collected at an output after being personalized by one or more of the processing modules. Each of the processing modules personalizes a single card at a time, such that one card at a time is transferred through each processing module, wherein the processing modules transfer cards in a cascading configuration. A controller is provided to transfer data and other information to and from each of the system components, and to monitor operation of the system. 
         [0017]    The present invention provides the advantages of a card personalization system and method having improved data integrity, reliability, and performance. 
         [0018]    These and other various advantages and features of novelty, which characterize the invention, are pointed out in the following detailed description. For better understanding of the invention, its advantages, and the objects obtained by its use, reference should also be made to the drawings which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described specific examples of an apparatus in accordance with the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    Referring now to the drawings in which like reference numbers represent corresponding parts throughout: 
           [0020]      FIG. 1  represents a front perspective view of one embodiment of a card personalization system in accordance with the principles of the present invention. 
           [0021]      FIG. 2  represents a rear perspective view of the card personalization system of  FIG. 1 . 
           [0022]      FIG. 3  represents a front perspective view of one embodiment of a mounting mechanism incorporated in the card personalization system of  FIG. 1  in accordance with the principles of the present invention. 
           [0023]      FIG. 4  represents a flow diagram of one embodiment of a method for personalizing a card in accordance with the principles of the present invention. 
           [0024]      FIG. 5  represents a side view of one embodiment of an input hopper in accordance with the principles of the present invention. 
           [0025]      FIG. 6  represents a top view of the input hopper of  FIG. 5 . 
           [0026]      FIG. 6   a  represents a side view of one embodiment of a card pusher and release mechanism of an input hopper in accordance with the principles of the present invention. 
           [0027]      FIG. 7  represents a top view of one embodiment of method for a card being picked for processing in accordance with the principles of the present invention. 
           [0028]      FIG. 8  represents a top view of the method of  FIG. 7  of a card being picked for processing. 
           [0029]      FIG. 9  represents a side view of a method for releasing a card tray in accordance with the principles of the present invention. 
           [0030]      FIG. 10  represents a side view of the method for releasing the card tray of  FIG. 9 . 
           [0031]      FIG. 11  represents a side view of the method for releasing the card tray of  FIG. 9 . 
           [0032]      FIG. 12  represents a side view of the method for releasing the card tray of  FIG. 9 . 
           [0033]      FIG. 13  represents a side view of the method for releasing the card tray of  FIG. 9 . 
           [0034]      FIG. 14  represents a side view of the method for releasing the card tray of  FIG. 9  with the card tray in a released position. 
           [0035]      FIG. 15  represents a flow diagram of one embodiment of a method for picking a card from an input hopper in accordance with the principles of the present invention. 
           [0036]      FIG. 16  a front perspective view of one embodiment of a magnetic stripe module in accordance with the principles of the present invention. 
           [0037]      FIG. 17  is a rear perspective view of the magnetic stripe module. 
           [0038]      FIG. 18  is a perspective view of the drive assembly used in the magnetic stripe module. 
           [0039]      FIG. 19  is a perspective view of a portion of the magnetic stripe module illustrating details of the card eject mechanism. 
           [0040]      FIG. 20  illustrates the upper plate with the write and read head units of the magnetic stripe module disposed in a service position. 
           [0041]      FIG. 21  is a front, right perspective view of interior portions of the laser module illustrating details thereof. 
           [0042]      FIG. 22  is a front, left perspective view of interior portions of the laser module illustrating details thereof. 
           [0043]      FIG. 23  is a longitudinal cross-sectional view of the card stop of the laser module illustrating details of the channel. 
           [0044]      FIGS. 24-26  are perspective views of the laser mechanism used in the laser module. 
           [0045]      FIG. 27  is a schematic depiction of the laser module and the arrangement of the laser power sources. 
           [0046]      FIGS. 28-29  are schematic depictions of portions of the laser mechanism illustrating the laser adjustment concept. 
           [0047]      FIG. 30  represents a rear perspective view of one embodiment of a graphics module in accordance with the principles of the present invention. 
           [0048]      FIG. 31  represents a rear perspective view of the graphics module of  FIG. 30  with a print ribbon incorporated. 
           [0049]      FIG. 32  represents a front perspective view of one embodiment of a roller configuration of a card path for the graphics module of  FIG. 30 . 
           [0050]      FIG. 33  represents a perspective view of a printhead in a print position for the graphics module of  FIG. 30 . 
           [0051]      FIG. 34  represents a top view of one embodiment of an output hopper in accordance with the principles of the present invention. 
           [0052]      FIG. 35   a  represents a perspective view of one embodiment of a card in sensor bracket for the output hopper of  FIG. 34  in accordance with the principles of the present invention. 
           [0053]      FIG. 35   b  represents a top view of the card in sensor bracket of  FIG. 35   a.    
           [0054]      FIG. 35   c  represents a front view of the card in sensor bracket of  FIG. 35   a.    
           [0055]      FIG. 35   d  represents a side view of the card in sensor bracket of  FIG. 35   a.    
           [0056]      FIG. 36  represents a perspective view of one embodiment of a card feeder exiting a card in accordance with the principles of the present invention. 
           [0057]      FIG. 37  represents a perspective view of the card feeder of  FIG. 36  exiting a card. 
           [0058]      FIG. 38  represents a perspective view of the card feeder of  FIG. 36  exiting a card. 
           [0059]      FIG. 39  represents a top view of one embodiment of a card feeder exiting a card in accordance with the principles of the present invention. 
           [0060]      FIG. 40  represents a top view of the card feeder of  FIG. 39  exiting a card. 
           [0061]      FIG. 41  represents a top view of the card feeder of  FIG. 39  exiting a card. 
           [0062]      FIG. 42  represents a perspective view of one embodiment of a magnetic stripe readhead unit in accordance with the principles of the present invention. 
           [0063]      FIG. 43  represents a side view of the magnetic stripe readhead unit of  FIG. 42 . 
           [0064]      FIG. 43   a  represents a cross sectional view of one embodiment of a readhead in the magnetic stripe readhead unit of  FIG. 43  in accordance with the principles of the present invention. 
           [0065]      FIG. 44  represents a side view of one embodiment of a readhead holder in accordance with the principles of the present invention. 
           [0066]      FIGS. 45   a - c  illustrate an alternative embodiment of a readhead and a readhead holder. 
           [0067]      FIG. 46  represents a perspective view of one embodiment of a roller in accordance with the principles of the present invention. 
           [0068]      FIG. 47  represents a top view of the roller of  FIG. 46 . 
           [0069]      FIG. 48  represents side cross sectional view of the roller of  FIG. 46 . 
           [0070]      FIG. 49   a  represents a top view of one embodiment of a roller including a locking pin in accordance with the principles of the present invention. 
           [0071]      FIG. 49   b  represents a bottom view of the roller of  FIG. 49   a.    
           [0072]      FIG. 50  represents a perspective view of one embodiment of a roller in accordance with the principles of the present invention. 
           [0073]      FIG. 51  represents a top view of the roller of  FIG. 50 . 
           [0074]      FIG. 52  represents a side view of the roller of  FIG. 50 . 
           [0075]      FIG. 53  represents a side view of the roller of  FIG. 50 . 
           [0076]      FIG. 54  illustrates a prior art magnetic head. 
           [0077]      FIG. 55  is a side view of a magnetic head having a resistance wear sensor. 
           [0078]      FIG. 56  is an edge view of the resistance wear sensor of  FIG. 55 . 
           [0079]      FIG. 57  is a perspective view of the cleaning mechanism within the cleaning module in accordance with the principles of the present invention. 
           [0080]      FIG. 58  is a top view of the cleaning mechanism in a stand-by operational state. 
           [0081]      FIG. 59  is a top view of the cleaning mechanism in a cleaning state. 
           [0082]      FIG. 60  is a top view of the cleaning mechanism in a tape replacement state. 
           [0083]      FIG. 61  represents a top side perspective view of one embodiment for a take up roll core in accordance with the principals of the present invention. 
           [0084]      FIG. 62  represents a partial sectional view of the take up roll core of  FIG. 61 . 
           [0085]      FIG. 63  represents a sectional view of the take up roll core of  FIG. 61  in one embodiment of a first configuration before or during web product take up. 
           [0086]      FIG. 63   a  represents a sectional view of the take up roll core of  FIG. 61  in one embodiment of a second configuration for web product removal. 
           [0087]      FIG. 64  is a perspective view, partly in section, of a direct drive cam mechanism for use in an embossing module. 
           [0088]      FIG. 65  is a cross-sectional view through the cam illustrating how the can is mounted on the shaft. 
           [0089]      FIG. 66  is a perspective view of a cam sleeve used to mount the cam on the shaft. 
           [0090]      FIG. 67  is a perspective view, partly in section, of an embossing wheel assembly for using in the embossing module. 
           [0091]      FIG. 68  illustrates the mounting bracket used in the embossing module. 
           [0092]      FIGS. 69 ,  70 , and  71  illustrate an alternate embodiment of a card feeder mechanism in the output hopper. 
           [0093]      FIG. 72  is a top view of an alternative embodiment of a magnetic stripe reader that can be used in the output hopper. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0094]    In the following description of the illustrated embodiments, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration of the embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized as structural changes may be made without departing from the spirit and scope of the present invention. 
         [0095]      FIGS. 1 and 2  illustrate perspective views of one embodiment of a card personalization system  10  in assembled form. The card personalization system  10 , referred hereafter as the system  10 , includes an operator station  20 , an input hopper  30 , a plurality of processing modules  40 , and an output hopper  50 . 
         [0096]    The operator station  20  includes a housing  27  having a work surface  21  formed on the top of the housing  27 . A system controller  22 , illustrated in dashed lines in  FIGS. 1 and 2 , resides in the housing  27 . The controller  22  controls operation of the system  10  and transfers data to and from the input hopper  30 , the modules  40  and the output hopper  50 . The controller  22  can be a computer or any central processing unit suitable for transferring data and processing information. Operator interface means  23 ,  23   a  are connected to a data port system  23   b  of the controller  22  to permit control commands and data input to the controller  22 . Preferably, the interface means  23 ,  23   a  are a keyboard and mouse, as depicted in  FIGS. 1 and 2 . However, it will be appreciated that other suitable interface means may be employed. Each module  40  also includes it own module controller (not shown) that controls the functions and operation of the respective module. 
         [0097]    In addition, the operator station  20  includes an interface or monitor  25  to enable display and viewing of data pertaining to the operation of the controller  22 , the input and output hoppers  30 ,  50 , and the processing modules  40 . As shown in  FIGS. 1 and 2 , the monitor  25  is preferably mounted to the station  20  through a support  24 , which may be but is not limited to a pole. Further, a status indicator  80  may be employed at the top of the support  24  for indicating an operational status of the system  10 . 
         [0098]    As shown in  FIG. 2 , data and control commands are communicated between the controller  22  and the various components of the system  10  via data lines  97 . Preferably, a data line  97  runs from the controller  22  to each system component, so that data and commands are directly received from the controller  22 . For example, a pair of data lines  97  connect to the input hopper  30  to provide control and/or data inputs to each input mechanism of the hopper  30 . Similarly, at least one data line  97  connects to the first module  40  to provide data and control inputs to the first module. 
         [0099]    As shown in  FIGS. 1 and 2 , an emergency stop button  29  is provided on the work surface  21 . When the button  29  is pressed, operation of the system  10  is stopped. In addition, the system  10  preferably includes at least one pause/resume button  28  to allow the system operator to temporarily pause system operation, such as when clearing a card jam, and to thereafter resume system operation simply by pressing the button  28 . The pause/resume button(s)  28  can be located at any convenient location on the system  10 . In the preferred embodiment, a pause/resume button  28  is provided on each of the input hopper  30  and the output hopper  50  (only the output hopper  50 , button is visible in the figures). If desired, pause/resume buttons could also be provided on one or more of the modules  40  and/or on the operator station  20 . Pause/resume capability could also be incorporated into the keyboard  23  or the mouse  23   a  and monitor  25 . 
         [0100]    The input hopper  30  is releasably connected at its upstream side  39   a  to a side of the operator station  20 . The input hopper  30  preferably includes at least one tray  37  holding a supply of cards  37   a . Preferably, the input hopper  30  includes a plurality of trays  37 , thereby increasing the number of cards that can be automatically fed into the system  10 . A cover  31  protects the inside of the input hopper  30 . A status indicator  35  is provided on the input hopper  30  to indicate an operational status of the input hopper  30 . The indicator  35  may be, but is not limited to, a light indicator. 
         [0101]    The input hopper  30  works by picking a card  37   a  from the supply of cards held in one of the trays  37 , and transferring the card into the adjacent downstream processing module  40  to begin personalization of the card. As an alternative to picking a card from the input hopper  30 , an acception card slot  26  is provided in the work surface  21  of the operator station  20  upstream of the input hopper  30  and communicating with the card track and card transport mechanism of the input hopper. The card slot  26  allows input of a single card into the system  10 , to enable personalization of a select card and/or to enable re-insertion of a previously picked card into the system, such as when an error occurs. Further description is provided below of an input hopper in accordance with the principles of the present invention. 
         [0102]    The plurality of processing modules  40  are disposed at a downstream side  39   b  of the input hopper  30 . The plurality of processing modules  40  are configured in a sequential arrangement, with each processing module being sequentially connected to a downstream side of a previous processing module or the input hopper  30 . Particularly, as shown in  FIGS. 1 and 2 , a first processing module is connected to the downstream side  39   b  of the input hopper  30 , with the additional processing modules each being sequentially arranged downstream. 
         [0103]    As with the input hopper  30 , each processing module  40  includes a cover  41  and a status indicator  45 . The covers  41  may include a transparent surface  43  allowing a user or operator to view the inside of each of the processing modules  40 . The status indicator provides an indication of an operational status of the respective processing module  40 , and may be but is not limited to a light indicator. A variety of processing modules  40  may be employed in the system  10 , some of which are further detailed below in accordance with the principles of the present invention. 
         [0104]    Examples of processing modules  40  that may be included in the system  10  are a magnetic stripe module (described below) for writing data to and reading data from a magnetic stripe on the cards, an embossing module (described below) for forming embossed characters on the cards, a smart card programming module for programming an integrated circuit chip on the cards, a printer module for performing monochromatic or multi-color printing, a laser module (described below) for performing laser personalization on the cards, a graphics module (described below) for applying monochromatic data and images to the cards, a cleaning module (described below) for cleaning the cards, a topping module for applying a topcoat to the cards, and a card punching module to punch or cut a hole into the cards and/or to punch the card into a specific shape. 
         [0105]    Each of the processing modules  40  is connected into the system  10  through a mounting mechanism  60 .  FIG. 3  best illustrates the features of the mounting mechanism  60 . As shown in  FIG. 3 , two adjacent mounting mechanisms  60   a  and  60   b  are shown detached from each other. It will be appreciated that mounting mechanism  60   a  includes equivalent parts as mounting mechanism  60   b . The mounting mechanisms  60   a ,  60   b  include frames  67   a ,  67   b . The frames  67   a ,  67   b  each include a top  73   a ,  73   b , and a bottom  71   a ,  71   b  to provide structural support for a processing module. At the top  73   a ,  73   b , a platform  65   a ,  65   b  is provided with a substantially flat surface, where a processing module is positioned and held. 
         [0106]      FIG. 3  shows a downstream side  75   a  of mounting mechanism  60   a  and an upstream side  75   b  of mounting mechanism  60   b . However, it will be appreciated that each mounting mechanism  60   a ,  60   b  includes an upstream side and a downstream side. As shown, the mounting mechanism  60   b  includes a pair of locator pins  63   b  that fit into a corresponding pair of locator holes (not shown) of the adjacent mounting mechanism  60   a . The locator holes and pins  63   b  provide a means for aligning and connecting adjacent mounting mechanisms  60   a ,  60   b  to ensure proper alignment of the mounting mechanisms and thereby the processing modules of the card personalization system. In addition, mounting holes  63   d  are disposed at the bottom  71   b  of the mounting mechanism  60   b , and similar mounting holes (not shown) are disposed at the bottom  71   a  of the mounting mechanism  60   a . The mounting holes  63   d  are connected by common screws  63   c  (only one screw is visible in  FIG. 3 ) which fasten adjacent mounting mechanisms together. A similar arrangement of mounting holes (not shown) and mounting screws  63   a  (only one screw is visible in  FIG. 3 ) is provided at the tops  73   a ,  73   b  of the mounting mechanisms  60   a ,  60   b . It will be appreciated any suitable screw or other fastener may be employed for connecting the mounting holes. Moreover, it will be appreciated that other configurations of locating pins and holes may be employed to provide proper connection and alignment between respective adjacent mounting mechanisms  60   a ,  60   b.    
