Patent Publication Number: US-8123216-B2

Title: Systems and methods for controlling actuator force as a controllable replacement for a common spring in sheet article processing and related sheet article processing apparatuses

Description:
TECHNICAL FIELD 
     The subject matter disclosed herein relates generally to apparatuses, systems, and methods that employ an actuator that can be used, for example, in place of a biased device such as, for example, a spring-loaded device. More particularly, the subject matter disclosed herein relates to apparatuses, systems, and methods that employ a pulse-width modulation controlled actuator that can replace a spring-loaded device, for example, to create different levels of drag on sheet articles such as envelopes to properly align such sheet articles with in a sheet processing device. 
     BACKGROUND 
     Mechanical devices, such as spring-loaded devices, are commonly used to provide a resistance during some portion of a process. Such spring-loaded devices can be tailored to provide a necessary amount of resistance to accomplish the desired effect of the resistance. Sometimes, it is desirable for such spring-loaded devices to provide different amounts of resistance at different times of a process or depending on the type of item being processed. For example, in some processes it can be desirable for the spring-loaded device to provide enough resistance to stop an item being processed along a process path and then provide less resistance or drag to controllable allow the item being processed to move along the process path. However, such spring-loaded devices, such as a common torsion spring, typically cannot provide a dual amount or different amounts of resistances on an object without some other mechanical force acting on the spring-loaded device, such as by varying size of an item being processed when the spring-loaded device and process path are at a constant distance or by varying the distance between the spring-loaded device and the process path. Thus, it is often necessary to determine a spring force that will at least partially fulfill the intent of the different amounts of resistance. 
     As in sheet article processing, spring-loaded devices can be used to align the sheet articles for processing and regulate flow therethrough by providing resistance that is applied against the sheet article as it passes such spring-loaded devices. For example, a standard set of rotary, spring return, registration fingers is often used in sheet article processing to register, i.e., properly align, the sheet articles being processed but still permit the sheet articles to pass by the registration fingers. For instance, it is desirable for the fingers to have enough force to serve as a registration surface for an object, such as an envelope or document that is being fed into a processing station at a significant velocity. It is also desired that the force of the spring-loaded device be light enough for the object to subsequently be pushed through these same registration fingers without damage or deformation of the object due to excessive resistance of the registration fingers. However, even finding a compromise force to fulfill these dual purposes for the rotary spring, such as a simple torsion spring, on the rotating fingers, still does not provide satisfactory results that truly meets both of these requirements. 
     A need exists for systems and methods that can act operate in a manner similar to spring-loaded devices, but can provide better options for resistance. 
     SUMMARY 
     In accordance with this disclosure, apparatuses, systems, and methods that employ controllable actuators that can provide multiple levels of resistance are provided. It is, therefore, an object of the present disclosure to provide an actuator that can be used in place of a biased device, such as, for example, a spring-loaded device. More particularly, the subject matter disclosed herein relates to a pulse-width modulation controlled actuator that can be used in place of a spring-loaded device, for example, to create different levels of drag on sheet articles such as envelopes to properly align such sheet articles. 
     An object of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which: 
         FIG. 1A  illustrates a top perspective view of an embodiment of a pulse-width modulation controlled actuator with a resistive force applied to an arm of the actuator according to the present subject matter; 
         FIG. 1B  illustrates a top perspective view of an embodiment of a pulse-width modulation controlled actuator with a less resistive force applied to an arm of the actuator according to the present subject matter; 
         FIG. 1C  illustrates a graphic representation of an embodiment of the pulse-width modulation used to create the resistive force and the less resistive force and the respective pulse-width modulation duty cycle of each according to  FIGS. 1A and 1B ; 
         FIGS. 2-6  illustrate perspective views of steps that can be used in registering and moving an object along a process path using an embodiment of a system using a pulse-width modulation controlled actuator according to  FIGS. 1A and 1B ; 
         FIGS. 7-10  illustrate perspective views of an embodiment of a system within an inserting station using a pulse-width modulation controlled actuator according to  FIGS. 1A and 1B  configured to use envelopes of one size; and 
         FIGS. 11-14  illustrate perspective views of the embodiment of a system within the inserting station illustrated in  FIGS. 7-11  configured to use a different sized envelope. 
