Abstract:
The invention is directed to a High Page Count method for mail inserters. The High Page Count method utilizes multiple source feeders to deposit source material onto a moving track at a rate equal to the speed at which the track operates. The High Page Count method is designed to optimize the mail inserter process by ensuring that no track position goes unfilled.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention may be described as an improved method for optimizing mail inserters to match the document feeder output with the speed of the track that carries the unique document downstream where it is grouped with common documents and is inserted into an envelope.  
         DESCRIPTION OF RELATED ART  
         [0002]    In a typical mail inserter used for statement processing or the like, one feeding unit serves as a master document feeder. This master document feeder is generally the first device on the track from start to end or from upstream to downstream track positions. As the master document travels downstream, all other machine functions will not be allowed to operate unless the master document is present. For example, without the master, an outer envelope will not be pulled; without the master, no marketing material will be pulled; without the master, the postage meter will not fire.  
           [0003]    By definition, the absence of the master document feeder is an empty track position. In normal operation, it is common occurrence to have a track outrun the master feeder. This is especially true if the master feeder is collating multiple pages together as a set. When the base machine outruns the master feeder, the feeder is not ready to deposit its material onto the track, and thus, loses its window of opportunity.  
           [0004]    Obviously, the optimal running state of the machine is always to maintain a full track with no empty positions. If empty positions occur, there is a wasted machine cycle, which lessens the machine&#39;s actual output and adds unnecessary wear to the machine.  
           [0005]    A unique and active solution to optimize the machine&#39;s performance is to provide a means by which the track is to be kept full by incorporating additional master feeders into the system. A total of two or more master feeders can be configured in succession down the track. If an upstream master feeder misses its window of opportunity and leaves an empty track position, the downstream feeder can ensure optimal machine operation by filling the empty position.  
         SUMMARY OF THE INVENTION  
         [0006]    This invention may be described as an improved method for optimizing mail output by utilizing more than one source feed unit to match the speed of the track. By matching the speed of the track, the source feed units ensure that there is no empty position on the track, and therefore, allow the mail inserter system to operate at maximum capacity.  
           [0007]    The High Page Count method can be configured in at least three different systems. In the first system an upstream source feed unit deposits the source material onto the track as fast as it can. Unfortunately, because the track operates at a rate in excess of what the upstream feeder can deposit source material at, there will occasionally be an empty track position. In this situation, the downstream feeder senses the empty track position and deposits it&#39;s source material onto the track, thereby ensuring that no track position goes unfilled.  
           [0008]    In the second system, the High Page Count method introduces a common feeder located upstream from the upstream source feed unit. This common feeder places common material onto the track at a rate equal to the track speed. As the common material gets to the upstream source feed unit, the upstream source feed unit will deposit it&#39;s source material onto the track position to accompany the common material. Again, as the upstream source feeder cannot match the rate of deposit with the speed of the track there will occasionally be an empty track position. In this situation, the downstream source feed unit will sense that the upstream source feed unit did not deposit source material onto a track position and will deposit it&#39;s source material onto the track, thereby ensuring that every track position receives source material.  
           [0009]    In the third system, the High Page Count method is configured such that the source feed units are positioned across from each other at the same track position. Once again, the primary source feed unit cannot match the rate of deposit with the speed of the track and the secondary source feed unit deposits it&#39;s source material when it detects that the primary source feed unit cannot make a deposit.  
           [0010]    Each of these three systems for the High Page Count method presents a unique solution for optimizing the mail inserter process by utilizing multiple source feed unit to match the rate at which the track operates. Furthermore, each of these three systems can be configured such that the downstream output stations can be placed at a right angle to the upstream source feed units thereby creating a more compact design.  
           [0011]    In each of the three systems for the High Page Count method, because the source material is being deposited from at least two source feed units the source material is in a random order on the track. Therefore, it is a goal of the High Page Count method, at the downstream section of the operation, to correct the randomness of the source material placement on the track and reorder the source material such that all the source material from the primary source feed unit is sorted into one path, and all of the source material from the secondary source feed unit is sorted into another path. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    [0012]FIG. 1 is a block diagram of a two source feed unit layout of the present invention.  
         [0013]    [0013]FIG. 2 is a flow chart of the high page count method with a second source feed unit downstream from the primary source feed unit.  
         [0014]    [0014]FIG. 3 is a block diagram of a common feeder located upstream from the two source feed units.  
         [0015]    [0015]FIG. 4 is a flow chart for the high page count method wherein a common feeder is located upstream from the two source feed units.  
         [0016]    [0016]FIG. 5 is a block diagram of the source feed units sharing the same track position.  