         [0107]    At an upstream side  75   b  of mounting mechanism  60   b , a bracket  61  is mounted at the top  73   a ,  73   b  of the mounting mechanism  60   a ,  60   b . The bracket  61  provides a common support structure, such that when adjacent mounting mechanisms  60   a ,  60   b  are connected together, the bracket  61  is shared between the adjacent modules. Preferably, the bracket  61  provides a mount structure for mounting the processing mechanisms of the processing modules. It will be appreciated that mounting mechanism  60   a  also includes a bracket, similar to bracket  61 , on its upstream side. Further, it will be appreciated that the bracket  61  may be disposed at the downstream sides of mounting mechanisms  60   a ,  60   b  to achieve the same shared results. The common bracket  61  between the adjacent mounting mechanisms also provides improved alignment of the card path between processing modules sharing the bracket  61  and mounted on the mounting mechanisms. Two adjacent processing modules are mounted on respective mounting mechanisms, such as  60   a ,  60   b , and share a bracket  61  as a common mount and support structure for the processing modules. Such a structure preserves alignment of the card path between processing modules. 
         [0108]    Preferably, each of the processing modules  40  mounted on a mounting mechanism, such as  60   a ,  60   b , are configured to have frames with widths of 9.0 inches, 6.25 inches, or 12.5 inches, or a combination thereof for mounting particular processing modules. Preferably, 12.5 inch frames use two 6.25 inch frames and respective covers, and front and back panels. 
         [0109]    The input hopper  30 , each module  40 , and the output hopper  50  also include at least one panel  94  on the backside thereof, as best seen in  FIG. 2 . The panel  94  angles outwardly and upwardly away from the rear of the hopper or module, and together with the other panels  94 , define a trough or channel  96 . The trough  96  provides a convenient location for passing electrical and data cables and the like along the rear of the system. Each hopper  30 ,  50  and the modules  40  include at least one passage  95  in a back side thereof through which power and data cables can pass into the interior of the hopper or module, to provide power, data and control signals to the respective hopper or module controller. Power to the system  10  is input from a power cable (not shown) that connects to a power plug-in  90  provided on the backside of the operator station  20  as shown in  FIG. 2 . If the system  10  requires more power than that provided by a single power plug-in, an additional power plug-in can be provided on one of the downstream modules  40 . In this case, upstream portions of the system  10  are provided power through the power plug-in  90 , while downstream portions of the system are provided power through the power plug-in associated with the module  40 . 
         [0110]    After a card has been personalized by each of the processing modules  40 , it is exited to an output hopper  50  that collects and stacks the finished cards. The output hopper  50  is disposed after the most downstream processing module  40 . The output hopper  50  includes at least one collecting tray  57 , and more preferably a plurality of collecting trays  57 . One collecting tray  57  is preferably used to collect properly personalized cards while a second tray  57   b  is used to collect improperly personalized cards or defective cards that result from errors in processing. As with the input hopper  30  and the processing modules  40 , the output hopper includes a cover  51  and a status indicator  55 . The cover  51  and the status indicator  55  operate similarly to the cover and status indicator for the input hopper  30  and therefore are not further discussed herein. Further description is provided below of the output hopper  50  in accordance with the principles of the present invention. 
         [0111]      FIG. 4  provides a flow diagram of one preferred method  80  for personalizing a card. The method  80  includes picking a plurality of cards, one at a time, from an input, and transferring the cards, one at a time, to a first processing module  81 . At the first processing module, personalized information is applied  83  to the cards as each card is transferred through the first processing module. After one card is finished being personalized by the first processing module, it is then transferred to at least one more processing module  85 . The at least one more processing module or next processing module is arranged in sequence downstream from the first processing module. It will be appreciated that any additional processing modules also are arranged in a sequential manner. Personalized information is applied to each of the cards one at a time using the next processing module  87 . 
         [0112]    The processing modules employ a cascading sequence  89  to transfer cards through each of the processing modules. Particularly, when a module has completed personalizing a card, the card is completely transferred out of the module before the next card is transferred into the module from an upstream module. Then, the following card is transferred into the upstream module, and so on. Card transfers cascade, one at a time, from the downstream most module to the upstream most module. In this manner, only one card is in a module at a time. This improves system integrity by simplifying control algorithms, and reduces the likelihood that cards or their data can ever be mixed up in a module. However, in certain modules, such as the smart card programming module, a plurality of cards can be processed at the same time. 
         [0113]    To further improve system integrity and assure that no module ever has two cards or parts of cards in it at any time, each module of the system  10  includes an entry and exit photocell. The entry photocell verifies that a card has entered the module, and the exit photocell verifies that a card has left the module. The entry and exit photocells of the modules are connected to the respective module controller so that the module knows when a card is entering or exiting the respective module. The module controller communicates this card status information to the system controller  22 . Means, such as entry rollers on the module itself or rollers from an upstream module, transfer cards into the respective module. Similarly, means, such as exit rollers in the module or a card transport system of the module, transfer cards to the next module. 
         [0114]    After a card is personalized by the processing modules, the card is collected in an output  91 . A controller, such as controller  22  shown and described in  FIGS. 1 and 2  and the module controllers, are operated  93  to transfer and monitor processing and data information to and from the input, processing modules, and output in personalizing the cards. 
         [0115]    The system  10  has been described so far as including a single module  40  of any one of the different types of modules  40 , i.e. a single magnetic stripe module, a single laser module, a single graphics module, etc. Often times, the time required by an individual personalization module to complete its particular personalization task may be long, such that the immediately adjacent upstream module must wait until the personalization task is complete before sending a new card to the downstream personalization module. Because the immediately adjacent upstream module must wait, further upstream modules may also have to wait for the personalization task of the first module to be completed. In effect then, a long personalization task in one module can effectively cause the system  10  to pause until the personalization of the one module is complete. 
         [0116]    To avoid this situation, a plurality of any one of the modules can be used, with the identical modules arranged side-by-side in the system  10 . By using a plurality of the same type of module, each module can be assigned to perform a similar personalization task. Therefore, if a first module that is assigned to perform for example, a laser personalization task, has not completed its personalization task, the next card from the immediately adjacent upstream module can be transported to the second laser module rather than waiting for completion of the personalization in the first laser module. Additional modules performing a particular personalization task can be added as needed in order to prevent pausing of the system. This concept of grouping modules that perform similar personalization tasks increases card throughput. 
         [0117]    In addition, if a plurality of one type of module is used, each module can be assigned different personalization tasks. For instance, if a plurality of laser modules are used, one laser module can be used to personalize one line of information onto a card, after which the card is transferred to the next laser module which is used to personalize a second line of information onto the card. If needed, the card can be transferred to additional laser modules for personalization of other information onto the card. Therefore, a long personalization task can be broken up into distinct task segments, with each module being assigned to handle one of the task segments, rather than the entire personalization task being performed by a single module. This also increases card throughput. 
       Processing Modules 
       [0118]    The following descriptions are provided to illustrate features and improvements upon respective processing modules of the card personalization system  10  in accordance with the principles of the present invention. 
         [0119]    Reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration of the embodiments in which the invention may be practiced. It is to be understood that other embodiments may be utilized as structural changes may be made without departing from the spirit and scope of the present invention. 
       Input Hopper 
       [0120]    Input hoppers are needed to provide a supply of cards and input the cards to be processed and personalized by any following processing modules. The input hopper  30  includes trays for holding a supply of stacked cards to be processed. In addition, cards are selected to be entered into a card track, and input to a downstream processing module. Typically, the cards are selected using roller assemblies and a suction cup to pick each card from a card tray. Usually, a card pusher is employed to apply a force against the card stack and continuously reseats the card stack after each picked card. However, these designs employ separating rollers that rotate towards a respective card to be picked and use the reduced air pressure provided by the suction cup alone to pick and pull a card from the card supply tray. In addition, a spring load usually is employed with the card pusher to provide the force against the card stack. 
         [0121]    Although these designs may be suitable for their purpose, improvements may still be made. There is still a need for an input hopper that provides a higher reliability and efficiency for holding and inputting cards to be processed by a card personalization system. The following description illustrates the features and improvements made upon existing designs of an input hopper in accordance with the principles of the present invention. 
         [0122]    As illustrated in  FIGS. 1 and 2 , the input hopper  30  of the system  10  is positioned adjacent to and immediately downstream from the operator station  20  for inputting cards upstream of all of the modules  40 . It will be appreciated that one or more similar input hoppers may also be located within the system downstream from the input hopper  30  and between two or more of the modules  40 . In this configuration, cards can be inserted at into the card path of the system at the location(s) of the input hopper, allowing the cards to bypass one or more of the modules  40 . Thus, multiple input hoppers can exist within the card personalization system  10 , including between modules  40 . 
         [0123]      FIGS. 5-15  illustrate an input hopper  200  according to the present invention. Preferably, the module  200  is capable of inputting cards up to 3000 cards per hour. 
         [0124]      FIGS. 5 and 6  illustrate side and top views of one preferred embodiment of the input hopper  200 . The input hopper  200  includes a frame  210  having a front  215   a , a back  215   b , a top  211   a , a bottom  211   b , and upstream and downstream sides  219   a ,  219   b  (best shown in  FIG. 6 ), respectively. The frame  210  includes a slot  213  extending from the front  215   a  toward the back  215   b . At least one card tray  230  includes a front  231   a , a back  231   b , a top  235   a , a bottom  235   b , and sides  233   a ,  233   b . The card tray  230  is disposed on the top  211   a  of the frame  210  and extends a length from the front  215   a  toward the back  215   b  of the frame  210 . A trough  247  provides a space for a supply of cards to be held before being picked for processing by downstream processing modules. The card tray  230  also includes a slot  237  extending from the front  231   a  toward the back  231   b  of the card tray  230 . The slot  237  of the card tray  230  corresponds with the slot  213  of the frame  210 . As shown in  FIGS. 5 and 6 , one tray  230  is illustrated. However, it will be appreciated that a plurality of card trays, such as card tray  230 , may also be employed. Preferably, the input hopper  200  employs card trays, such as the card tray  230 , in pairs. 
         [0125]    A card pusher  260  is operatively connected to the frame  210  and its corresponding card tray  230 . The card pusher  260  extends through the slots  213 ,  237  of the frame  210  and card tray, respectively. Further, the card pusher  260  is movable back and forth along the slots  213  and  237 . The card pusher  260  includes a backstop  265  having a handle, and is pivotally engaged to a frame  261  having a support structure  263 . The backstop  265  includes an upper portion  279   a  with a section  265   a  having a width greater than a width of a section  265   b  of a lower portion  279   b . The width of section  265   a  also is greater than a width of both slots  213  and  237  of the frame  210  and card tray  230 . The section  265   a  prevents the card tray  230  from detaching from the frame  210  when in use. The card tray  230  is released using a release mechanism  220  actuated by movement of the card pusher  260  toward the front of the frame and tray, and when the card pusher  260 , particularly section  265   a , is cleared from the slots  213  and  237 .  FIGS. 9 to 14  below best illustrate the release of the card tray  230 . 
         [0126]      FIG. 6   a  illustrates one preferred embodiment of the backstop  265  of the card pusher  260 . Within the backstop  265 , an upper shaft  275   a  and biasing member  275   c  reside in the upper portion  279   a . A lower shaft  275   b  resides in the lower portion  279   b  having a roller  277  operatively connected to the lower shaft  275   b . The upper shaft  275   a , lower shaft  275   b , and roller  277  are biased by the biasing member  275   c  to normally disable a pivot position of the backstop  265  relative to the frame  261 . The biasing member  277  is shown as a spring. However, it will be appreciated that other biasing members may be employed. The roller  277 , lower shaft  275   b , and upper shaft  265   a  may be pushed upward towards the upper portion  279   a  of the backstop  265  to enable a pivot position of the backstop  265  relative to the frame  261 . The features and details will be further discussed in  FIGS. 9 through 14  below. 
         [0127]      FIGS. 7 and 8  illustrate one preferred embodiment of picking a card  290  from the card tray  230 .  FIG. 7  illustrates a suction cup  289  operatively connected to an active vacuum line  289   a  and driven by a picker drive  287   a . The vacuum line  289   a  is illustrated as portion being an elbow joint, and it will be appreciated that any suitable line may extend from the joint  289   a  and attach to a conventional vacuum source (not shown). Preferably, the active vacuum line  289   a  incorporates a valve for opening and closing the active vacuum supply to the suction cup  289 . More preferably, the valve is a solenoid valve used to open the active vacuum line to the suction cup  289 . The suction cup  289  moves toward the card tray  230 , as shown by the arrow A, to pick a card from the card tray  230 . Separation rollers  253   b  contact the card  290  and rotate in a direction outwards from the card  290 , shown by arrows B. The rotation of the separator rollers  253   b  bend the card  290  in an outward direction from the card stack  291 , thereby facilitating picking of the card  290  from the card tray  230  using the suction cup  289  having the active vacuum applied. The separation rollers  253   b  rotate as described to break intimate card surface contact at edges of the card  290  to allow a single card to be pulled from the card stack  291 . 
         [0128]      FIG. 8  illustrates the suction cup  289  in contact with the card  290 , and arrow C represents the direction the card  290  is pulled using the suction cup  289 . Further, a vacuum valve line connectable to an active vacuum source is operatively connected to the suction cup  289 . As shown in  FIG. 8 , the separation rollers  253   b  select and bend the card  290 , and the suction cup  289 , employing the active vacuum through the vacuum valve line  289   a , pulls the card  290  straight back (arrow C) to the card path  250 . The card  290  is pulled past the retainers  243  and out of the card tray  230 . Preferably, the retainers  243  are clips. Once the card  290  is in the card path  250 , a tab belt  255  moves the card, such as the card  290 , downstream along the card path  250  to entry rollers  253   a . The tab belt  255  includes tabbed portions  255   a  that contact the card and drive the card along the card path  255 . Preferably, a card guide  251  including a slot  251   a  is used to help facilitate transfer of the card downstream along the card path  250 . The entry rollers  253   a  input a card, such as  290 , into a downstream processing module. 
         [0129]      FIGS. 9 to 14  represent positions of the card pusher  260  along the slots  213  and  237  in the release of the card tray  230 . At the front  215   a  of the frame  210 , a locking member  221  is releasably engaged to the card tray  230  at a lock receiving portion  239 . Preferably, the locking member  221  is engaged to the card tray  230  when the card tray  230  is placed on top of the frame  210  and the input hopper  200  is in use. A release mechanism  220  also is disposed at the front  215   a  of the frame  210 , and is connected at the bottom  211   b.    
         [0130]    As best shown altogether in  FIG. 5 , the release mechanism  220  includes a ramp  225 , curvature member  223 , and finger portion  227 .  FIG. 9  illustrates the card pusher  260  approaching the ramp  225  (arrow D) of the release mechanism  220 .  FIG. 10  shows the roller  277  of the card pusher  260  in contact with the ramp  220 . When the roller  277  moves along the ramp  277  toward the front  215   a  of the frame  210 , the roller may be simultaneously pushed upward into the backstop  265  of the card pusher  260 . In addition, the upper shaft  275   a  and the lower shaft  275   b , such as described above in  FIG. 6   a , also move upward within the backstop  265 . The spring  275   c  is also pushed upward enabling the upper shaft  275   a  to clear the pivot point  267  actuating the backstop  265  into a pivotable position. 
         [0131]    As the card pusher  260  moves along the ramp and contacts the curvature member  223 , shown in  FIGS. 10 ,  11 , and  12 , the backstop  265  is simultaneously enabled into the pivotable position as described above. The backstop  265  walks around the curvature member  223  pivoting the backstop  265  of the card pusher from its normally upright position, when in use, toward a prostrate position. When the backstop  265  is in the prostrate position, the card pusher  260  moves through a space  237   a  of the card tray  230  to clear the slots  213  and  237 . Simultaneously, a bearing block  273 , as shown in  FIGS. 12 and 13 , contacts a hanging portion  221   a  of the locking member  221 . As the card pusher  260  moves toward the front  215   a  of the frame  210 , the bearing block  273  pushes the locking member  221 , through contact with the hanging portion  221   a , away from the lock receiving portion  239  of the card tray  230 .  FIGS. 12 to 14  illustrate the card pusher  260  cleared from the slots  213 ,  237  and the locking member in a release position. 
         [0132]    The finger portion  227  of the release mechanism  220 , and a curvature member  271  of the backstop  265  restore the card pusher  260  back to its upright position for use. As the card pusher  260  moves toward the back  215   b  of the frame  210 , the curvature member  271  of the backstop  265  contacts the finger portion  227  ( FIGS. 1 and 14 ), and can walk around the finger portion  227  to pivot the backstop  265  back to the upright position. 
         [0133]    The input hopper  200  employs the following motors and drive mechanisms in operating its respective functions. A tab belt motor  283  drives the tab belt  255  to move the card. A separator motor  285  and separator roller drive  285   a  operate the separation motors  253   b  to pick a card. In addition, the picker motor  287  and drive  287   a  move the suction cup  289  back and forth from the card supply  291  of the card tray  230 . The card pusher  260  includes a motor  281  and drive  281   a  to move the pusher along the slots  213  and  237  of the frame  210  and card tray  230  of the input hopper  200 . 