     
    
    
     DETAILED DESCRIPTION 
     Reference will now be made in detail to the description of the present subject matter, one or more examples of which are shown in the figures. Each example is provided to explain the subject matter and not as a limitation. In fact, features illustrated or described as part of one embodiment can be used in another embodiment to yield still a further embodiment. It is intended that the present subject matter covers such modifications and variations. 
     The term “sheet article” is used herein to designate any sheet article, and can comprise, for example and without limitation, envelopes, sheet inserts folded or unfolded for insertion into an envelope or folder, and any other sheet materials. 
     The term “mail article” is used herein to designate any article for possible insert into a mailing package, and can comprise, for example and without limitation, computer disks, compact disks, promotional items, or the like, as wells any sheet articles. 
     The term “duty cycle” is used herein to describe the proportion of “on time” when power is being supplied by a pulse-width modulation (also referred to herein as “PWM”) controller to “off time” when power is not supplied by the PWM controller. Duty cycle is generally expressed in percent with 100% being fully on. For example, a low duty cycle corresponds to low power, because the power is off for most of the time, while a high duty cycle corresponds to high power, because the power is on for most of the time. 
     The term “document set” is used herein to designate one or more sheet articles and/or mail articles grouped together for processing. 
     As defined herein, the term “insert material” can be any material to be inserted into an envelope, and can comprise, for example and without limitation, one or more document sets, sheet articles, mail articles or combinations thereof. 
     The present subject matter describes methods and systems for using a pulse-width modulation controlled actuator in place of a biased device such as, for example, a spring-loaded device. The method of control can be applied to both linear and rotational devices. Using a pulse-width modulation controlled solenoid, for example, allows for dynamic control and manipulation of the effective force of the solenoid. This is particularly useful in applications where it is desired for a mechanical device to have a high holding or return force during some portion of a process, while having a lighter, spring-like force during other portions of a process. 
     Such pulse-width modulation controlled actuators can be used in conjunction with a standard set of rotary, spring return, registration fingers used in sheet article processing. For example, such embodiments can be used in inserting stations or systems. Such inserting stations, or inserting systems can be used, for example, for processing sheet articles and mail articles such as envelopes, folders, flats, insert materials, and documents sets. In the inserting station, sheet articles such as envelopes and flats can be registered, held in a stationary position and/or opened for inserting insert material therein. The sheet articles and mail articles can also be registered, held and/or inserted into other sheet articles such as envelopes and flats in the inserting station. Further, processing to such sheet articles such as envelopes, folders, flats, insert materials, and documents sets can also occur in the inserting station. 
     In such embodiments of the actuators, it can be desirable for the fingers to have enough force to serve as a registration surface for an object or sheet article, such as envelope or other document, being fed into the fingers at a significant velocity. It can also be desirable that the force of the actuator be light enough for the object or sheet article, such as an envelope or other document, to subsequently be pushed through these same registration fingers without damage or deformation of the object or sheet article due to excessive resistance of the registration fingers. By using a rotary solenoid implementing the PWM control method disclosed herein, these dual requirements can be achieved. When the object to be registered is being fed into the fingers, the PWM duty cycle can be at or near 100% providing maximum force for registration during impact. Having the PWM duty cycle at or near 100% can also provide the quickest possible return time to the registration position. Then, when it is desired for the object to be easily pushed through the fingers, the PWM duty cycle can be drastically reduced in order to provide the desired (lighter) resistive force. 
     This control method of an electric solenoid contrasts with a spring-loaded device where the force created by the solenoid is typically greatest when it is fully engaged. In the example above, the effective force or resistance that the registration fingers have is reduced when the object is forced through the registration fingers and they are rotated in the direction opposite of the energizing force. Conversely, if a spring were used, the force would actually increase as the fingers are rotated against the spring. 