         [0017]    [0017]FIG. 6 is a flow chart for the high page count method wherein the two source feed units share the same track position.  
         [0018]    [0018]FIG. 7 is a block diagram of the downstream output station.  
         [0019]    [0019]FIG. 8 is a block diagram of the high page count method in an alternate embodiment with the downstream output station shown perpendicular to the upstream source feed units. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0020]    For the purpose of promoting an understanding of the principles of the invention, references will be made to the embodiments illustrated in the drawings. It will, nevertheless, be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention illustrated herein being contemplated as would normally occur to the one skilled in the art to which the invention relates.  
         [0021]    Turning to FIG. 1, there is shown a block diagram of a two source feed unit layout for System  1  of the present invention.  
         [0022]    System  1  comprises at least two source feeder units  10  and  11 . A first source feed unit  10  located at the beginning of a track  12  serves as a primary source feed unit  10 . A second source feed unit  11  is located downstream from the primary source feed unit  10 . Each source feed unit contains source material  17 . The source material  17  represents unique material that is customized for individual purposes. For example, if the high page count method is used for compiling billing material the source material  17  would represent an individuals billing statement, which is unique to a particular individual. Additionally, each source feed unit  10  and  11  contains a sensor  15  that detects whether the track  12  is empty or whether the track has already been loaded with source material  17 .  
         [0023]    In order to correct the randomness that occurs as a result of multiple source feed units operating on a single track, each system described herein contains at least one output station  4 A and  4 B for each source feed unit  10  and  11 , as shown in FIG. 7. Each output station  4 A and  4 B contains multiple sorting paths  14 A-D, which allow the mail to be sorted in sequential order. For instance, the mail that is produced from source material  17 , as shown in FIG. 1, from source feed unit  10  is directed to a collector, such as bin  5 A, at output station  4 A. Mail that is generated using source material  17 , as shown in FIG. 1, from source feed unit  11  is similarly directed to a collector, such as bin  5 C, at output station  4 B. Each output station  4 A and  4 B contains at least one bin  5 , however, an alternate embodiment would contain multiple collectors, such as bins  5 A-D, so that depending on line speed, economics, and operator speed, in the event of overflow of one bin  5 A a backup bin  5 B is present to accept the overflow mail. The output stations  4 A and  4 B would know what mail to receive because each track section  16  is monitored such that the system knows whether source feed unit  10  or source feed unit  11  deposited a piece of source material  17  on a particular track section  16 . Furthermore, each output station  4 A and  4 B contains diverters  19  to direct the mail from its respective source feed unit  10  and  11  into the collectors, such as the bins,  5 A-D, at the output stations  4 A and  4 B. The output stations  4 A and  4 B of this invention operate continuously, wherein a downstream track section  7  of the output stations  4 A and  4 B moves at a speed that is faster than an upstream track section  6  at the upstream source feed units  10  and  11 .  
         [0024]    Turning to FIG. 2, there is shown a flow chart of the high page count method with the second source feed unit  11  downstream from the primary source feed unit  10 . The High Page Count method has the ability to ensure that there are no empty track spaces  16 . The method begins by putting the track  12  in motion. Step  22  determines whether the primary source unit feeder  10  is ready. The primary source feeder unit  10  is ready when it has compiled all of the source material  17  that it needs for an individual. If the response to step  22  is YES, the primary source feed unit  10  deposits its source material  17  onto the track space  16 , as is shown in step  24 . After the primary source feeder  10  has deposited the source material  17  onto the track space, step  26  shows that the track  12  is advanced one position and the cycle begins again at step  22  for the primary source feed unit  10 . Alternatively, if the response to step  22  is NO, the primary source feed unit  10  does not deposit any source material  17  onto the track space  16  and automatically proceeds to step  26  wherein the track  12  is advanced one position.  
         [0025]    At the same time the primary source feed unit  10  is running through its cycle to determine whether it will deposit source material  17  onto the track space  16 , the secondary source feed unit  11  is running through a similar cycle. As is illustrated by step  28 , the secondary source feed unit  11  begins its cycle by determining whether the secondary source feed unit  11  is ready. As with the primary source feed unit  10 , the secondary source feed unit  11  is ready when it has compiled all of the source material  17  that it needs for an individual. If the response to step  28  is NO, the secondary source feed unit  11  automatically proceeds to step  34  wherein the secondary source feed unit  11  waits until the track  12  is advanced one position and the secondary source feed unit  11  begins its cycle again with step  28 .  