         [0134]      FIG. 15  illustrates a flow diagram of a preferred embodiment for a method  800  of picking a card (also shown in  FIGS. 7 and 8 ) to be transported downstream to a processing module. A suction cup is advanced  801  to a card stack supply. An active vacuum is supplied to the suction cup to suitably grab the card. A force exerted on the card stack supply by a card pusher is relaxed  803 , so as to enable separation rollers to position the card to be picked. The separation rollers rotate away from the card  805  to contact edges of the card and bend the card outwardly away from the card stack supply. The card is picked by using the suction cup, having the applied active vacuum, and the rotation of the separation rollers. The card is picked by pulling the card out of the card stack supply in a substantially straight direction ( FIG. 8 ). The card is pulled toward the card path. Preferably, one card at a time from a card tray is picked to enter the card path. The active vacuum is released  809  so that the card may enter the card path for transfer downstream  811 . As illustrated in the previous figures, a tab belt such as  255  may be employed to transfer the card downstream on the card path such as the card path  250 . 
         [0135]    After the card is released from the card stack supply, the card pusher may restore a suitable force against the remaining card supply, and reseat the card stack supply against the separation rollers. A higher number of cards available in the card supply require a lower amount of force to reseat the card stack against the separation rollers. As the card stack supply decreases, the amount of force needed by the card pusher to reseat the card stack supply increases. Preferably, the card pusher is actively driven, for instance by a motor, in applying the force against the card stack and reseating the supply of cards. After the card stack is reseated, the separation rollers may turn inwards toward the next card to realign the card stack for the next pick. Preferably, a controller, such as described above, is used to provide the necessary data information in controlling the input hopper settings. 
         [0136]    The individual motor and solenoid control of the input module, for instance, the picker motor, vacuum activation via valves, separator motor and pusher motor contribute to the reliability of the present invention. The input module picks many different card types which include combinations of different thickness and material, GSM punch-outs, and embossed cards. The individual motor control and system methods of transferring card types to be picked reliably through software changes on a card by card basis, where previous input devices have required mechanical adjustments. 
         [0137]    The input hopper of the present invention provides an improved input module with increased reliability and efficiency. In addition to other advantages, the input hopper of the present invention enables a card to be efficiently picked from the card stack supply for transfer downstream to a processing module. The separation roller configuration and active applied active vacuum present a reliable structure for picking a card. Further, the actively driven card pusher provides an improved design for resetting the card supply for the next card pick that also is more reliable. The release mechanism and lock features incorporated for the card tray provide convenience and added security when the input hopper is in use with the card personalization system. 
       Magnetic Stripe Module 
       [0138]    The magnetic stripe module  100  is illustrated in detail in  FIGS. 16-20 . In the preferred arrangement, as shown in  FIG. 1 , the magnetic stripe module  100  is positioned immediately downstream from the input hopper  200 . However, the module  100  could be positioned anywhere in the system, and not just immediately after the input hopper  200 . In the preferred arrangement, the magnetic stripe module  100  receives cards from the input hopper  200 , and programs data onto the magnetic stripe of each card if instructed to do so by the controller  22 . The module  100  is also designed to read the magnetic stripe after programming to determine whether adequate programming has occurred. If a card does not have a magnetic stripe or magnetic stripe programming on a card is not required, the card can simply be passed through the module  100  to the next module. Preferably, the module  100  is capable of programming of up to 3000 cards per hour. 
         [0139]      FIGS. 16-20  illustrate details of the interior of the module  100 . Each card enters the module via an inlet drive assembly comprising a pair of drive rollers  102   a ,  102   b . Each drive roller  102   a ,  102   b  is rotatably driven by a motor  104 , such as a stepper motor, via gears  106   a ,  106   b  which are connected by drive shafts to the rollers  102   a ,  102   b . One of the drive rollers  102   a ,  102   b , such as the drive roller  102   a , is spring biased toward the other drive roller to maintain good driving contact with the card and to accommodate embossing that may be present on the card. 
         [0140]    A lower input guide  108 , best seen in  FIGS. 16 and 20 , helps guide cards into the module  100  as they enter. Upper and lower guide tracks  110   a ,  110   b  extend from the inlet of the module  100  to the outlet for guiding cards through the module  100  along a defined card path. The guide tracks  110   a ,  110   b  receive upper and lower edge regions of each card to maintain a consistent travel path through the module  100 , with the plane of the cards being oriented generally vertically. 
         [0141]    After passing through the rollers  102   a ,  102   b , the card is next engaged by a drive assembly  112  which drives the card through the remainder of the module  100 . The drive assembly  112 , portions of which are visible in  FIGS. 16 ,  17  and  20  but is best seen in  FIG. 18 , preferably comprises a tab belt drive mechanism that includes a drive belt  114  and a plurality of tabs  116  fixed to the belt. 
         [0142]    Previous drive mechanisms have utilized a carriage or drive rollers for moving a card. A carriage mechanism is relatively complex and requires a large number of parts, requires a relatively complex connection between the drive motor and the carriage, has sliding parts that are subject to wear, and has a relatively high inertia that reduces the transport speed. Further, a carriage must be returned to the entrance after moving a card to the exit in order to pick up the next card. Drive rollers, on the other hand, cannot be used on areas of the card that contain embossing. Further, a drive roller mechanism has a relatively large number of components particularly in connecting the drive motor to the rollers, introduces torsional compliance, creates problems when transferring the card from one set of drive rollers to another set, requires certain frictional characteristics to engage the card properly, the drive rollers are subject to contamination and must be regularly cleaned, and the drive roller shafts limit placement of the write and read heads. 
         [0143]    The use of a tab belt drive mechanism eliminates many of the deficiencies that result from using carriage or drive roller mechanisms. The tab belt is simple with fewer parts, provides a more direct connection between the drive motor and the belt, has no sliding parts that are subject to wear, has a relatively low inertia thereby increasing speed, can be used with embossed cards, there is less compliance than drive rollers, there are no “hand-off” problems such as found when using drive rollers, does not depend upon friction between the belt and the card, and limitations on the placement of the write and read heads are reduced. 
         [0144]    Moreover, it has been discovered that better programming is achieved using a tab belt compared to using drive rollers. This is due to the fact that drive rollers have greater torsional compliance than a tab belt and contain additional components that lead to greater card speed variations and lower quality programming. 
         [0145]    In the preferred embodiment, three tabs  116 , only two of which are visible in  FIG. 18 , are provided on the belt  114 , with the tabs being equally spaced on the belt  114 . The use of multiple tabs increases the speed of the drive assembly  112 , thereby increasing the speed of the module  100 , by reducing the card pick-up time of is the tabs, as will become apparent from the following description. Further, multiple tabs improves the reliability since the belt will still operate with two or even one tab. However, it is possible to utilize a lesser number of tabs, such as a single tab, if the reduced speed provided thereby is sufficient. 
         [0146]    As shown in  FIGS. 17 and 18 , the belt  114  is engaged with a drive pulley  118  which drives the belt  114 . The drive pulley  118  is rotatably driven by a motor  120 , preferably a DC servo motor. In addition, the belt  114  passes around idler pulleys  122 ,  124  positioned adjacent the inlet and outlet of the module  100  (see  FIGS. 16-18 ). The idler pulley  122  is positioned above the drive roller  102   b , as shown in  FIGS. 16 and 20 , such that, upon rotation of the belt  114 , the tab  116  can engage the rear edge of the card after the card is driven into the module by the drive rollers  102   a ,  102   b . Further rotation of the belt  114  drives the card through the module  100  to the module exit for pick-up by the next module. 
         [0147]    The belt  114  is subject to wear and must be replaced as needed. In addition, the tabs  116  can break off from the belt  114  and/or become damaged, thereby necessitating belt replacement. Therefore, the belt  114  is mounted so as to be readily replaceable as required. As seen from  FIG. 18 , when belt replacement is necessary, the belt can be lifted upward out of engagement with the pulleys and replaced with a new belt. To determine whether a tab  116  has broken off, during operation the belt  114  passes through a tab sensor  126  which senses the tabs  116 , or absence thereof, and passes a signal to the controller  22  when a tab is missing, so that the system operator can be notified that the belt should be replaced. 
         [0148]    To prevent the sensor  126  from interfering with belt removal, the sensor  126  and the mounting block  128  upon which the sensor  126  is mounted, are mounted so as to movable between an operative position, shown in  FIG. 18 , and a removal position (not shown). The block  128  includes a slot  130  formed therein, and a cap screw  132  extends through the slot  130  and into threaded engagement with a suitable threaded hole (not shown) provided in a support plate  134  of the module ( FIG. 17 ). The block  128  is pivotable about a pivot shaft  129 , with pivoting of the block  128  and the sensor  126  mounted thereon limited by the ends of the slot  130 . A bias spring  136  is connected at one end to a plate  138  that is fixed to the block  128  and connected at its opposite end to a post  140  that is fixed to the plate  134 . During use, the block  128  is pivoted to the position shown in  FIG. 18  by the bias spring  136  and the cap screw  132  tightened to maintain proper belt tension. When belt removal is necessary, the cap screw  132  is loosened allowing the block  128  to pivot. The block  128  is then positioned away from the post  140  to allow the belt  114  to be removed without interference from the sensor  126  or the plate  138 . 
         [0149]    As further shown in  FIG. 18 , a back-up bar  142  is positioned behind a portion of the belt  114 . The tabs  116  on the belt  114  means that these areas of the belt will be stiffer depending upon the size of the tab used. These stiffer portions will produce a drive speed variation as they curve around any of the pulleys. The bigger the tab is and/or the smaller the pulleys are, the greater the speed variation will be. It is best, therefore, to use big pulleys and small tabs. However, as the tab becomes small, it will be weaker and may not be stiff enough to provide solid drive to the rear edge of the card particularly in cases where card movement may be obstructed. As a result, the small tab may bend and go behind the card, resulting in a card jam. Therefore, the backsides of the tabs are constructed to make the tabs stiffer when driving the card forward through the module  100 . Preferably, the backsides of the tabs are provided with a fillet to increase the stiffness thereof. The frontsides of the tabs  116  are generally planar and project from the belt  114  generally at right angles thereto to provide optimum forward driving engagement with the rear edge of the card. 
         [0150]    However, as will be described further below, it is often necessary to reverse the belt to drive the card in reverse within the module  100 . During card reversal, the filleted backside of the tab will contact the leading edge of the card. It is possible that the fillet on the backside of the tab  116  may cause the tab to slip behind the card. The back-up bar  142  prevents this by limiting the rearward movement of the tab  116  and belt  114  during reversal, and maintaining contact between the backside of the tab and the leading edge of the card. 
         [0151]    The module  100  further includes separate write and read units  144 ,  146 . The write unit  144  is disposed upstream of the read unit  146 , with the write unit  144  programming predetermined data on the magnetic stripe on the card, and the read unit  146  thereafter reading the data on the magnetic stripe to determine the adequacy of the programming operation. The data to be programmed onto the magnetic stripe of the card by the write unit  144  is provided to the module  100  by the controller  22 , the data being specific to the intended use of the card. The read unit  146  reads the data on the magnetic stripe to determine any deficiencies in writing operation of the write unit  144 . 
         [0152]    Many conventional systems utilize a single write/read unit for both writing and reading. In these systems, the card is initially driven through the unit in a write pass. Thereafter, the card must be reversed and driven back through the unit for a read pass. The requirement for forward and backward movement increases the programming operation time, thereby detracting from the overall throughput rate of such a system. In addition, the forward and backward movements increase wear on the module and on the cards themselves. Further, the single head utilized cannot be optimized for both writing and reading functions so optimal writing and reading may not be achieved. 
         [0153]    The separate write  144  and read  146  units eliminates the requirement to reverse the card travel direction for a read operation, which results in an increase in the throughput rate of the module  100  and a decrease in wear. Moreover, the write head and read head used in the units  144 ,  146  can be selected to optimize the writing and reading operations. As shown in  FIG. 20 , the write and read units  144 ,  146  each include a pressing device  148 , such as a roller, positioned opposite the write and read heads (not shown) for supporting the side of the card opposite the magnetic stripe. The magnetic stripe of the card faces the write and read heads and passes between the head and the pressing device  148 . The construction and operation of write and read units is well known to those of ordinary skill in the art, and further description thereof is not provided. An apparatus that utilizes separate write and read units is disclosed in U.S. Pat. No. 4,937,438. 
         [0154]    The write and read units  144 ,  146  and the upper guide track  110   a  are supported on a plate  150 . During use, the plate  150  is supported in a horizontal position as shown in  FIGS. 16 and 17  and is fixed to a pair of supports  152  by cap screws  154 . Extending from the back end of the plate  150  is a pair of pins  156 . The pins  156  allow the plate  150  to be disposed in a service position, which is shown in  FIG. 20 , to facilitate access to the write and read heads of the units  144 ,  146 . The supports  152  include holes  158 , shown in  FIG. 18 , that are positioned to receive the pins  156 . By loosening the screws  154 , the plate  150  can be rotated vertically to the position shown in  FIG. 20 , with the pins  156  aligned with and received within the holes  158 , to thereby maintain the plate  150  in the service position. 
         [0155]    Once the write unit  144  is finished programming, the card is transported by the belt  114  and tab  116  to the read unit  146 . If the read unit  146  determines that the programming of the magnetic stripe is satisfactory, the card is driven by the belt  114  toward the exit where the card waits for the next module to complete its personalization operation(s). If the next module is ready to receive the programmed card, the belt  114  completes driving the card from the module  100 . The drive belt  114  is arranged such that the tab  116  drives the leading edge of the card into engagement with input rollers in the next module. This eliminates the need for exit rollers in the module  100 . 
         [0156]    If the read unit  146  determines that an error has occurred in the magnetic stripe programming, the belt  114  can be reversed to drive the card back through the write unit  144  so that the magnetic stripe on the card can again be passed through the red unit  146  or through the write unit  144 . If the magnetic stripe is reprogrammed, the card can once again be driven through the read unit  146  to determine the adequacy of the programming operation. 
         [0157]    An eject mechanism  160  is also provided to allow the operator an easy way to remove a jammed card from the card track when the module  100  is not able to move the card out to the next module. This could occur because of a fault in the module  100  or a fault in the downstream module. U.S. Pat. No. 4,518,853 discloses a card eject mechanism in a magnetic stripe encoding apparatus where the eject mechanism is under electronic control to act as a collection place for defectively programmed cards. 
         [0158]    The eject mechanism of the present invention is best seen in  FIG. 19 . In the preferred embodiment, the eject mechanism  160  is designed to be manually actuated by the system operator, based upon a signal provided by the read unit  146  and the controller  22 . 
         [0159]    With reference to  FIG. 19 , the eject mechanism  160  comprises a pivoting door  162  that interrupts the lower guide track  110   a  and supports the bottom edge of the card downstream from the read unit  146 . The door  162  is connected to the end of a pivot block  164  that is pivotally supported by supports  166 ,  168  for pivoting movement about pivot axis  170 . A spacer  172  is connected to the bottom of the pivot block  164  and engages with the plate  134  to act as a stop to define the standard, or non-eject, position of the door  162  and block  164  shown in  FIG. 19 . A spring  174  is connected to the pivot block  164  for biasing the block  164  to the non-eject position. 
         [0160]    An actuating mechanism  176 , best seen in  FIG. 19 , is disposed below the plate  134  and is arranged to contact the eject mechanism  160  for pivoting the door  162  to an eject position. The actuating mechanism  176  projects upwardly through a hole  178  provided in the plate  134  and contacts the pivot block  164  to cause pivoting of the block  164  and the door  162  about the axis  170  when the mechanism  176  is moved upwardly. Actuation of the actuating mechanism  176  preferably occurs by the system operator pressing a button associated with the controller  22 , preferably a button on the keyboard  23 . 
         [0161]    Rather than using an actuating mechanism, the system operator may be required to manually pivot the door  162  by reaching into the module  100 . In this case, when a card is to be ejected, the system is preferably paused while the system operator proceeds to the module  100  to manually pivot the door  162  and eject the card. 
         [0162]    When the door  162  is pivoted to the eject position, the card is able to fall downward through a channel  180  in the plate  134 . The ejected card falls onto a chute  182  which leads to a holding bin  184 . Preferably, a sensor  186  is provided to detect if the door  162  is partially open (e.g. the card did not fall completely through the channel  180 ). Further, a sensor  188  is provided in the holding bin  184  to detect the presence of the card in the bin  184 . If the door  162  is partially open or if a card is detected in the bin  184 , operation of the system will not proceed until the card has been removed. 
       Laser Module 
       [0163]    The laser module  700  is illustrated in detail in  FIGS. 21-26 . The module  700  is designed to perform laser personalization on the cards in which information, such as card holder information like the card holder&#39;s name, or information such as logos or the name of the card issuing authority, is added to the card by a laser beam projected onto the card. Laser personalization and the process by which a laser generates personalization information on a card is well known to persons of ordinary skill in the art. If a card does not require laser personalization, the card can simply be passed through the module  700  to the next module. Preferably, the laser module  700  is designed to personalize up to 3000 cards per hour. 