       FIGS. 1A and 1B  illustrate an actuator, generally designated  10 . The actuator  10  can comprise a solenoid  12  and an arm generally designated  14 . The solenoid  12  can be a rotary solenoid as shown. Alternatively, the solenoid  12  can be a linear solenoid. The solenoid  12  can comprise a shaft  16  on which the arm  14  can be attached. The arm  14 , for example, can be a single structure. Alternatively, the arm  14  can comprise two or more fingers  14 A,  14 B that are spaced apart from each other and can be positioned at opposing ends of the shaft  16 . With a rotary embodiment, the solenoid  12  can rotate the shaft  16  such that the arm  14  rotates about an axis A passing through the shaft  16 . 
     The actuator  10 , and in particular the solenoid  12 , can be in communication with a controller  20  that provides a pulse-width modulated power supply to the solenoid  12 . The pulse-width modulated power supply applied to the solenoid  12  creates rotational forces on the arm that vary in intensity depending on the amount of voltage supplied during pulses of high voltage and intervals of low voltage or no voltage. The solenoid can be in wired communications with the controller  20 . Alternatively, the controller  20  can be in wireless communications with a power supply that acts as part of the controller  20  with the power supply wired to supply power to the solenoid. The controller  20  can thus modulate the power supply remotely. 
     By using pulse-width modulation of the power supplied to the solenoid  12 , the force applied by the actuator  10  can be controlled by a method that can mimic a spring-loaded device. The actuator  10  with the solenoid  12  and arm  14  can be controlled by the controller  20  so that the movement of the arm  14  with the solenoid  12  is controlled by pulse-width modulation as described above. The controller  20  can provide a pulse-width modulation having a high pulse-width modulation duty cycle to the solenoid  12  to provide a resistive force F LARGE  on the arm  14  as shown in  FIG. 1A . A high pulse-width modulation duty cycle can be any duty cycle that can create a resistive force F LARGE  on the arm  14  of the actuator  10  great enough to prevent passage of an object, such as envelope E, past the arm  14  of the actuator  10 . For example, a high pulse-width modulation duty cycle can be a duty cycle of about 100% that provides a maximum force on the arm  14 . In fact, in some embodiments, the level of voltage provided can be higher than the voltage for which the solenoid is rated. This over-excitation can cause the fingers to swing into its lowered blocking position very quickly. Since the voltage level is only high for short periods of time and this over-excitation period is mixed with other periods of low voltage, the average voltage applied to the solenoid does not exceed its rated amount. In another example, the high pulse-width modulation duty cycle can be between about 50% and about 100%. Such duty cycles can depend on the amount of maximum voltage accessible to the controller and actuator, the type and size of the object, and the amount of force acting on the object and actuator. 
     The controller  20  can provide a pulse-width modulation having a low pulse-width modulation duty cycle to the solenoid  12  to provide a less resistive force F SMALL  on the arm  14  as shown in  FIG. 1B . A low pulse-width modulation duty cycle can be any duty cycle that can create a less resistive force F SMALL  on the arm  14  of the actuator  10  that is small enough to allow passage of an object, such as envelope E, past the arm  14  of the actuator  10 . For example, the low pulse-width modulation duty cycle can be between about 1% and about 70%. Again, such duty cycles can depend on the amount of maximum voltage accessible to the controller, the type and size of the object, and the amount of force acting on the object and actuator. 
       FIG. 1C  illustrates a schematic graphical representation to illustrate an embodiment of the concept of a pulse-width modulation that can be used to supply power to the actuator  10  to create the force F LARGE  and the force F SMALL  on the arm  14 . The on and off periods of the voltage for the modulated portion in the graph of  FIG. 1C  are exaggerated to illustrate the concept. In practice, the ON and OFF periods for the voltage can typically be extremely short in duration (for example, milliseconds), thus making it difficult to illustrate accurately in a graph. 