         [0026]    If the response to step  28  is YES, the secondary source feed unit  11  proceeds to step  30  and determines whether the track space  16  located directly in front of the secondary source unit  11  is empty. If the response to step  30  is NO, the secondary source feed unit  11  again automatically proceeds to step  34  wherein the secondary source feed unit  11  waits unit the track  12  is advanced one position and the secondary source feed unit  11  begins its cycle again with step  28 .  
         [0027]    If the response to step  30 , however, is YES, the secondary source feed unit  11  will deposit its source material  17  onto the empty track space  16  located directly in front of the secondary source feed unit  11 . After the secondary source feed unit  11  deposits its source material  17  the secondary source feed unit  11  then proceeds to step  34  wherein the secondary source feed unit  11  waits for the track  12  to advance one position and the secondary source feed unit  11  begins its cycle again with step  28 .  
         [0028]    Turning to FIG. 3 there is shown a block diagram of a common feeder  13  located upstream from the two source feed units  10  and  11  for System  2  of the present invention.  
         [0029]    System  2  comprises a common feeder  13  located upstream from at least two source feeder units  10  and  11 . The common feeder  13  contains common material  18 . Common material  18  represents material that must be included in every piece of mailing. For instance, if the High Page Count method is used for sending out billing statements, the common material may be a standard form that accompanies every billing statement. The common feeder  13  is located at the beginning of the track  12 . The first source feed unit  10  is located downstream from the common feeder  13  and upstream from the secondary source feed unit  11 . The first source feed unit  10  serves as the primary source feed unit. The second source feeder unit  11  is located downstream from both the primary source feed unit  10  and the common feeder  13 . Each source feed unit  10  and  11  contains source material  17  and the central processing unit of the system (CPU) monitors source feed units  10  and  11  to verify whether the primary and secondary source feed units  10  and  11  have deposited the source material  17  onto the track space  16  on track  12 .  
         [0030]    The process whereby the High Page Count method operates with a common feeder  13  is similar to the process where there are multiple source feed units  10  and  11 . However, the source feed units  10  and  11  will not have a step that will ask whether the track space  16  is empty. When the High Page Count method runs with a common feeder  13  the only time a track space  16  will be empty is when it initially reaches the common feeder  13 . The common feeder  13  then deposits its common material  18  onto the track  12 , and the track  12  is advance one position. When the track space  16  gets to the source feed units  10  and  11  the track space  16  has already been filled with common material  18 . Therefore, instead of determining whether the track space  16  is empty, the source feed units  10  and  111  are reprogrammed to determine whether the track space  16  has source material  17 .  
         [0031]    Turning to FIG. 4, there is shown a flow chart for the High Page Count method of FIG. 3 wherein a common feeder  13  is located upstream from the two source feed units  10  and  11 .  
         [0032]    The cycle for System  2  begins by putting the track  12  in motion and the common feeder  13  deposits common source material  18  onto the track  12 .  
         [0033]    Step  112  determines whether the primary source unit feeder  10  is ready. The primary source feed unit  10  is ready when it has compiled all of the source material  17  that it needs for an individual. If the response to step  112  is YES, the primary source feed unit  10  deposits its source material  17  onto the track space  16 , as is shown in step  114 . After the primary source feed unit  10  has deposited the source material  17  onto the track space  16 , step  116  shows that the track  12  is advanced one position and the cycle begins again at step  112  for the primary source feed unit  10 . Alternatively, if the response to step  112  is NO, the primary source feed unit  10  does not deposit any source material  17  onto the track space  16  and automatically proceeds to step  112  wherein the track  12  is advanced one position.  
         [0034]    At the same time the primary source feed unit  10  is running through its cycle depositing source material  17  onto the track space  16 , the secondary source feed unit  11  is running through a similar cycle. As is illustrated by step  120 , the secondary source feed unit  11  begins its cycle by determining whether the secondary source feed unit  11  is ready. As with the primary source feed unit  10 , the secondary source feed unit is ready when it has compiled all of the source material  17  that it needs for an individual. If the response to step  120  is NO, the secondary source feed unit  11  automatically proceeds to step  126  wherein the secondary source feed unit  11  waits until the track  12  is advanced one position and the secondary source feed unit  11  begins its cycle again with step  120 .  
         [0035]    If the response to step  120  is YES, the secondary source feed unit  11  proceeds to step  122  and determines whether the track space  16  located directly in front of the secondary source unit  11  is empty. If the response to step  122  is NO, the secondary source feed unit  11  again automatically proceeds to step  126  wherein the secondary source feed unit  11  waits unit the track  12  is advanced one position and the secondary source feed unit  11  begins its cycle again with step  120 .  