         [0164]    Turning to  FIGS. 21-22 , the details of the laser module  700  are shown. As is conventional in laser personalization systems, the interior of the module that contains the laser system and the region of the module where the card is personalized is designed to contain all laser light thereby preventing personnel from exposure to such light. A card enters the module  700  through an inlet slot  702  provided in a wall  704  of the light-tight region of the module  700 . A first pair of input drive rollers  706   a ,  706   b  engage the leading edge of the card and drive the card to a second pair of input drive rollers  708   a ,  708   b  which complete the input of the card into the module  700 . 
         [0165]    As seen in  FIG. 22  and in dashed lines in  FIG. 21 , the drive rollers  706   a ,  706   b  extend substantially the entire height of the wall  704  so that the rollers  706   a ,  706   b  engage substantially the entire surface of the card along the height thereof. In addition, each roller  706   a ,  706   b  is rotatably driven by a motor  708 , preferably a stepper motor, via a drive mechanism that includes a drive belt  710  and gears  712   a ,  712   b . Further, the front roller  706   a  is biased toward the back roller  706   b  in order to contain laser light within the interior of the module  700 . 
         [0166]    Each roller  708   a ,  708   b  is also rotatably driven by the motor  708  via a suitable drive train mechanism. The rollers  708   a ,  708   b  are shorter than the rollers  706   a ,  706   b  to allow a card pusher mechanism  714 , described below, to engage the trailing edge of the card to completely push the card into and out of the personalization region. 
         [0167]    A first pair of output drive rollers  716   a ,  716   b  engage the leading edge of the card after personalization, and drive the card through a slot  717  into a second pair of output drive rollers  718   a ,  718   b  which drive the card into the next module. The rollers  716   a ,  716   b , like the rollers  706   a ,  706   b , engage substantially the entire surface of the card along the height thereof, and the front roller  716   a  is biased toward the rear roller  716   b  in order to contain laser light within the interior of the module  700 . Each output roller  716   a ,  716   b ,  718   a ,  718   b  is also driven by a motor  720 , preferably a stepper motor  708 , via suitable drive trains. 
         [0168]    Between the rollers  706   a ,  706   b  and output of the module  700 , the card is guided at its top and bottom edges by top and bottom guide tracks  722 ,  724 , respectively. The guide tracks  722 ,  724  maintain a consistent travel path through the module  700 , with the plane of the card being oriented generally vertically. 
         [0169]      FIGS. 21-22  illustrate the card in a personalization region  726  ready to be personalized by a laser mechanism  728  that is positioned to project a laser beam  730  onto appropriate portions of the card surface. In order to achieve effective personalization, precise and repeatable positioning of the cards in the region  726  is required. Misalignment of a card in the region  726  will lead to incorrect location of the personalization on the card. 
         [0170]    The card is pushed into the personalization region by the card pusher mechanism  714  which includes a push pin  732  that projects rearwardly from one end of a drive arm  734 . The other end of the arm  734  is connected to and rotatably driven by a drive shaft  736  that is driven by a motor  738 , preferably a stepper motor. 
         [0171]    The card is guided in the personalization region  726  by a pivoting card stop  740  at the top edge of the card and a track  742  at the bottom edge of the card. The card stop  740  and track  742  are separate from the guide tracks  722 ,  724  and separate from the structure that supports the rollers  708   a ,  708   b ,  716   a ,  716   b . This allows the card stop  740  and track  742 , and the card held thereby, to be tilted and/or rotated by a suitable mechanism (not shown). These movements are often necessary when the card surface to be personalized is not completely planar to ensure that the laser beam  730  contacts the card surface at right angles to the card surface being personalized. 
         [0172]    The card stop  740  is constructed to repeatably and precisely position the card in the region  726 . The stop  740 , which is shown in  FIGS. 21-23 , is mounted on a pivot pin  744  for pivoting movement about the axis of the pin  744 . In addition, the stop  740  is biased downward (i.e. in a counterclockwise direction about the pin  744 ) by a suitable bias mechanism (not shown) in order to force the card downward into the track  742 , thereby securely holding the card in position during personalization. 
         [0173]    As shown in  FIG. 23 , the stop  740  defines a channel  746  in which the upper edge of the card travels. The channel  746  includes a horizontal portion  748  at the beginning of the channel  746 , a downwardly sloping portion  750 , an upwardly sloping portion  752 , and a downwardly sloping portion  754  adjacent the exit end of the channel  746 . The shape of the channel  746  is such that, after the card is initially pushed into a preliminary or rough position by the pusher mechanism  714  as discussed below, the bias force of the stop  740  will force the card backward to a final, personalization position. 
         [0174]    When the card first enters the personalization region  726 , the arm  734  of the pusher mechanism  714  is rotated upward to allow the rollers  708   a ,  708   b  to drive the card partially into the region  726 . As the rear edge of the card approaches the nip of the rollers  708   a ,  708   b , the shaft  736  is rotated by the motor  738  to bring the pin  732  down into engagement with the rear edge of the card. Once the rear edge leaves the nip, the pin  732  will begin pushing the card into the region  726  to a preliminary, rough position. 
         [0175]    As the card is pushed by the pin  732 , the upper edge of the card disposed in the channel  746  of the stop  740 , along with the sloped portions of the channel  746 , forces the stop  740  upward (i.e. the stop  740  pivots in a clockwise direction), against the bias force on the stop  740 . The card is pushed by the pin  732  until the upper, front edge of the card is engaged with the sloping portion  754  of the channel  746 , at which point the pin  732  stops and then backs up away from the card. The sloped portion  754 , under the bias force that biases the stop  740  downward, then moves the card backward to the card&#39;s final, personalization position. Therefore, the pusher mechanism  714  only needs to roughly position the card in the region  726 , with the stop  740  then finally and precisely locating the card in a consistently repeatable position in the region  726 . 
         [0176]    After personalization by the laser mechanism  728  is complete, the pin  732  once again begins pushing the rear edge of the card. Continued pushing by the pin  732  forces the leading edge of the card out of the stop  740  and the channel  746  and into the nip of the rollers  716   a ,  716   b . When this occurs, the rollers  716   a ,  716   b  take over driving the card and drive the card to the rollers  718   a ,  718   b  for subsequent discharge from the module  700  to the next module. As with the other modules, the card waits at the exit of the module  700  until the next module is done personalizing its current card and is ready to output that card. 
         [0177]    Details of the laser mechanism  728  are shown in  FIGS. 24-27 . The laser mechanism  728  is constructed to permit easier set-up than in previous laser mechanisms used in laser personalization systems. Further, the laser mechanism  728  has fewer parts than previous laser mechanisms, and is designed to maintain laser adjustments, even when the laser mechanism is moved. 
         [0178]    Preferably, the laser mechanism  728  utilizes a pair of lasers  760 ,  762 , shown in detail in  FIGS. 24-26 , that are operated out of phase from each other during the laser personalization process. The use of two lasers  760 ,  762  operated out of phase permits an approximate doubling of the speed of the laser personalization process compared to the use of a single laser. Each laser  760 ,  762  requires its own power source  764 ,  766  which, as shown in  FIG. 27 , are mounted behind the module  700 . 
         [0179]    As shown in  FIGS. 24-26 , each laser  760 ,  762  outputs a laser beam  730 , with the beams traveling through a beam splitter cube  768 , then being expanded in a beam expander  770 , and thereafter being deflected by a galvo mechanism  772  through a focusing lens  774  and onto the card. A safety stop shutter  776 , shown in the closed position, is provided to selectively block passage of the beam  730  after the beam expander  770 . The construction and operation of lasers, a beam splitter cube, a beam expander, a galvo mechanism, a focusing lens, and a safety stop shutter are well known in the art, and are not further described herein. 
         [0180]    The lasers  760 ,  762  are mounted to permit easy and accurate adjustments of the lasers. Each laser  760 ,  762  is adjustably mounted as described below at both its front and rear ends for adjustments along at least two axes. In particular, the laser  760  is mounted for adjustments along the “x” and “z” axes, while the laser  762  is mounted for adjustments along the “x” and “y” axes. For the laser  762 , the “y” direction is the same as the “z” direction after reflection in the beam splitter cube  768 . 
         [0181]    With reference initially to  FIGS. 28-29 , the concept of the laser adjustments will be described. In previous laser systems, when one or more of the lasers was moved, a painstaking process was required in order to achieve proper positioning of the lasers so that the laser beams pass through a common axis prior to entering the beam expander. This difficulty in adjustment is due to the fact that adjustment of each laser along two axes is necessary. For conventional lasers having a single adjustment location, this means that after adjusting a laser along a first axis, adjustment of the laser along the second axis changes the just made adjustment along the first axis. The laser then needs to be re-adjusted along the first axis, which changes the second axis adjustment which therefore needs to be re-adjusted. By repeating this process numerous times, a final adjustment can eventually be reached. 
         [0182]    It has been discovered that by adjustably mounting each laser at both the front and rear ends thereof, faster adjustment of the lasers  760 ,  762  can be achieved. In particular, through suitable selection of the front end adjustment positions of the lasers, by first adjusting the front end of each laser until the laser beams pass through a common axis prior to passing through the beam expander  770 , the rear ends of the lasers can subsequently be adjusted without affecting the front end adjustments so that the beams continue to pass through the same axis. 
         [0183]    In  FIG. 28 , the common point through which the laser beams  730  are to pass is designated by CP. To measure whether the beams  730  are hitting the common point CP, a pin hole or quadrant sensor S can be located at the common point CP during the adjustment process. The front end adjustment point “A” of the laser  760  is located at the common point CP, which is spaced a distance X from the mirror m of the beam splitting cube  768 . The rear end of the laser  760  is separately adjustable. By first adjusting the front end of the laser  760  until the beam  730  passes through the common point CP, as sensed by the sensor S, subsequent adjustments of the rear end of the laser  760  can be made without changing passage of the beam  730  through the common point CP. 
         [0184]    For the laser  762 , the front end adjustment point “A” is located as shown in  FIG. 28 , with “A” located a distance X from the mirror m. The rear end of the laser  762  is separately adjustable. Because the distance X of the adjustment point “A” for the laser  762  is equal to the distance X of the adjustment point “A” for the laser  760 , by first adjusting the front end of the laser  762  until the beam  730 , which is deflected by the mirror m of the beam splitter  768 , passes through the common point CP, as sensed by the sensor S, subsequent adjustments of the rear end of the laser  762  can be made without changing passage of the beam  730  through the common point CP. This concept is illustrated in  FIG. 29 , which shows three different beam paths, labeled  1 - 3 , for the laser  762 . In each case, because of the common adjustment point “A” of the front end of the laser  762 , regardless of subsequent adjustments of the rear end of the laser  762 , the laser beams  730  continue to pass through the common point CP. 
         [0185]    With reference now to  FIGS. 24-26 , the mounting of the lasers  760 ,  762  will be described. In describing the mounting and adjustments of the laser  760 ,  762 , the front end adjustment positions of each laser  760 ,  762  will be designated by the letter “A” in  FIGS. 24-26 , while the rear end adjustment positions will be designated by the letter “B”. Further, the laser  760  will be designated by the numeral “1”, and the laser  762  will be designated by the numeral “2”, and the adjustment directions will be designated by “x”, “y” or “z”. Further, the laser mechanism  728  includes a first support plate  778  (shown in dashed lines in  FIG. 24 ), and a second support plate  780 . The laser  760  is connected to and supported by a first mount plate  782 , a second mount plate  784 , and a third mount plate  786 . Further, the laser  762  is connected to and supported by a first mount plate  788 , a second mount plate  790 , and a third mount plate  792 . 
         [0186]    For the laser  760 , the front end of the laser  760  includes locator pins A 1 X and A 1 Z defining the front end adjustment locations, as shown in  FIGS. 24-26 . The rear end of the laser includes locator pins B 1 X and B 1 Z defining the rear end adjustment locations. The locator pins A 1 X and B 1 X are fixed to the second mount plate  784  and extend through slots provided in the first mount plate  782 , so that the plate  784  can move relative to the plate  782  to allow adjustment of the laser  760  in the “x” direction. As evident from  FIG. 25 , the plate  784  is connected to the plate  786 , so that the plate  786  moves in the “x” direction with the plate  784 . The locator pins A 1 Z and BIZ are fixed to the plate  786  and extend into slots in the support plate  780  to allow adjustment of the laser in the “z” direction. 
         [0187]    For the laser  762 , the front end includes locator pins A 2 X and A 2 Y defining the front end adjustment locations, as shown in  FIGS. 24-26 . The rear end of the laser includes locator pins B 2 X and B 1 Y defining the rear end adjustment locations. The locator pins A 2 X and B 2 X are fixed to the mount plate  792  and extend into slots provided in the plate  778 , so that the plate  792  can move relative to the plate  778  to allow adjustment of the laser  762  in the “x” direction. The locator pins A 2 Y and B 2 Y are fixed to the plate  790  and extend through slots in the plate  788  so that the plate  790  can move relative to the plate  788  to allow adjustment of the laser  762  in the “y” direction. 
         [0188]    Adjustments of the lasers  760 ,  762  about the respective locator pins can be accomplished using adjustment mechanisms similar to those used in previous laser systems. A person having ordinary skill in the art would know how to implement the conventional adjustment mechanisms with the lasers  760 ,  762 . 
       Graphics Module 
       [0189]    Monochrome images often are applied to personalized cards. Graphics, such as a photo, logo, account number or other personalized information that would not be applied using the normal three color process, may be applied using these particular graphics modules. Previous designs have employed a card path for entry and processing of cards into the module. Typically, separate roller assemblies are employed for entering a card and for transferring the card along the card path for processing. In the past, separate motors, such as stepper motors, were employed to control each of the roller assemblies. Further, the position of the card is referenced from the trailing edge of the card for processing. Further, a print ribbon supply from a supply roll is fed adjacent to a printhead used for printing on the card, to a take up roll. 
         [0190]    Although these designs may be suitable for their purpose, improvements may still be made upon graphics modules used in card personalization systems. For example, there is still a need to solve card handoff problems between rollers and improve overall consistency in the handoff of cards between rollers. In addition, there is a need to provide improvements to graphics modules in determining the position and location of a card within the module. Further, there is need to provide a graphics module where print ribbon is easily metered and efficiently used. The following description illustrates the features and improvements made upon existing designs of a graphics module in accordance with the principles of the present invention. 
         [0191]      FIGS. 30-33  illustrate a graphics module  600 . If a card does not require any processing of graphics using the graphics module  600 , the card may be simply passed through the module  600  to the next module. Preferably, the module  600  is capable of applying graphics on a card up to 3000 cards per hour. 
         [0192]      FIGS. 30-31  illustrate perspective views of one preferred embodiment for a graphics module  600  used in the card personalization system of the present invention. The graphics module  600  includes a frame  610  having ends  611   a ,  611   b , a top  613   a , and a bottom  613   b . The frame also includes an upstream side  615   a  and a downstream side  615   b . A card path  630  is disposed between the ends  611   a ,  611   b . At the upstream side  615   a , the card path  630  includes a photo cell  620  incorporating a sensor (not shown) that senses an entry of a card input into the graphics module  600 .  FIG. 31  illustrates the graphics module  600  having a print ribbon  690  incorporated through the module  600 . 
         [0193]    Entry rollers  645   a , as best shown in  FIG. 32  are employed for entry of the card into the graphics module  600  for processing of the card. The card is transferred or passed to mid-module transport rollers  645   b  ( FIG. 32 ) that move the card along the card path  630  during a printing stage. Preferably, the entry rollers  645   a  operate at a higher speed when passing a card than the transport rollers  645   b . Particularly, the card is moved by the entry rollers  645   a  at a higher speed than when the card is moved by the processing rollers  645   b , when the speed of the card is dropped down for printing. Preferably, as shown in  FIG. 32 , a pair of rollers is employed for the entry rollers  645   a , and another pair of rollers  645   b , are employed for the transport rollers. However, it will be appreciated that more rollers may be employed as suitable for the transport of a card along the card path. Roller drives  643  drive both rollers of the roller pairs  645 . As shown in  FIGS. 30 and 32 , roller drives  643  are shown that drive the entry rollers  645   a , the transport rollers  645   b , and the exit rollers  645   c.    
         [0194]    A motor  641  is operatively connected to the roller drives, such as  643 , in rotating the rollers. Preferably, one motor  641  is employed to control the rotation and speed of the entry rollers  645   a , the transport rollers  645   b , the exit rollers  645   c  and the print roller  646 . More preferably, the motor  641  is a DC servo motor rather than a stepper motor that is more suitable for rapid speed changes especially when the changes are over a large range of speeds. The use of one motor eliminates the need for multiple stepper motors and presents improved handoff and transfer of the cards between the rollers within the module  600 . The motor  641  operates at high speed for entry and transport of a card then reduces the speed so that the module  600  may begin printing the necessary personalization information. Preferably, a card passing through the module  600  is always in the grip of at least one set of rollers. For instance, a card that is in the grip of the entry rollers  645   a  would enter the transport rollers  645   b , before the card would be released from the entry rollers. This eliminates the potential for a handoff problems in card transfer between different roller sets employing separate motors and controls. With the positive control of the card through roller hand offs the position of the card within the module  600  can be reliably predicted. 