     As shown in  FIG. 1C , the maximum voltage that can be supplied to the actuator is N volts. When the actuator  10  is expected to hold an object, such as envelope E, a high pulse-width modulation duty cycle DC H  (superimposed with line V FULL ) for the time period for holding the object can be used. This creates the force F LARGE  on the arm  14  as shown in  FIG. 1A  that can hold an object, such as envelope E. For example, as shown in  FIG. 1C , the high pulse-width modulation duty cycle DC H  can be about 100% meaning that the supply of voltage is maintained “on” over this time period to provide a maximum voltage V FULL  over this time period. As described above, the high pulse-width modulation duty cycle DC H  can be less than 100% with a different modulation pattern. Similarly, at least a portion of the high pulse-width modulation duty cycle DC H  can be greater than 100% with a different modulation pattern to provide an over-excitation. 
     When the actuator  10  is expected to release an object, such as envelope E, to allow it to pass the arm  14  of the actuator  10 , a low pulse-width modulation duty cycle DC L  for the time period for holding the object can be used. This creates the force F SMALL  on the arm  14  as shown in  FIG. 1B . For example, as shown in  FIG. 1C , the low pulse-width modulation duty cycle DC H  can be much lower than the high pulse-width modulation duty cycle DC H . The low pulse-width modulation duty cycle DC L  can be created by intermittent supplies of voltage V mod  meaning that the supply of voltage is maintained “ON” only over certain portions of this time period. The low pulse-width modulation duty cycle DC L  can vary. As described above, the low pulse-width modulation duty cycle DC L  can depend on the amount of maximum voltage accessible to the controller and actuator and the type and size of the object. Further, different modulation patterns can be used to create the low pulse-width modulation duty cycle DC L . 
     As shown in  FIG. 1C , the pulse-width modulation having the high pulse-width modulation duty cycle DC H  can be immediately followed by the pulse-width modulation having the low pulse-width modulation duty cycle DC L . Depending on the process in which the actuator  10  is used, the steps of providing the high pulse-width modulation duty cycle DC H  and providing the low pulse-width modulation duty cycle DC L  can be continually repeated when processing multiple objects. 
     As shown in  FIG. 1A , the arm  14  can be moved to an active position during application of the high pulse-width modulation duty cycle DC H  to the solenoid  12 . This means that the arm  14  is forced to rotate into and held in a blocking position, shown in  FIG. 1A  to permit holding of an object. During the application of the low pulse-width modulation duty cycle DC L  to the solenoid  12 , the arm is movable to a passive position. This means that the arm  14  is held in a rotated position similar to the active position, but the force applied is smaller to permit the object to push past arm  14  to move the arm  14  to the passive position. Thereby, the actuator  10 , and in particular, the solenoid  12 , does not need a return spring mechanism therein for returning the arm from the active position. 
     Referring now to  FIGS. 2-6 , one example of a system and method for registering and moving objects, such as sheet articles, along a process path is provided in further detail. In  FIGS. 2-6 , a system  40  is provided. In this embodiment, the objects being processed in the system  40  are sheet articles although any suitable articles could be processed and used according to the present disclosure. For example, the sheet articles can be envelopes E 1 , E 2 . The system  40  can be used to register, i.e. properly align, and move the sheet articles within a process. The system  40  can be part of a large system. For example, the system  40  can define a portion of an inserting system for mail processing that can be used for inserting material into items such as envelopes, folders and the like. 
     As seen in  FIGS. 2-6 , the system  40  can comprise a process path  30  for conveying the sheet articles, as shown herein, envelopes E 1 , E 2 , from an upstream position U to a downstream position D. The system  40  can also comprise an actuator  10  as described above that comprises a solenoid  12  and an arm  14 . The solenoid  12  can be a rotary solenoid and can comprise a shaft  16  on which the arm  14  can be attached. The arm  14 , for example, can be a single structure. Alternatively, the arm  14  can comprise two or more fingers  14 A,  14 B that can be spaced apart from each other along the shaft  16 . The actuator  10  can be positioned at a predetermined location along the process path  30  proximate to the process path  30 . For example, the actuator  10  can be located at an insertion station where the envelopes E 1 , E 2  can be registered and stuffed with insert material I before being allowed to move on down the process path  30 . The insert material I can, for example, comprise sheet articles and mail articles. 