         [0036]    If the response to step  122  is YES, the secondary source feed unit will deposit its source material  17  onto the empty track space  16  located directly in front of the secondary source feed unit  11 . After the secondary source feed unit  11  deposits its source material  17  the secondary source feed unit  11  then proceeds to step  126  wherein the secondary source feed unit  11  waits for the track  12  to advance one position and the secondary source feed unit  11  begins its cycle again with step  120 .  
         [0037]    Turning to FIG. 5 there is shown a block diagram of the source feed units  10  and  11  sharing the same track position for System  3  of the present invention.  
         [0038]    System  3  comprises two source feed units  10  and  11  located across from each other at the same track space  16  on track  12 . Unlike the previously described arrangements of the High Page Count method where the source feed units do not share the same track position, this arrangement requires a greater level of timing to ensure that the source feed units  10  and  11  do not collide the source material  17  when they are placed onto the track  12 . In this system, as in the other two systems, source feed unit  10  operates as the primary source feed unit, and source feed unit  11  operates as the secondary source feed unit. Both source feed units  10  and  11  contain source material  17  and the CPU of the system monitors source feed units  10  and  11  to verify whether the primary and secondary source feed units  10  and  11  have deposited the source material  17  onto the track space  16  on track  12 .  
         [0039]    Turning to FIG. 6 there is shown a flow chart for the High Page Count method of FIG. 5 having said two source feed units  10  and  11  sharing the same track space  16  on track  12 . The method for System  3  begins at step  50  by putting the track  12  in motion and beginning a cycle. Step  56  determines if the primary source feed unit  10  is ready to deposit its source material  17  onto the track  12 . If the answer to step  56  is YES, the primary source feed unit  10  proceeds to step  58  whereby the primary source feed unit  10  determines whether the track  12  is empty. If the response to step  58  is YES, the primary source feed unit  10  deposits its source feed material  17  onto the track  12  and automatically renews its cycle by proceeding directly back to step  52 . If the response to step  58  is NO, indicating that the track  12  is full, the primary source feed unit  10  also proceeds automatically to step  52 . If at step  56  the response is that the primary source feed unit  10  is not ready to deposit its source material  17  onto the track  12 , the system proceeds to step  70  wherein the secondary source feed unit  11  is queried as to whether it is ready. If the response to step  70  is NO, the system automatically returns to the beginning of the cycle at step  52 . On the other hand, if the response at step  70  is YES, indicating that the secondary source feed unit  11  is ready to deposit its source material  17  onto the track  12 , the system proceeds to step  72  wherein the secondary source feed unit  11  determines if the track  12  is empty.  
         [0040]    At step  72 , if the track  12  is full this would indicate that the primary source unit  10  has fully performed its cycle and has deposited its source material  17  onto the track. In this case, the secondary source feed unit  11  returns to the beginning of the cycle at step  52 . If the primary source feed unit  10  has not deposited its source material  17  and the response to step  72  is YES, indicating that the track  12  is empty, the secondary source feed unit  11  proceeds to step  74  wherein the secondary source feed unit  11  deposits its source material  17  onto the track  12 .  
         [0041]    In an alternate embodiment of the High Page Count method, the two source feed units  10  and  11 , or more than two, can be programmed such that they perform a true load balancing between such two or more units. This load balancing system can be performed in either an “intelligent” or “non-intelligent” manner.  
         [0042]    In the “non-intelligent” load balancing system, for example, the primary source feed unit  10  ensures that the secondary source feed unit  11  has a turn by purposely not filling the track space  16 . In this manner, the material is used up more equally. In a system using multiple feeders, each feeder would pause feeding the same number of times that there are feeders on the system.  
         [0043]    In the “intelligent” load balancing system, the primary source feed unit  10  must check the secondary source feed unit  11  to determine whether the secondary source feed unit  11  is ready. If the secondary source feed unit  11  is ready, the primary source feed unit  10  is allowed to leave an empty track position  16 . This mode is considered “intelligent” load balancing because inter-communications are required and a test for downstream readiness must be performed.  
         [0044]    As is shown in FIG. 8, in an alternate to the embodiment of the High Page Count shown in FIG. 7, method the downstream section with output stations  4 A and  4 B is placed perpendicular to the upstream source output units  10  and  11 . The benefit of this perpendicular setup is that it reduces operator foot traffic. Therefore, in the embodiment shown in FIG. 8, the operator is able to cover more of the unit in fewer steps.  
         [0045]    Various features of the invention have been particularly shown and described in connection with the illustrated embodiments of the invention. However, it must be understood that these particular products, and their method of manufacture, do not limit but merely illustrate, and that the invention is to be given its fullest interpretation within the terms of the appended claims.