         [0195]    A printhead  650  disposed between the transport rollers  645   b  and the exit rollers  645   c  and along the card path  650 . Preferably, the printhead  650  is movable to and from the card path  650 , along the track  651 , as best shown in  FIG. 33 , in a direction perpendicular to path  630 . More, preferably, the printhead  650  may reside in one of three positions including a ready position, a printing position and a ribbon loading position. The ready position constitutes a position where the printhead  650  has been wrapped with the proper ribbon  690  for applying the personalized graphics information, and may reside a short distance (card thickness plus clearance) from the print roller  646 . The printing position of the printhead  650  is when the card is moving at the reduced speed along the card path  630  and is in proper position for graphics printing proximate to the card path  630 . The printhead  650  would reside at the card path pressing the ribbon and card against the print roller  646  so printing may occur.  FIGS. 30 and 33  illustrate the graphics module  600  in the print position. The ribbon loading position or load position occurs when the printhead  650  resides above the end of the track  651 , farthest from the print roller  646 . The loading position enables for loading/unloading of ribbon product from the supply and take up spools. 
         [0196]    In the print position, the printhead  650 , having the print ribbon product wrapped adjacent to the printhead  650 , presses against the card being processed. Preferably, the printhead  650  is a thermal printhead. Pressure is applied against the ribbon and card for a suitable amount of time so that the print ribbon product may be transferred and adhere onto the card. After the necessary personalization graphic(s) have been input onto the card, the printhead  650  and ribbon  690  are removed away from the card, and the card may be put in position for release from the graphics module  600 . 
         [0197]    When in the loading position, the printhead  650  and carriage  651  are moved away from the card path  630  far enough to contact and push a release bar  653 . The release bar  653  is operatively connected with a capstan  657 , and may push the capstan  657  when being moved by the carriage  651  into its loading position. In this configuration, the capstan  657  is moved away from supply roll  660  and take up roll  670 , so that each of the rolls  660 ,  670  may be removed of used ribbon product or loaded with additional ribbon product. Preferably, the capstan  657  normally is biased against the take up roll  670 , when the printhead  650  is in a position other than the loading position, such as in the ready or printing positions.  FIG. 30  illustrates the capstan biased against the take up roll  670 . 
         [0198]    When the capstan  657  is in its normally biased position against the take up roll  670 , the amount of ribbon needed for printing a particular graphic image can easily and accurately be measured. Preferably, the capstan  657  resides about the outer diameter of the take up roll  670 . Particularly, by positioning the capstan  657  about the outer diameter of the roll  670 , the amount of rotation required by the capstan  657  to meter a specific amount of ribbon product used for printing on the card, is consistent regardless of the diameter of the take up roll  670 . In addition, the take up roll  670  rotates accordingly to take up the used print ribbon product, and maintains compact and controlled tack up roll  670  during regular print and take up conditions. 
         [0199]    The graphics module  600  also includes an accumulator  655  or tensioning member that maintains tension in the print web. The accumulator  655  is pivotable about a pivot region  655   a  and contacts the print web before being fed to the printhead  650  and take up roll  670 . The accumulator  655  is biased against the print web so that the print web maintains a suitable tension in the print web. Further, the accumulator  655  enables the take up roll  670  to reverse its rotation and feed print ribbon backwards past the printhead  650  while still maintaining tension in the print web. For example, in the event of a print error, the take up roll may reverse its rotation, and the accumulator  655  automatically pivots against the print web, accordingly without the need for the supply roll to reverse its rotation. Tension in the web is maintained and unused print web may be saved. The accumulator  655  provides additional ribbon saving capability to the graphics module  600 . Particularly, the accumulator  655  provides a ribbon saving feature when the take up roll reverses its rotation to recover previously unused print web. 
         [0200]    As above with the input hopper, a controller, such as  22  described above, is used to provide the necessary data information in controlling the graphics module settings. Preferably, a controller  680  is disposed on the frame  610  of the module  600 , and is in communication with the main controller in controlling the module  600 . A electro-mechanical break  661 , as shown in  FIG. 33  controls the resistance torque applied to the supply roll  660 . Preferably an electro-mechanical break is used to provide a necessary torque to resist the free rotation of the supply roll  660  maintaining tension in the web. More preferably, a larger diameter of the supply roll  660  requires more torque in order to maintain a constant tension in the web. On the other hand, a smaller diameter requires less torque to achieve the same tension. Therefore, as the print web supply on the supply roll  660  diminishes, the necessary torque required on the supply roll  660  also decreases. Moreover, tension in the web is further maintained in the event of power failure, as the break  661  controlling the supply roll  660  torque is not connected to the interlock of the card personalization system. Thus, if a power failure occurs, tension in the print web may be maintained. 
         [0201]    In addition to other advantages, the graphics module of the present invention provides improved card transfer between rollers and increased ribbon saving features. One motor is used to drive all the entry, transfer and exit rollers along with the print roller. A card processed in the graphics module is always in the grip of at least one set of rollers. Such configuration also allows for improved monitoring of the position and location of a card. The graphics module of the present invention can be more conveniently and accurately metered. Further, the tension of the print web can be maintained during many instances of operation. 
       Output Hopper 
       [0202]    An output hopper is needed to collect processed and personalized cards. Typically, an output hopper includes trays for collecting cards that have passed through the processing modules of a card personalization system, and are ready for exit. Cards are exited off of a card path, using a card feeder, and collected into output trays. A card feeder pushes a processed card off the card path and into a card collection tray. Typically, a plurality of collection trays is employed, where at least one collection tray is used as a reject tray. 
         [0203]    Although these designs may be suitable for their purpose, improvements may still be made to an output hopper. There is still a need for an output hopper that provides increased reliability in exiting a card off of the card path for collection. Further, there is a need to provide improved efficiency in recognizing that a card is ready for exiting off of the card path. The following description illustrates the features and improvements made upon existing designs of an output hopper in accordance with the principles of the present invention. 
         [0204]    As illustrated in  FIGS. 1 and 2 , the output hopper  50  of the system  10  is positioned adjacent to and immediately downstream from the last module  40  for collecting cards. It will be appreciated that one or more similar output hoppers may also be located within the system at other locations, including between two or more of the modules  40 . In such a configuration, cards can be collected at various points along the card path of the system, allowing the cards to bypass one or more of the modules  40 . Thus, multiple output hoppers can exist within the card personalization system  10 , including between modules  40 . 
         [0205]      FIGS. 34-41  illustrate the output hopper  50  according to the present invention. Preferably, the hopper  50  is capable of collecting and stacking cards at a rate of up to 3000 cards per hour. 
         [0206]      FIG. 34  illustrates a top view of the output hopper  50 . The output hopper includes a frame  310  having a front  313   a , a back  313   b , and an upstream side  311   a , and a downstream side  311   b . A card collection tray  320  is releasably connected to the frame  310 , and is disposed from the front  313   a  towards the back  313   b  of the frame  310 . Preferably, a plurality of card collection trays  320  is employed, where at least one collection tray  320   a  is used as a reject tray. As shown in  FIG. 34 , three collection trays are illustrated; two collection trays  320  for correctly personalized cards, and one reject tray  320   a  for incorrectly processed cards. However, it will be appreciated that any suitable number of trays may be employed as needed for each card personalization system. 
         [0207]    Each collection tray  320 ,  320   a  includes at least one handle  321 ,  321   a . As shown in  FIG. 34 , the handle  321  is disposed at a front  329   a  of each collection tray, and the handle  321   a  is disposed at the back  329   b  of each collection tray. However, it will be appreciated that any suitable number or configuration of handles may be employed. Each tray also includes a card retainer  323  which supports the cards in the card tray to keep the cards in an organized stack. The card retainer  323 , held in the card tray  320   320   a  by a track, can slide along the length of the card tray. A magnetic stripe reader unit  370  may be employed along the card path  351  downstream of the reject collection tray  320   a  and upstream of the collection trays  320 . The magnetic stripe reader unit  370  is used to verify that the card in the output hopper module is the correct card to be transferred into a card collection tray. Each card is transferred through the reader unit  370  and moved in position in front of the appropriate card tray. The card is then exited into the card tray if the read/verify test is successful. Any processed card that fails the read/verify test is moved backwards on the card path  352  and exited into the reject collection tray  320   a . The reader can read any track of data on the magnetic stripe of a card. The details and features of a magnetic stripe reader  370  in accordance with the principles of the present invention are provided in the discussion below. 
         [0208]      FIGS. 34 ,  36  to  41  illustrate one preferred embodiment of a card path  352  defined by tracks  351 ,  357  capable of guiding cards through the module, guiding cards out of the card path  352  for transfer into a card collection tray, and providing upward bias force on cards for reading magnetic stripes with the magnetic stripe reader  370 . The lower card track  351  is spring loaded in order to bias cards upward against the upper fixed card track  357 . The lower track  351  also is split at the midpoint of the magnetic stripe reader  370 . The card path  352  defined by the tracks  351 , 357  extends between the upstream side  311   a  and downstream side  311   b.    
         [0209]    Entry rollers  353  are disposed at the upstream side  311   a , and employed for entering processed cards into the output hopper  50  along the card path  351 . A tab belt  355  moves processed cards along the card path  351  to the respective card collection trays for exiting. The tab belt  355  includes tabs  355   a  that contact side edges of processed cards to drive the card along the card path  351 . 
         [0210]      FIGS. 36 to 38  illustrate one preferred embodiment of a card feeder  340  used to exit a card off of the card path  351  and into a card collection tray  320 ,  320   a . As a processed card  390  is transferred along the card path  351 , the appropriate card feeder  340  is activated and moves its pusher arm forward so that the card stop blocks the card path  351 . This ensures the card  390  is positioned in front of the appropriate card collection tray with the leading edge of the card aligned with the back end  329   b  of the respective card collection tray  320 . Each card feeder  340  includes a head portion  341  that is substantially elongated. Preferably, the card feeder  340  is at least the same length of a card  390 . The head portion  341  contacts the card  390  and pushes the card  390  off the card path  351  towards and into the collection tray  320  ( FIGS. 37 and 38 ). The collection tray  320  includes at least one retention member  322  defined on each side  327   a ,  327   b  of the collection tray  320 . The retention members  322  securely maintain exited cards, such as  390 , fed into the collection tray  320 . Preferably, there is a separate card feeder  340  for each collection tray  320 . 
         [0211]    One preferred approach to feed cards into respective collection trays is to employ a ramped or slanted surface  343  on the head portion  341  of each card feeder  340 . The slanted surface  343  contacts the card  390 , as shown in  FIG. 37 , and pushes the card  390  off of the card path  351 . As shown in  FIG. 38 , the card  390  is slanted due to the contact with the ramped surface  343  of the head portion  341 , and the card  390  passes retention members  322  residing on one side  327   b  of the collection tray  320 . As the card feeder  340  pushes the card  390  into the trough  325  of the collection tray  320 , the card  390  passes retention members  322  of the other side  327   a  of the collection tray  320 . The arrow A represents the direction of card travel and movement of the card feeder  340 .  FIGS. 36 to 38  illustrate a card feeder  340  for a collection tray  320 . However, it will be appreciated that similar structures may be employed for other collection trays, such as reject tray  320   a .  FIGS. 39 to 41  represent top views of the card  390  being pushed off the card path  351 , and fed into the collection tray. Similar features are illustrated in  FIGS. 39 to 41  already discussed above, and are not further described. 
         [0212]      FIGS. 69-71  illustrate an alternate embodiment of a card feeder  340 ′ for pushing cards into the collection trays  320 ,  320   a . In this embodiment, the head portion  341 ′ of the card feeder  340 ′ has a planar surface  343 ′ rather than a ramped surface  343 . The head portion  341 ′ is mounted to be tilted at an angle while pushing a card into a tray. The head portion  341 ′ is connected to the end of link arms  380 ,  381  via pivots  382 ,  383 , respectively. The opposite ends of the link arms  380 ,  381  are connected to a drive wheel  384  that is rotatable in a counterclockwise direction as viewed from above in  FIG. 69 . 
         [0213]    At the home position of the card feeder  340 ′ illustrated in  FIG. 69 , the head portion  341 ′ and surface  343 ′ are parallel to the card path. As illustrated in  FIG. 70 , rotation of the drive wheel  384  causes the head portion  341 ′ to be pushed toward the tray. At the same time, the head portion  341 ′ is titled by the link arms  380 ,  381  so that the surface  343 ′ is disposed at an angle for pushing the card into the tray. Continued rotation of the drive wheel  384  drives the head portion  341 ′ further toward the tray  320  while the link arms  380 ,  381  tilt the surface  343 ′ in the opposite direction to complete the insertion of the card into the tray, as shown in  FIG. 71 . Once the card is inserted, the drive wheel  384  continues rotating back to the home position ready for another card insertion cycle. 
         [0214]      FIGS. 35   a - 35   d  illustrate one preferred embodiment of a card in sensor bracket  350 . The card in sensor bracket  350  includes a substantially planar body  361  having a first end  361   a , a second end  361   b , and sides  361   c ,  361   d . The first end  361  includes side flanges  363 , and the second end  361   b  includes an angled flank  365 . Each collection tray includes a sensor bracket, such as sensor bracket  350  as shown in  FIG. 34 . Each sensor bracket is connected to the frame  310 , for example through a common mounting plate  357 , and resides above the card path  351 , so that processed cards may pass along the card path  351  under each sensor bracket  350 . The sensor bracket includes a space  369  so that a suitable sensor (not shown) may be incorporated therein to sense a processed card waiting to be fed into a collection tray. A projection  367  extends substantially perpendicular from the planar body  361 .  FIGS. 35   b - 35   d  illustrate top, front, and side views of the sensor bracket, respectively. 
         [0215]    It will be appreciated the output hopper of the present invention may also be configured to receive and exit cards in the card path of the system between other processing modules. This would allow for multiple output modules to exist within a card personalization system, where a disposed output module may operate between other processing modules. 
         [0216]    In addition to other advantages, the output hopper of the present invention is cost effective and maximizes the number of card collection trays within the module space. The process of exiting cards utilizing the card feeder, card track and card collection trays of the present invention provides a fast, reliable method of exiting cards in a minimal amount of space. Card exiting features such as the ramped surface on the head portion of the card feeder, tongues on the lower track guides and the card tray retention members provide more reliability in feeding cards into collection trays. Further, the card in sensor bracket allows for an improved structure for sensors to sense a card as it is fed into a collection tray. 
       Magnetic Stripe Readhead Unit 
       [0217]      FIGS. 42-45  illustrate a magnetic stripe readhead unit  500 . Magnetic stripe readhead units read personalized information off of magnetic stripe portions residing on personalized cards. Typically, such magnetic stripe readhead units are mounted on frames and are disposed along the card path. The readhead units contact passing cards reading the information stored on the magnetic stripe. Typically, readhead units are used in card personalization systems for verifying that the correct personalized information is stored on the magnetic stripe of a card. If a card does not have a magnetic stripe or reading a magnetic stripe is not required, the card may be simply passed through the unit  500 . 
         [0218]    Although these designs may be suitable for their purpose, improvements may still be made upon a magnetic stripe readhead unit. There is still a need for a magnetic stripe readhead unit that provides sufficient clearance for cards, while maintaining suitable contact against the magnetic stripe of the card. In addition, a readhead unit mounting structure is needed that prevents unnecessary and undesirable movement of the readhead, while providing increased convenience in assembly and cost effective parts. The following description illustrates the features and improvements made upon existing designs of a magnetic stripe readhead unit in accordance with the principles of the present invention. 
         [0219]      FIG. 42  illustrates one preferred embodiment of a magnetic stripe readhead module  500 , referred hereafter as reader unit. The reader unit  500  includes a frame  510  having a top  521   a , a bottom  521   b , sides  517   a ,  517   b , and a front  523   a  and a back  523   b . The side  517   b  defines a winged portion having a mounting projection  511  extending substantially perpendicular from the side  517   b  outward from the front end  523   a  of the frame  510 . It will be appreciated that side  517   a  includes an identical structure and arrangement as the side  517   b , in providing a symmetrical frame  510 . The mounting projection  511  includes mounting holes  511   a , which can enable fasteners such as screws to mount the frame  510  to another structure. For example,  FIG. 34  illustrates a magnetic stripe reader unit mounted to the frame of the output hopper  50 . Preferably, the reader unit  500  is mounted between a reject tray and the collection trays for correctly processed cards, such as shown in  FIG. 34  (collection trays  320 ,  320   a ). 
         [0220]    Both the front end  523   a  and the back end  523   b  include a readhead holder  530  mounted thereon. Locating pins  543  illustrated on the back end  523   b  provide alignment for the holder  530  to the frame  510 , and enable the readhead to be accurately positioned without the need for added adjustments. As shown in  FIG. 42 , locating pins  543  are illustrated on the back  523   b . However, it will be appreciated that the front end  523   a  includes the identical locating pin structure as the back end  523   b . A shoulder screw  560  employs a compression spring (not shown) so a uniform force is applied by both readheads  550  (shown in  43 ) residing on the readhead holders  530 . 