     A controller  20  ( FIGS. 1A and 1B ) can also be included in the system  40  that can control the movement of the arm  14  with the solenoid  12  by pulse-width modulation. As described above, the controller  20  can provide a high pulse-width modulation duty cycle to the solenoid to provide a maximum force on the arm to position the arm in the process path to register the sheet article against the arm to align the sheet article in a predetermined position. The controller  20  can also provide a low pulse-width modulation duty cycle to the solenoid to provide a less resistive force on the arm to permit the sheet article to push past the arm along the process path. 
     The process path can comprise one or more openings  32  into which the arm  14  can be extend upon application of the maximum force by the solenoid. One or more pusher members  34  for moving a sheet article along the process path  30  can be provided. The pusher members  34  can travel along the openings  32  in the process path  30 . The pusher members  34  can be moved along the process path  30  by one or more movable conveyor devices, such as a belt, a chain, or the like. In the embodiment shown, at least some of the pusher members  34  can be used to push insert material I along the process path  30  and into the envelopes E 1 , E 2 . As stated above, the insert material I can comprise sheet articles and mail articles. The insert material I can form document sets that can be inserted into the envelopes E 1 , E 2 . 
     The arm  14  can be rotatable into an active position in the process path upon providing the high pulse-width modulation duty cycle DC H  to the solenoid (see as an example  FIG. 1C ). The arm  14  is configured to be movable to a passive position during the low pulse-width modulation duty cycle DC L  to the solenoid (see as an example  FIG. 1C ). The solenoid  12  can be configured such that, upon providing the low pulse-width modulation duty cycle DC L  to the solenoid  12 , the envelopes E 1 , E 2  with the insert material I inserted therein can be movable past the arm  14  along the process path  30 . The arm  14  in this manner can be rotatable out of the process path  30  by the movement of the envelopes E 1 , E 2 . In such an embodiment, the actuator  10  does not need a return spring mechanism secured therein for returning the arm  14  from an active position. 
     An embodiment of a method that can be used on the system  40  for registering and moving a sheet article along a process path  30  will now be described. The actuator  10  that comprises the solenoid  12  and arm  14  can be controlled, for example, by the controller  20 . In particular, the movement of the arm  14  with the solenoid  12  can be controlled by pulse-width modulation to provide different levels of force on the arm  14 , thereby providing different levels of resistance against applied torque from the contact of the sheet articles against the arm  14 . Sheet articles, in the form of the envelopes E 1 , E 2 , can be moved into and along the process path  30 . 
     As shown in  FIG. 2 , after a first envelope E 1  is stuffed and moved out of the insertion station, a pulse-width modulation having a high pulse-width modulation duty cycle can be supplied to the solenoid  12  of the actuator  10  to provide a resistive force F LARGE  on the arm  14  to position the arm  14  in the process path  30 . As stated above, the solenoid  12  can be a rotary solenoid that rotates the shaft  16  and the arm  14  attached thereto about an axis. 
     This rotation of the arm  14  with the solenoid  12  using a high pulse-width modulation duty cycle to create a resistive force F LARGE  moves the arm  14  into an active position in the process path  30 . In this active position, the arm  14  can extend through the process path  30 . For example, the arm  14  in the form of fingers  14 A,  14 B can extend into the openings  32  in the process path  30  in which the pusher members  34  can travel as shown in  FIG. 3 . This active position that blocks the movement of the envelopes can also be considered the registration position of the arm  14  that will provide proper alignment of the next envelope E 2 . As shown in  FIG. 3 , the rotation of the arm  14  with the solenoid  12  into an active position in the process path  30  using a high pulse-width modulation duty cycle to block the movement of the envelopes can occur before the next envelope E 2  arrives. As stated above, the high pulse-width modulation duty cycles can depend on the amount of maximum voltage accessible to the controller, the type and size of the object, and the amount of force acting on the envelope E 2  and actuator. 
     The envelope E 2  can be fed onto the process path  30  and moved along the process path  20  at an upstream position U before the actuator  10 . As shown in  FIG. 4 , the envelope E 2  can be moved along the process path  30  up to the actuator  10  with its arm  14  in an active position. The unstuffed envelopes can be moved into the process path in different manners, including the envelope feeding mechanism that will be described below with reference to  FIGS. 7-14 . The envelope E 2  can then be registered against the arm  14  to align the envelope E 2  in a predetermined position. This predetermined position in which the envelope is placed by the registration can be, for example, an alignment that permits the inserting of the envelope E 2  with insert material I. 