         [0221]    Preferably, both readhead holders  530  include a top  531   a  and a bottom  531   b . A fastener  561 , such as a screw, resides toward the top  531   a , and mounts the readhead holders  530  onto the frame  510 . The bottom  531   b  of the readhead holder  530  includes a readhead support  533  having at least one card guide  541  disposed on sides of the readhead support  533 . Further, a spring  535  disposed about the side of the readhead holder  530  biases the readhead  550  in the card travel direction indicated by arrow A.  FIGS. 42 and 43  illustrate a spring  535 , support  533  and card guides  541  on one side of the readhead holder  530 . However, it will be appreciated that both readhead holders  530  include identical spring  535 , readhead support  533  and card guide  541  structures. As best shown in  FIG. 43 , a readhead  550  is removably connected to the readhead holder  530  through pivot pins  565 . The pivot pins  565  connect to the sides of the readhead holder  530  and are biased in the card direction by the springs  535 . 
         [0222]    Further, as best shown in  FIG. 43 , a cam mechanism  572  is fixed to a shaft  574 , which is pivotally mounted within the frame  510 . The shaft  574  can be operated between a first position (as shown in  FIG. 43 ) and a second position (not shown) indicated by direction of arrow B. The first position, as shown in  FIG. 43 , the cam  572  is not in contact with the readhead holder  530 , thereby enabling the reading of information on the card. As the shaft  574  is rotated in the direction of arrow B, the cam  572  also rotates so that areas  576   a ,  576   b  come into contact with the readhead holder  530  to pivot the readhead holder  530  away from the card track so that the readhead  550  and readhead portion  559  do not contact the card surface. In cases where a readhead module such as  500  processes cards without magnetic stripes, moving the head out of the card track is advantageous for the purpose of eliminating unnecessary wear of the readhead portion  559  of the readhead  550 . 
         [0223]    As best shown in  FIG. 43   a , a readhead  550  includes notches  557  in sides  555   a ,  555   b  of the readhead  550 . The readhead  550  is pivotally connected to the pins  565  on each readhead holder  530  through the notches  557 . Preferably, the readhead unit  500  can read on both the front  523   a  and back  523   b  sides. As above, a spring force biases the readhead in the card travel direction A, and is applied by springs, such as springs  535  of the readhead holder  530  shown in  FIGS. 42 and 43 . 
         [0224]    Preferably, the readhead holders  530  are constructed of an at least partially flexible material, so that the holders  530  may bend outward from the frame  510  as a card travels through the readhead unit  500 . However, the material of the readhead holder  530  preferably is rigid enough to prevent twisting relative to the face of the card to maintain suitable contact of the readhead portion  559  against a magnetic stripe located on a card. More preferably, the readhead holders  530  include a pivot region  537  disposed between the top  531   a  and the bottom  531   b . The pivot region  537  includes portion of the readhead holder  530  that is thinner than the rest of the readhead holder. The pivot region  537  enables the readhead holder to bend at the pivot region  537  and function as a hinge. The pivot region  537  can bend enough to allow clearance of cards passing through the reader unit  500 . Preferably, the readhead holders  530  may bend while still maintaining suitable contact of the readhead portion  559  against a magnetic strip located on a card. 
         [0225]      FIG. 44  illustrates another preferred embodiment of a readhead holder. The readhead holder  530   a  includes a rigid frame  590  having a resilient plate  580 . Pointed ends  590   a  of the rigid frame  590  contact against the plate  580 . Preferably, the pointed ends  590   a  rest directly against the plate  580 . A readhead  550   a  is mounted on the plate  580 . The plate  580  is mounted onto the frame  590  through a fastener  591 , such as a screw or bolt. The plate  580  constrains movement of the readhead  550   a  in the card travel direction and in a direction upwardly and downwardly perpendicular to the card travel direction. Further the plate  580  may resiliently bend to and from the magnetic stripe of the card to allow clearance of passing cards, while maintaining suitable contact with its read portion against the magnetic stripe of passing cards. 
         [0226]    In another embodiment of a readhead holder,  FIGS. 45   a - c  illustrate a readhead holder  530   b  having a frame  592  that includes supports  592   a . The supports  592   a  include pins or bellows  566  that are operatively connected to the readhead  550   b  at the slotted notch  557   a  (also shown in  FIG. 45   c ). The readhead  550   b  is rotatably connected to the readhead holder  530   b  through the pins  566  ( FIG. 45   b ). As best shown in  FIG. 45   b , the readhead holder  530   b  can be operatively connected to a frame of a readhead unit schematically depicted as  500   a . Preferably, the readhead holder  530   b  is connected to the frame  500   a , and is biased using a spring  570  ( FIG. 45   b ).  FIG. 45   c  illustrates the readhead  530   b  that includes a top  554   a  and a bottom  554   b . The slotted notch  557   a  is shown disposed on the side  556   a . It will be appreciated that side  557   b  includes an identical slotted notch as side  557   a.    
         [0227]    In addition to other advantages, the readhead unit  500  provides improved frame structures and supports for constraining movement of a readhead while still maintaining suitable contact against the magnetic stripe of passing cards. Further, the readhead unit of the present invention provides a structure that is convenient to assemble, and eliminates the need for adjustments. In addition, the readhead unit provides an easily replaceable readhead without replacing the entire readhead unit. The design offers unit that occupies minimal space, having few parts, and is cost effective. 
         [0228]    An alternative embodiment of a magnetic stripe reader  1500  for use in the output hopper  50  is illustrated in  FIG. 72 . The reader  1500  could be used in other modules as well for reading the magnetic stripe on the card. The reader  1500  is designed to reduce or eliminate vibrations of the card as the magnetic stripe is being read by the readhead, thereby making data recovery from the magnetic stripe by the readhead more reliable. 
         [0229]    One source of these vibrations comes from the use of rigid upper and lower card guide means. The upper and lower card guide means can never be exactly parallel to each other or the surfaces are not flat with the result that there is a space between the card and the guide means at one end or the other. This space allows the end of the card to move up and down at that end resulting in similar forward/backward motion of the card at the readhead. This makes accurate timing of the data difficult and reduces the reliability of the reading function. 
         [0230]    In the past, problems of this type have been eliminated or reduced by using a compliant bias spring member at either the top or bottom card guide means. This compliant bias spring member contacts the card along the entire edge thereby reducing or eliminating any space between the card and the guide means. However, in some cases it is not possible to use compliant bias spring members, or additional card motion stability may be required. 
         [0231]    In the reader  1500  illustrated in  FIG. 72 , a pair of rubber rollers  1502  are mounted below the readhead  1504 , one roller  1502  at the front of the card  1506  and one roller  1502  at the back of the card. The rollers  1502  are mounted on suitable bearings on fixed pins  1508 . In addition, a roller  1510  is mounted opposite the readhead  1504 . The readhead  1504  and roller  1510  are preferably mounted in one of the previously described holders, for example one of the holders  530 ,  530   a , or  530   b.    
         [0232]    The centers of the rollers  1502  are spaced apart a distance to provide compression of the rubber of the rollers  1502 . As a result, there is some resistance to the card  1506  as it passes through the rollers  1502 . This results in a damping effect on the motion of the card thereby eliminating or reducing rapid motion changes in the card relative to the readhead  1504  with an increase in read reliability. 
         [0233]    An additional rubber roller  1512  also with a suitable bearing on a fixed pin mount  1514  can optionally be used. The roller  1512  is spaced from the roller  1502  it contacts to provide compression of the rubber. The additional roller  1512  contributes more damping and smoothing of the card motion relative to the readhead  1504 . In this case, it has been found that the variations in motion of the card are reduced from about 25% to 5%, and the read reliability was increased from 1 error in 20 cards to 1 error in 10,000 cards. 
       Magnetic Head 
       [0234]    The present invention also includes improvements relating to magnetic heads that are used for writing or recording data to, and reading data from, magnetic stripes on the cards. 
         [0235]    In one improvement, a chip having memory is placed in the magnetic head, such as the magnetic head of the write unit  144  or the magnetic head of the read unit  146 , or on the readhead  550 . Placing a chip in the magnetic head allows the system  10  to access information about the head, such as part number, capabilities, install date, number of cards passed by the head, etc. This information can be used, for example, to initiate maintenance, and to keep track of magnetic head service life and performance. This information can be very useful to improve reliability of a module incorporating the head and therefore the system as, a whole. This type of information is very difficult to obtain by conventional means as it requires manual entry and correlation to each specific head, and heads could easily be exchanged invalidating the data or leading to wrong conclusions. 
         [0236]    In another improvement, the magnetic head can include wear detection capability. In magnetic heads that are commonly used for recording, wear takes place as cards are repeatedly passed by in contact with the face of the head. A conventional magnetic head  900  is illustrated in cross-sectional side view in  FIG. 54 . The magnetic performance of a head changes slightly for the better as it wears down but it becomes more difficult to maintain good contact with the card as the head wears. As the flat area  902  from wear gets larger, small changes in the angular alignment between the head and the card will move the center of the head out of intimate contact with the card leading to performance degradation. Also, once the head has worn down to the bottom of the magnetic depth md (typically less than 0.02 inches) further wear produces a sudden failure of the head. 
         [0237]    The inclusion of a wear indicator sensor in a magnetic head would allow the head to be replaced before sudden failure, or on a regular service interval since advance warning would be provided by the sensor. When the head is new, the value of the head is calibrated and then recorded in the system  10 , or the module in which the head is utilized, or loaded into a memory chip provided in the head as discussed above. As the head wears, the value of the head changes, and based on a set value, notification would be made to the system  10  that the head should be serviced within a set period of time. 
         [0238]    In the preferred embodiment, illustrated in  FIGS. 55 and 56 , a sensor  904  is placed at the contact face of a magnetic head  906 . A semi-conducting material  908  is placed between two layers of conductive material  910   a ,  910   b , that are surrounded by electrical insulators  912   a ,  912   b . The resistance measured across conductive material  910   a  and  910   b  depends on the area of the semi-conducting material  908  so that as material  908  is worn away, the resistance will increase. In this way, head wear can be measured that closely resembles the mechanical wear of the head  906 . 
         [0239]    In an alternate embodiment, suitable materials are used to create a capacitive element for monitoring head wear. In yet another embodiment, an external circuit is used to measure the inductance of the electrical winding  914  used for writing or reading during idle times of the machine cycle. Inductance will change slowly as the head wears but will then change rapidly as the magnetic bottom is worn through. 
       Cleaning Module 
       [0240]      FIGS. 57-60  illustrate a cleaning mechanism  1000  of a cleaning module that forms one of the modules  40  within the system  10 . The cleaning module, via the cleaning mechanism  1000 , is designed to clean both sides of the card in order to remove contaminants from the card surfaces. Contamination, such as foreign particles, dirt and oil, on the card surfaces can interfere with a personalization task and degrade the resulting quality of the personalization. The cleaning module is preferably located before the graphics module  600  and the laser module  700 , because the tasks performed by these modules are particularly susceptible to card contamination. However, the cleaning module could be located at any location in the system  10  downstream from the input hopper  30 . In addition, the system  10  could utilize more than one cleaning module. 
         [0241]    Many conventional cleaning modules and cleaning mechanisms used therein include a pair of cleaning rollers between which a card is passed to remove contaminates from each side of the card. The contaminates are thereafter removed from the cleaning rollers using stripper tape that contacts each cleaning roller to strip or remove the contaminates from the rollers. An example of a conventional cleaning module and cleaning mechanism is disclosed in U.S. Pat. No. 5,401,111. The stripper tape is typically provided from a supply roll, and after stripping contaminates from the rollers, is wound onto a take-up roll. Thus, stripper tape is a consumable item that needs periodic replacement. 
         [0242]    To extend the life of the stripper tape, the tape is often re-used by taking the used tape of the take-up roll and using it as the supply roll. This has disadvantages because it requires user intervention in order to physically remove the take-up roll and place it onto the supply roll spool for re-use. 
         [0243]    The cleaning mechanism  1000  is designed to resolve this and other deficiencies of conventional card cleaning mechanisms. The cleaning mechanism  1000  is designed to automatically re-use stripper tape  1002  before the stripper tape is wound onto a take-up roll  1004 . Thus, the life of a supply roll  1006  of the stripper tape is extended, which reduces the frequency with which user intervention with the cleaning mechanism  1000  is required. 
         [0244]    Turning now to  FIG. 57 , the specifics of the cleaning mechanism  1000  will be described. A pair of input rollers  1008   a ,  1008   b  are provided at the entrance to the module to receive cards from an upstream module and drive the cards into the cleaning mechanism  1000 . Upper and lower input guides  1010   a ,  1010   b  help guide the cards into the nip between the rollers  1008   a ,  1008   b  and define upper and lower card tracks that define a card path leading to a cleaning roller assembly  1012 . 
         [0245]    A pair of output rollers  1014   a ,  1014   b , illustrated in  FIGS. 58-60 , are provided adjacent the exit side of the mechanism  1000  for driving cards from the cleaning module on to the next module. An upper card guide  1016  and a lower card guide (not shown) disposed opposite the guide  1016  guide the cards as they exit the roller assembly  1012  and define a card path leading to the exit of the module. 
         [0246]    As shown in  FIG. 57 , the input rollers  1008   a, b  and the output rollers  1014   a, b  are driven by an electric motor  1018 , for example a stepper motor, via a drive belt  1020  and pulley  1022  for the rollers  1008   a, b  and a similar drive belt and pulley (not shown) for the rollers  1014   a, b . The input rollers  1008   a, b  and output rollers  1014   a, b  are preferably driven at the same speed, for a reason which will become apparent below. 
         [0247]    The input rollers  1008   a, b  drive cards into the cleaning roller assembly  1012  which includes a pair of cleaning rollers  1024   a ,  1024   b  ( FIG. 57 ). Cards pass through the nip of the cleaning rollers  1024   a, b  so that the roller  1024   a  contacts one side of the card and the roller  1024   b  contacts the other side of the card. The outer surfaces of the cleaning rollers  1024   a, b  are tacky or sticky so that contaminates on the card surfaces are picked up by, and adhere to, the cleaning rollers. The use of cleaning rollers having tacky outer surfaces is described in U.S. Pat. No. 5,401,111. The diameter of each roller  1024   a, b  is selected so as to be approximately equal to, or greater than, the length of the card, so that outer surface portions of the rollers that have already contacted a portion of the card do not rotate around to contact another portion of the card. 
         [0248]    With continued reference to  FIG. 57 , the cleaning rollers  1024   a, b  are mounted for rotation on a turret body that includes a lower turret plate  1026  and an upper turret plate  1028 . Each turret plate defines a track therein for guiding the upper and lower edges of the cards as the cards travel through the rollers  1024   a, b . Drive wheels  1030   a ,  1030   b , which are in driving engagement with each other, are connected to the rollers  1024   a, b , respectively, for driving the rollers  1024   a, b  in synchronous, opposite rotation. The drive wheels  1030   a, b  are preferably rubber wheels, although other drive wheel types could be used. The drive wheels  1030   a, b  are driven by a drive chain that includes a driving wheel  1032 , for example a rubber wheel, in driving engagement with the drive wheel  1030   b , a rubber wheel  1034 , a first pulley  1036  connected to the wheel  1034 , a belt  1038 , and a second pulley  1040  that is connected to and driven by a shaft  1042  extending from the input roller  1008   b . As a result, the rotation of the cleaning rollers  1024   a, b  is synchronized with, and at the same rotational speed as, the rotation of the input rollers  1008   a, b  and the output rollers  1014   a, b . Therefore, as a card is driven by the input rollers  1008   a, b  into the cleaning rollers  1024   a, b , and from the cleaning rollers into the output rollers  1014   a, b , a smooth transition of the card is achieved. 
         [0249]    The turret body comprising the turret plates  1026 ,  1028  is rotatable about a central longitudinal axis through the center of the plates  1026 ,  1028 , with the axis extending parallel to the longitudinal axes of the cleaning rollers  1024   a, b . The cleaning rollers  1024   a ,  1024   b , which are rotatably mounted on the plates  1026 ,  1028 , rotate with the plates  1026 ,  1028 . Rotation of the turret body is used to disengage the drive connection between the drive wheel  1030   b  and the driving wheel  1032 , and to position the cleaning rollers  1024   a ,  1024   b  for subsequent engagement by the stripper tape  1002  to remove contaminates from the cleaning rollers. The turret body is rotated by an electric motor  1044 , for example a stepper motor, through a suitable drive mechanism, such as a belt and pulley, that is connected to a shaft that extends downwardly from the turret plate  1026 . An example of a mechanism for rotating a turret body is disclosed in U.S. Pat. No. 5,401,111. 
         [0250]    A tab  1046  is connected to the upper turret plate  1028 , as shown in  FIGS. 58-60 . A sensor  1048  senses the tab  1046  to determine a home position of the turret body. The home position of the turret body is illustrated in  FIG. 58 , where it is seen that the sensor  1048  will sense the tab  1046 . Removal of contaminates from the cleaning rollers  1024   a, b  occurs by rotating the turret body either clockwise or counterclockwise from the home position. Preferably, the turret body is rotated to a first cleaning position so that contaminates are first removed from the cleaning roller  1024   a , followed by rotation of the turret body to a second cleaning position to remove contaminates from the cleaning roller  1024   b.    
         [0251]    In order to remove contaminates from the cleaning roller  1024   a , the turret body is first rotated in a clockwise direction by the motor  1044  to the first cleaning position shown in  FIG. 59 . In the first cleaning position, the driving wheel  1032  is no longer engaged with the drive wheel  1030   b , thereby disengaging the cleaning roller drive mechanism and preventing the cleaning rollers from being driven. After the cleaning roller  1024   a  is cleaned, the turret body is then rotated approximately 180 degrees in a counterclockwise direction from the position shown in  FIG. 59  to the second cleaning position. In the second cleaning position, the cleaning roller  1024   b  occupies the position formerly occupied by the cleaning roller  1024   a  in the first cleaning position, and the first cleaning roller occupies the position formerly occupied by the second cleaning roller. As with the first cleaning position, at the second cleaning position the driving wheel  1032  is not engaged with either drive wheel  1030   a  or  1030   b , so that the cleaning rollers cannot be driven. After the cleaning roller  1024   b  is cleaned, the turret body is rotated, preferably in a counterclockwise direction, back to the home position, at which point another card can be driven into the cleaning rollers  1024   a, b  for cleaning. 
         [0252]    Details of the stripper tape  1002  and the movements thereof will now be described with reference to  FIGS. 57-59 . The stripper tape  1002  is supplied from the supply roll  1006  and used stripper tape is wound onto the take-up roll  1004 . The supply roll  1006  is disposed on a non-driven, rotatable spindle  1050  which rotates when stripper tape  1002  is pulled from the roll  1006 . An encoder is connected to the spindle shaft to detect supply roll rotation and predict the amount of tape remaining on the roll. A capstan roller  1052  is biased against the outer surface of the supply roll  1006  to resist rotation of the supply roll  1006 . The take-up roll  1004  is disposed on a spindle  1054  that is rotatably driven by an electric motor  1056 , for example a stepper motor. When it is time to take-up a portion of used stripper tape  1002 , the electric motor  1056  is actuated to rotate the spindle  1054  thereby causing rotation of the take-up roll  1004  to wind a specific amount of used stripper tape onto the take-up roll. 
         [0253]    Turning to  FIG. 58 , which shows a stand-by position of the stripper tape, it is seen that the stripper tape leads from the supply roll  1006  and initially passes around a fixed guide roller  1058 , then around a first movable roller  1060 , around a first rotatable tape drive roller  1062 , around a movable backing roller  1064 , around a second rotatable tape drive roller  1066 , and finally around a second movable roller  1068  before proceeding to the take-up roll  1004 . The stripper tape  1002  has one surface  1070  (shown in  FIG. 57 ) that is coated with a substance that is more adhesive than the surface of the cleaning rollers  1024   a, b . The adhesive surface  1070  is arranged to face away from the backing roller  1064  so that it faces the cleaning rollers  1024   a, b . By contacting the adhesive surface  1070  with the outer tacky surface of the cleaning rollers, contaminates are removed from the cleaning rollers so that the cleaning rollers can perform a cleaning operation on a new card. 
         [0254]    With reference to  FIGS. 58 and 59 , the movable rollers  1060  and  1068  are mounted on slide blocks  1072 ,  1074 , respectively, which are each slidably supported on a pair of rods  1076 ,  1078 , respectively. Only one rod of each pair is visible in the drawings. The roller  1060  is therefore movable along the axes of the rod pair  1076  with the slide block  1072  between the position shown in  FIG. 58  and the position shown in  FIG. 59 . Likewise, the roller  1068  is movable along the axes of the rod pair  1078  with the slide block  1074  between the position shown in  FIG. 58  and the position shown in  FIG. 59 . A spring  1079  (see  FIG. 59 ) is connected at one end thereof to the slide block  1072 , and a spring  1080  (see  FIG. 58 ) is connected at one end thereof to the slide block  1074 . The opposite ends of the springs  1079 ,  1080  are interconnected by a cable  1081  which passes around a pair of pulleys  1082   a ,  1082   b  that are mounted on a plate  1083 . The springs  1079 ,  1080  and the cable  1081  synchronize movements of the rollers  1060 ,  1068  so that, if the roller  1060  moves from the position in  FIG. 58  to the position in  FIG. 59 , the roller  1068  will also move from the position in  FIG. 58  to the position in  FIG. 59 . The purpose of the movements of the rollers  1060 ,  1068  will be discussed below. 
         [0255]    The rotatable tape drive rollers  1062 ,  1066  are fixed in position unlike rollers  1060  and  1068 . However, the rollers  1062 ,  1066  are rotatably driven by respective electric motors  1084   a ,  1084   b  through suitable drive mechanisms (not shown) provided under respective roller drive housings  1063 ,  1067 . The outer surfaces of the rollers  1062 ,  1066  have a contact surface reducing, knurled texture which allow the rollers  1062 ,  1066  to grip and release the adhesive surface  1070  of the stripper tape  1002 , and, when the rollers  1062 ,  1066  are rotated in the appropriate direction, pull stripper tape from the supply roll  1006 . 
         [0256]    The backing roller  1064  is mounted on a slide block  1085  (best seen in  FIG. 60 ) that extends under the turret body and is connected to the plate  1083 , so that the slide block  1085  and plate  1083  move in unison. The slide block  1085  is slidable along the axes of rod pair  1086  (only one rod is visible in  FIGS. 58 and 59 ), and is selectively driven along the rod pair  1086  by an electric drive motor  1087  (see  FIG. 57 ) through a suitable drive mechanism (not shown). The backing roller  1064  is therefore movable from the stand-by position, shown in  FIG. 58 , to a cleaning position, shown in  FIG. 59 , where the adhesive surface  1070  of the stripper tape  1002  is brought into contact with the outer surface of the cleaning roller  1024   a.    
         [0257]    The backing roller  1064  is also movable to the position shown in  FIG. 60  when loading of a new stripper tape supply roll is necessary. As the backing roller  1064  moves to the position shown in  FIG. 60 , the slide block  1085  contacts the free end of a rod  1087  whose opposite end actuates a lever mechanism  1088  associated with the capstan roller  1052 . The slide block  1085  pushes the rod  1087  backward which, through the lever mechanism  1088 , forces the capstan roller  1052  out of engagement with the supply roll  1006  to facilitate removal of the previous supply roll and loading of a new supply roll. Further, as the slide block  1085  moves to the position shown in  FIG. 60 , arms (not shown) projecting from each side thereof contact the slide blocks  1072 ,  1074 , for example by engaging a flange  1089  on the slide block  1074  and a similar flange (not shown) on the slide block  1072  (see  FIG. 57 ). Contact between the arms of the slide block  1085  and the slide blocks  1072 ,  1074  force the slide blocks  1072 ,  1074  to the position shown in  FIG. 60 . Rather than mechanically driving the roller  1064  to the loading position shown in  FIG. 60 , a handle  1090  can be connected to the slide block  1085  to allow manual actuation of the roller  1064  to the loading position. 
         [0258]    The positions of the various rollers in  FIG. 60  facilitates loading of new stripper tape, because the tape does not need to be threaded through the relatively tortuous tape path formed by the rollers in the stand-by position shown in  FIG. 58 . Instead, the tape  1002  is simply passed around the roller  1058 , passed between the rollers  1060 ,  1064 ,  1068  and the rollers  1062 ,  1066 , and wound onto the take-up roll. Once the new tape is loaded, the roller  1064  is driven back to the stand-by position shown in  FIG. 58 , with the rollers  1060 ,  1068  automatically returning to their stand-by positions. 
         [0259]    The cleaning cycle of the cleaning mechanism  1000  will now be described with reference to  FIGS. 58 and 59 . With the stripper tape  1002  in the stand-by position ( FIG. 58 ), a card is passed between the cleaning rollers  1024   a ,  1024   b  which pick up contaminates from the card surfaces. The cleaned card waits at the exit of the cleaning module until the adjacent downstream module is ready to receive the card. The turret body is then rotated in a clockwise direction which disengages the cleaning roller drive mechanism and brings the cleaning roller  1024   a  into position ready for cleaning. The backing roller  1064  is then driven toward the cleaning roller  1024   a  to the position shown in  FIG. 59  until the stripper tape  1002  contacts the outer surface of the cleaning roller  1024   a.    
         [0260]    The tape drive roller  1066  then rotates counterclockwise to pull tape forward across the surface of cleaning roller  1024   a . Tape driven in this direction causes the length of tape between tape drive roller  1066  and the take up roll  1004  to increase allowing the movable roller  1068  to move toward the card path. Simultaneously the length of tape between the supply roll  1006  and the tape drive roller  1062  is decreased, which forces the movable roller  1060  to move away from the card path. The length of tape moved in this direction is equal to, or greater than, the circumference of cleaning roller  1024   a  to ensure that the entire roller surface is cleaned. If the movable roller  1060  reaches the limit of its travel and more tape is still required, the remainder of the tape needed will be peeled off the supply roll  1006 . 
         [0261]    With the surface of cleaning roller  1024   a  cleaned, the backing roller  1064  returns to the ready position (see  FIG. 58 ) disengaged from the cleaning roller  1024   a . Tape drive roller  1062  then rotates clockwise to pull tape backward, in the opposite direction. Tape driven in this direction causes the length of tape between tape drive roller  1062  and the supply roll  1006  to increase allowing the movable roller  1060  to move toward the card path. Simultaneously the length of tape between the take up roll  1004  and the tape drive roller  1066  is decreased forcing the movable roller  1068  to move away from the card path. The length of tape moved in this direction will determine the amount of tape that will be reused. This length is selectable and ranges from zero (e.g. no reuse), to a length equal to the forward tape movement (e.g. 100% reuse). If the tape length moved backwards is less than the tape length moved forward, the movable roller  1068  will not reaches its ready position. In this case the take up roll  1004  will be driven clockwise causing the movable roller  1068  to move away from the card path until it reaches its ready position. The turret body is then rotated in a counterclockwise direction 180 degrees to place cleaning roller  1024   b  in position for cleaning. The rest of the roller cleaning cycle is then repeated for the cleaning roller  1024   b.    
         [0262]    It should be noted that both rollers do not need to be cleaned during one card cycle. The first roller  1024   a  could be cleaned, the turret returned to its home position, then another card passed between the cleaning rollers  1024   a, b , followed by the cleaning of the second cleaning roller  1024   b.    
       Rollers 
       [0263]    Rollers are often used, for instance, in card personalization systems. Typically, rollers are used to transport cards from processing module to processing module, including entry of cards into processing modules and exiting of cards out of processing modules. In addition, rollers are used within processing modules, such as, in input hoppers for picking cards, or in graphics modules passing cards from a set of rollers used for entry of a card to a set of rollers employed for processing the graphics onto a particular card. In the past, rollers have employed a hub portion having a cylindrical body connected to the hub, and providing a surface for gripping a card. Further, a set screw applied through the body and the hub attaches the roller to a rotatably driven shaft. 
         [0264]    Although these designs may be suitable for their purposes, improvements may still be made upon rollers. There is still a need to prevent stripping of set screws, set screws becoming loose during operation, and dirt entering the set screw head. Further, there is a need to provide an improved structure that is convenient for assembly, while still maintaining cost effective parts. The following description illustrates the features and improvements made upon existing designs of rollers in accordance with the principles of the present invention. 
         [0265]      FIGS. 46 to 48  illustrate one preferred embodiment of a roller. The roller  400  includes a body  410  having top  421   a , a bottom  421   b . Preferably, the body is a cylindrical body having an opening  417  through the top  421   a  and the bottom  421   b , that defines an inner diameter  411   b  and outer diameter  411   a . More preferably, the cylindrical body  410  is constructed of a compliant or resilient material such as rubber. The roller  400  includes a hub  430  connected to the cylindrical body and having an opening  433  through the top  431   a  and bottom  431   b . The opening  433  defines an inner diameter  437   b  and an outer diameter  437   a . At least two through holes  435  oppositely disposed are transversely located to the opening  433 . 
         [0266]    The cylindrical body  410  may be connected by an interference fit with the hub  430 . In addition, the cylindrical body  410  may be molded onto the hub  430 . 
         [0267]    As shown in  FIGS. 49   a  and  49   b , a retention member  450 , such as a pin, may be fitted into one of the oppositely disposed transverse through holes  435  and connected to a rotatably driven shaft (not shown). The shaft also would include a corresponding through hole, so that the retention member  450  may fit through the shaft and across to the other oppositely disposed transverse through hole  435 . Preferably, the retention member extends a length out from the oppositely disposed transverse through holes. 
         [0268]    As shown in  FIGS. 46 to 48 , a lip portion  413  resides about the circumference defined by the outer diameter  411   a  of the cylindrical body  410 . Preferably, the lip portion  413  is flexible as the cylindrical body is constructed of a compliant material. The lip portion  413  includes a width and defines a recess area  415  between the lip portion  413  and the inner diameter  411   b . The lip portion provides a retention means for the retention pin  450  ( FIGS. 49   a  and  49   b ). Preferably, the recessed area resembles a dished out area about the circumference of the cylindrical body  410 .  FIGS. 46 to 48  illustrate the recess area about the entire circumference of the cylindrical body  410 . However, it will be appreciated that any suitably sized recess area may be employed to accommodate retaining the pin. 
         [0269]    Preferably, the hub is constructed of metal parts. However, it will be appreciated that a plastic material may also be employed. 
         [0270]      FIGS. 50 to 53  illustrate another preferred embodiment of a roller. The roller  400   a  includes a hub  430   a  and body  410   a  similar to the hub  430  and body  410  described above. Two recess areas  415   a  are illustrated at each of the oppositely disposed transverse holes  435 . As shown in  FIGS. 51 to 53 , the cylindrical body employs different sized recesses  415   a  than the dished out recess area  415  above. The hub  430   a , and other features of the body  410   a  are substantially similar to the descriptions above and are not further detailed. 
         [0271]    In addition to other advantages, the rollers of the present invention provide improved retention structures. For instance, the transverse holes and recess area in cooperation with a retention member, such as a pin, eliminate the need for a set screw. The roller offers the advantages of preventing stripping of its retention parts, and an arrangement that is more difficult to wear. Further, the roller of the present invention provides a more convenient configuration for assembly and disassembly. For instance the resilient lip may be depressed to remove the retention pin without the need for a screwdriver. In addition to the above advantages, the roller of the present invention provides a structure that is cost effective and maintenance friendly. 
       Take Up Roll Spindle 
       [0272]    Take up rolls are often used in the processing modules of a card personalization system, for instance, in a print module, a graphics module or a cleaning module, such as described above. Take up rolls collect used web product for disposal after a supply of web product, such as from a supply roll that is spent. Typically, during collection of used web product, the take up roll core bears a high amount of force from the web product being tightly wound onto it. The force of the wound web product around the core can cause the core to compress which makes it difficult for the web product and core to be removed from the spindle for disposal. Present designs have disposed of both the take up roll core and the used web product wound around the core. Such designs increase costs and consume time, as the take up roll must be replaced after each roll of used web product is collected. In addition, local restrictions may require the core to be removed from the web product and disposed of separately 
         [0273]    Therefore, there is a need to provide a spindle that enables users to conveniently dispose of used web product without having to remove and dispose of the core. Furthermore, there is a need to provide a spindle for a take up roll that can be reused to minimize the replacement of parts, thereby reducing costs and increasing time efficiency. 
         [0274]      FIGS. 61-62  illustrate one preferred embodiment of a spindle  1100  for a take up roll. The spindle  1100  includes a top  1120   a  and a bottom  1120   b . First oppositely disposed primary housing portions  1130  and  1135  and second oppositely disposed secondary housing portions  1132  (shown in  FIGS. 63-63   a ) define an outer side surface  1127  of the spindle  1100 . The primary and secondary housing portions  1130 ,  1132 ,  1135  further define a cavity  1190  (shown in  FIGS. 63-63   a ) extending from the top  1120   a  to the bottom  1120   b . The secondary housing portions  1132  are moveable relative to and in contact with the primary housing portions  1130 . Preferably, the primary housing portions  1130  and  1135  are larger than the secondary housing portions  1132 , and define a majority of the outer surface  1127 . The outer side surface  1127  is substantially cylindrical for winding used web product. A first plate  1121  is disposed on the top  1120   a  of the spindle  1100 . Likewise, a second plate  1123  is oppositely disposed from the first plate  1121  at the bottom  1120   b  of the spindle  1100 . The second plate  1123  includes a shaft portion  123   a  that is adaptable for connection to a drive shaft (not shown) for driving the spindle  1100 . 
         [0275]    Preferably, both plates  1121 ,  1123  include a cut-out surface  1121   b  defining a ridge  1121   a  about the circumference of the plate, and cooperating with lip portions  1133 ,  1134  connected to the housing portions  1130 ,  1132 . The housing portions are retained within the cut-out surface  1121   b  and are restricted from moving past the ridge  1121   a . As shown in  FIG. 62 , the cut-out surface  1121   b  and ridge  1121   a  are illustrated at the first plate  1121 . It will be appreciated that similar structures may be employed on the second plate  1123  and bottoms of the housing portions  1130 ,  1132 . 
         [0276]    As best shown in  FIG. 62 , the spindle  1100  includes a rotating member  1150  disposed within a portion of the cavity  1190  and extending coaxially in the cavity  11190  between the top  1120   a  and the bottom  1120   b . The rotating member  1150  is operatively connected to a handle  1140  disposed on the first plate  1121 . The rotating member  1150  and the handle  1140  are rotatably connected to plates  1121  and  1123 , and are rotatable relative to the first plate  1121 , second plate  1123 , and the housing portions  1130 ,  1132 . The rotating member  1150  includes at least two flanges  1150   a  that protrude radially outward from the rotating member  1150 . Rollers  1152  are operatively connected to the rotating member  1150 , and are contactable with the primary and secondary housing portions  1130 ,  1135  and  1132 . Preferably, the rollers  1152  are connected to the rotating member  1150  through resilient o-rings so as to allow restricted rolling movement between the rollers  1152  and the rotating member  1150 . More preferably, the rotating member  1150  contains the same o-rings  1154  commonly connected with the rollers  1152 , such as in a figure eight configuration. In  FIG. 62 , o-rings  1154  are illustrated as dashed lines at the tops and bottoms of both the rotating member  1150  and the rollers  1152 . 
         [0277]    In  FIG. 62 , two oppositely disposed flanges  1150   a  are disposed at a top  1155   a  of the rotating member  1150 , and extend longitudinally downward from the top  1155   a  along a length of an outer side surface of the rotating member  1150 . It will be appreciated that other configurations and number of flanges also may be employed. For instance, flanges may extend longitudinally downward along the entire length of the rotating member  1150 . Likewise, oppositely disposed flanges, such as  1150   a , may also be disposed at a bottom  1155   b  of the rotating member  1150 . Bosses projecting down from surface  1121   b  of the first plate  1121  form stops  1121   c  that limit the range of rotation of the rollers  1152 , rotating member  1150  and flanges  1150   a , as best shown in  FIGS. 63 ,  63   a . It will be appreciated that stops, such as stops  1121   c , may be formed on the second plate  1123 . The function of the rollers  1152  and rotating member  1150  are further detailed below. 
         [0278]    A locking mechanism  1142  is operatively connected to the handle  1140 . The locking mechanism  1142  includes a detent  1142   a  operatively connected thereto, and is actuatable into a locked position so as to prevent rotation of the handle  1140  and rotating member  1150 . In the locked position, the detent  1142   a  stops the handle  1140  from rotating and stops the rotating member from rotating. The detent  1142   a  of the locking mechanism  1142  is releasable from the locked position, so as to enable rotation of the handle  1140  and rotating member  11150 . 
         [0279]      FIGS. 63-63   a  illustrate examples of the spindle  1100  in a first configuration and a second configuration, respectively. The first configuration represents the spindle  1100  in a position prior to taking up web product and during the taking up of web product. The second configuration represents the spindle in a position such that web product can be removed. In  FIG. 63 , the spindle  1100  includes a first diameter  1125  during the first configuration. The rotating member  1150  is shown in a position where the flanges  1150   a  are held against the rollers  1152  that push the secondary housing portions  1132 , such that the secondary housing portions  1132  are pushed outward from the cavity  1190  to define the first diameter  1125 . 
         [0280]    Preferably, the primary housing portions  1130  and  1135  include an inner surface facing the cavity  1190  provided with a tapered surface  1130   a . More preferably, the primary housing portion  1130  is fixed to at least one of the plates  1121 ,  1123  through holes  1130   c  that correspond to holes (not shown) in the plates  1121 ,  1123 . It will be appreciated that the primary housing portion  1130  may be fixed to both plates  1121 ,  1123 . A suitable fastener, such as a screw, may be employed to fix the one housing portion  1130  to the plates  1121 ,  1123 . The other primary housing portion  1135  is moveable within a cut-out surface, such as cut-out surface  1121   b  of the plate  1121 , and is retained by a ridge and lip structure, such as ridge  1121   a  and lip  1133  described above. The tapered region  1130   a  tapers or slants in a direction toward the outer surface  1127 . The secondary housing portions  1132  include side surfaces  1132   a  that contact the tapered surface  1130   a  of the primary housing portions, and move relative to the primary housing portions  1130  and  1135 . Preferably, the side surfaces  1132   a  are tapered. As shown in  FIGS. 63 and 63   a , the secondary housing portions  1132  include the outer surface  1132   b  being smaller than the inner surface  1132   c . Preferably, the secondary housing portions are substantially trapezoidal or wedge shaped in cross section. 
         [0281]    In  FIG. 63   a , the second configuration represents the spindle  1100  in a position for removing used web product. As shown in  FIG. 63   a , the secondary housing portions are shown as being moved inwards toward the cavity  1190 . In addition, the movable primary housing portion  1135  is shown as being moved inwards toward the cavity  1190 . A second diameter  1125   a  is defined by movement of the housing portions into the second configuration. The rotating member  1150  is shown moved counterclockwise, relative to the arrangement illustrated in  FIG. 63 , in a position where the flanges  1150   a  are rotated away from rollers  1152 . The movement of the rotating member  1150  enables the rollers  1152  to roll against the surface of the rotating member  1150  and the inner surface  1132   c  of the secondary housing portions  1132  as rollers  1152  move. As shown in  FIG. 63   a , movement of the rollers  1152  allows the secondary housing portions  1132  to move inwards and collapse to the cavity  1190 . Similarly, the movable primary housing portion  1135 , is moved from its position in the first configuration, and is enabled to move inwards and collapse to the cavity  1190 . The moved housing portions define the second diameter  1125   a . The second diameter  1125   a  is smaller than the diameter defined in the first configuration enabling the now loosely wound web product around the spindle  1100  to be easily removed by sliding the web product up and off of the spindle. 
         [0282]    When the locking mechanism detent  1142   a  is defeated the handle  1140  can be rotated with the connected rotating member  1150  so as to release locking mechanism  1142  and actuate the spindle  1100  into the second configuration to enable removal of web product. As shown in  FIG. 63   a , the rotating member  1150  is moved counterclockwise into the second configuration. To move the rotating member  1150  and rollers  1152  back to the first configuration, the handle  1140  is rotated in the clockwise direction until the rollers  1152  contact stops, such as stops  1121   c  and the cavity  1190  is expanded to its maximum. In this position the lock moves into its detent position locking the position of the handle and preventing the rotating member  1150  from rotating. 
         [0283]    When web product is wound around the spindle  1100  of a take up roll, a substantial amount of force is exerted upon the rollers  1152 . Preferably, the spindle  1100  and its parts are constructed of a metal material so as to provide a durable, long lasting core that can counter the force exerted by the web product wound around the spindle  1100 . More preferably, the rollers  1152  are cylindrical in shape, such that the force required to move the rollers is the force necessary to overcome the friction associated with rolling motion and not sliding. The motion of rollers  1152  against both the rotating member  1150  and the secondary housing  1132  portions is a rolling motion and requires minimal force to initiate even if the compressive force on the outer spindle surface is great. The cylindrical shape of the rollers provides an arrangement such that the rotating member  1150  and the rollers  1152  can be easily moved from the first configuration to the second configuration to change the diameter for removing web product when the rotating member  1150  is not locked by a locking mechanism, such as  1142  above. 
         [0284]    In addition to processing modules of a card personalization system, the spindle  1100  may be used for other take up rolls employed for other products, such as but not limited to paper, plastics or other products being wound on a core. In addition to other advantages, the spindle of the present invention enables users to conveniently dispose of used web product without having to remove and dispose of the core with the used web product. Further, the spindle of the present invention provides a take up roll that can be reused to minimize the replacement of parts, thereby reducing costs and increasing time efficiency. 
       Embossing Module 
       [0285]    Details of portions of the embossing module  1200  are illustrated in  FIGS. 64-68 . The embossing module  1200  is configured and arranged to form embossed data on the cards. The embossed data can be alphabetic, numeric, symbols, and other characters and combinations thereof. These will hereinafter be referred to generically as characters. The embossed characters typically pertain to cardholder information, such as cardholder name, account number, card expiration date, and the like. 
         [0286]      FIG. 67  illustrates a portion of the embossing module  1200 . The module  1200  includes an embossing wheel  1202  composed of a punch side  1204  and a die side  1206 . The punch side  1204 , which is of known construction, contains a plurality of punches arranged in a circular fashion. Each punch contains a punch character used to produce a corresponding embossed character on the card. The die side  1206 , also of known construction, contains a plurality of dies arranged in a circular fashion. Each die contains a die character that corresponds to a respective oppositely positioned punch character. When the punch is actuated into engagement with a card, the corresponding die is actuated into engagement on the opposite side of the card from the punch, thereby creating a corresponding embossed character on the card. During embossing, the card will be suitably positioned between the punch and die sides  1204 ,  1206 . After embossing, the card will exit the module through an exit path  1208 . The wheel  1202  is driven by a motor  1210 . Further, a punch actuator and a die actuator are provided to actuate the individual punches and dies of the punch side  1204  and die side  1206  during embossing. 
         [0287]    The construction and operation of the embossing module  1200  described so far are conventional. One way to increase the card throughput of the system  10  is to reduce the time needed to emboss a card. Embossing time is based, in part, on how fast the punches and dies of the wheel  1202  can be brought into position during embossing, and on how fast the punches and dies can be actuated into and out of engagement with the card. Therefore, reductions in the rotation time of the embossing wheel  1202  and in the actuation times of the punches and dies can increase production rate. Although increasing the speed of rotation of the wheel  1202  during movements, and increasing punch and die actuation speeds is possible, these speed increases can create problems if not properly accounted for. 
         [0288]    With reference to  FIG. 64 , an actuator  1220  that can be used to actuate the punches is illustrated. An identical actuator will be provided to actuate the dies. The actuators  1220  will be suitably positioned relative to the punch side  1204  and die side  1206  to be able to actuate the respective punches and dies. 
         [0289]    The actuator  1220  includes a drive motor  1222 , preferably a servo motor, a plunger  1224  that is slidably disposed within a housing  1226 , and a drive cam  1228  that is fixed to a shaft  1230  of the motor  1222  for driving the plunger  1224 . The motor  1222 , housing  1226  and plunger  1224  are shown in cross-section for clarity and to illustrate details thereof. The use of a cam to drive a plunger is known from DataCard Corporation&#39;s model 150i embosser, available from DataCard Corporation of Minnetonka, Minn. 
         [0290]    The plunger  1224  includes an actuating end  1232  that actuates the punch/die when the plunger is actuated to an actuating position. The opposite end of the plunger  1224  includes a follower  1234  that rides on the outer surface of the cam  1228  as the cam is rotated. The outer surface of the cam  1228  is eccentric, whereby as the cam rotates, the plunger  1224  is driven out during an actuation cycle. The plunger  1224  is biased by a suitable mechanism, such as a spring  1236 , back to a retracted position. A pin  1238  extends through the follower  1234  and connects to a bearing  1240  that is disposed within an elongated slot  1242  defined in a block  1243  connected to the housing  1226 . The bearing  1240  helps to keep the follower axis aligned with the cam axis to ensure line contact between the two, and thereby realize maximum life. 
         [0291]    The cam  1228  is configured to be clamped onto the shaft  1230  by a locking screw  1244 . As illustrated in  FIG. 65 , a sleeve  1246  is disposed between the cam  1228  and the shaft  1230 . The sleeve  1246  acts to absorb wear instead of the shaft  1230 . As a result, the shaft needs to be replaced with less frequency. Instead, the sleeve  1246  can be replaced as needed. 
         [0292]    The sleeve  1246 , which is preferably made of metal, such as stainless steel, comprises a pair of constant diameter end portions  1248   a ,  1248   b  and a collapsible central portion  1250  about which the cam  1228  is disposed. The central portion  1250  comprises a pair of cut-out fingers  1252   a ,  1252   b  that are able to collapse into engagement with the outer surface of the shaft  1230  as the cam  1228  is clamped onto the shaft. The end portions  1248   a ,  1248   b , however, are substantially unaffected by the collapse of the fingers  1252   a ,  1252   b  and maintain a substantially constant diameter. 
         [0293]    An important feature of the actuator  1220  is that the cam  1228  is directly mounted on and driven by the motor shaft  1230 . In previous embossers, the cam is typically mounted on a shaft that is separate from the motor shaft. As a result, a coupling is needed to couple the two shafts. When two shafts are used, if exact alignment of the shafts is not achieved, or if the shafts become misaligned during use, excessive shaft wear and shaft failure can results. However, it is extremely difficult to exactly align the shafts with each other, so these problems cannot be entirely eliminated when separate shafts are used. 
         [0294]    In the actuator  1220 , as shown in  FIG. 64 , the cam  1228  is mounted directly on the motor shaft  1230 , which eliminates the alignment issues when two shafts are used. Each end portion  1248   a ,  1248   b  of the sleeve  1246  surrounds the shaft and is supported by the housing  1226  within a sleeve bearing  1254   a ,  1254   b . Further, the opposite end of the shaft  1230  is supported by a bearing  1256 . An intermediate portion of the shaft  1230 , near the top of the motor housing, is provided a reduced diameter section  1258 . A bearing  1260  disposed in the motor housing surrounds the section  1258 . The bearing  1260  acts only as a retainer to retain the shaft  1230 , but the bearing  1260  is non-functional in that it does not rotationally support the shaft  1230 . The reduced diameter section  1258  allows the shaft  1230  to bend and float slightly during use. However, the sleeve bearings  1254   a ,  1254   b  maintain the proper orientation of the shaft  1230  at the location of the cam  1228  and absorb the embossing loads. Thus, the shaft  1230  is supported by three bearings  1254   a ,  1254   b ,  1256  rather than the customary four bearings that are used to support two separate shafts coupled by a coupling. 
         [0295]    Returning now to  FIG. 67 , the motor  1210  is preferably a servo motor. To achieve fast move times of the embossing wheel  1202 , large current pulses are provided to the servo motor  1210  to actuate the motor. However, when the embossing wheel  1202  stops at a desired position, the large current pulses tend to cause the wheel  1202  to oscillate slightly back and forth from the desired position. This oscillation can create slight inaccuracies in the positioning of the resulting embossed character on the card. Therefore, a reduction or elimination of the oscillation can improve the accuracy of the embossing process. 
         [0296]    As illustrated in  FIG. 67 , a friction brake  1270  is positioned adjacent the end of the shaft  1272  of the motor  1210 . The friction brake  1270  includes a brake shaft  1274  that is coupled to the motor shaft  1272  by a rigid coupling  1276 . The brake  1270  and coupling  1276  are shown in cross-section to illustrate details thereof. 
         [0297]    The brake  1270  preferably comprises a magnetic particle brake. Magnetic particle brakes are known in the art, and generally include a disk that is coupled to the shaft  1274 , with the disk being surrounded by magnetic particles. When an electric current is applied to the particles, a force is applied to the disk tending to retard rotation of the shaft  1274 . Removal of the electrical current removes the retardation force. As practiced, a current is continuously applied to the brake  1270  to produce a constant retardation force. However, it is contemplated that electrical current could be applied only when the retardation force is necessary. 
         [0298]    It is to be realized that other friction devices could be used in place of a magnetic particle brake, as long as the friction device is capable of retarding rotation of the shaft  1274 . For example, a spring loaded friction device could be used. 
         [0299]    The brake  1270  is secured to a mounting bracket  1278  that in turn is fixed to stationary structure  1280  of the module  1200  by fasteners  1282 . The brake  1270  is secured to a central portion  1284  of the bracket via fasteners  1286  (only one fastener is visible in  FIG. 67 ). The bracket  1278 , which is illustrated in detail in  FIG. 68 , includes a pair of compliant arms  1288 ,  1290  that extend outwardly from the central portion  1284 . 
         [0300]    With the mounting of the brake  1270  on the bracket  1278 , the brake  1270  is prevented from rotating. However, the compliant arms  1288 ,  1290  permit flexing of the brake  1270 , to thereby accommodate forces that can cause slight misalignment of the shafts  1272 ,  1274 . 
         [0301]    The operation of the brake  1270  is as follows. A current is supplied to the motor  1210  to rotate the wheel  1202  to the desired position. The rotation force is sufficient to overcome the retardation force applied by the brake  1270 . Once the desired position is reached, the current to the motor is stopped. However, forces set-up in the servo motor after removal of the current tend to cause the shaft  1272  to oscillate back and forth slightly. However, the retardation force provided by the brake  1270  is larger than the forces tending to cause oscillation. As a result, the retardation force of the brake  1270  maintains the wheel  1202  at the desired position without the oscillation, thereby increasing the accuracy of the embossing process. 
         [0302]    The above specification, examples and data provide a complete description of the manufacture and use of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.