     As shown in  FIG. 5 , the pusher members  34  can push the insert material from an upstream position U towards a downstream position D along the process path  30 . At this point, either during insertion or after insertion, a pulse-width modulation having a low pulse-width modulation duty cycle can be provided to the solenoid  12  to provide a less resistive force F SMALL  on the arm  14  to permit the envelope E 2  to pass by the arm  14 . The less resistive force F SMALL  can be such that the less resistive force F SMALL  will permit the envelope E 2  to be push past the arm  14  along the process path  30  by the pusher members  34  as shown in  FIG. 6 . The less resistive force F SMALL  can be such that enough force is provide that the insert material I will be inserted into the envelope and the pusher members  34  contact the envelope before the pusher members  34  pushes the envelope past the arms  14  causing to the arm  14  to raise upward. As stated above, the low pulse-width modulation duty cycle can be a fraction of the high pulse-width modulation duty cycle. Also, the low pulse-width modulation duty cycles can depend on the amount of maximum voltage accessible to the controller, the type and size of the object, and the amount of force acting on the envelope E 2  and actuator. 
     As shown in  FIG. 6 , upon providing the low pulse-width modulation duty cycle to the solenoid  12 , the envelope E 2  can move past the arm along the process path  30 , the movement of the envelope E 2  can rotate the arm  14  of the actuator  10  out of the process path  30  and into a passive position. The less resistive force F SMALL  can still provide enough resistance to keep the stuffed envelope E 2  registered with the pusher members  34 . As described above, the pulse-width modulation having the high pulse-width modulation duty cycle that creates the resistive force F LARGE  on arm  14  can be immediately followed by the pulse-width modulation having the low pulse-width modulation duty cycle that creates the less resistive force F SMALL  on arm  14 . Further, the steps of providing the pulse-width modulation having the high pulse-width modulation duty cycle and providing the pulse-width modulation having the low pulse-width modulation duty cycle can be continually repeated. 
     Referring now to  FIGS. 7-14 , one example of a more specific embodiment for using a pulse-width modulation actuator  10 , as described above, in a sheet processing system is illustrated. In  FIGS. 7-14 , an inserting station or system, generally designated  50 , is provided for processing sheet articles. In particular, the inserting station  50  can be used to stuff insert material I, such as document sets of sheet articles and/or mailing articles, into an envelope. The inserting station  50  can comprise an actuator  10 , a controller  20  and a process path  30 . The actuator  10 , controller  20  and process path  30  can comprise a system  40  for registering and moving a sheet article along the process path  30  within the inserting station  50 . The inserting station  50  and system  40  can be part of a larger sheet processing system. The system  40  can be used to register, i.e. properly align, and move the sheet articles within the larger sheet processing system. The system  40  will be described in the context of the inserting station  50  below. 
     As illustrated in  FIGS. 7-14 , the inserting station  50  can comprise a process path  30  for conveying the sheet articles, which can be envelopes and document sets of sheet articles and/or mailing articles that comprise insert material, from an upstream position U to a downstream position D. The inserting station  50  can also comprise an actuator  10  as described above that comprises a solenoid  12  (not shown in  FIGS. 7-14 ; see  FIGS. 1A-6 ) and an arm  14 . The solenoid can be a rotary solenoid and can comprise a shaft  16  on which the arm  14  can be attached. The arm  14 , for example, can be a single structure. Alternatively, the arm  14  can comprise two or more fingers  14 A that are spaced apart from each other along the shaft  16 . The actuator  10  can be positioned at a predetermined location along the process path  30  proximate to the process path  30 . For example, the actuator  10  can be located on a support carriage  52  above the process path  30  so that the arm  14  of the actuator  10  can be rotated into a position to register envelopes and stuff the envelopes with insert material I before being allowed to move down the process path  30 . 
     For example, in  FIGS. 7-10 , the support carriage  52  positions the actuator  10  in a location to stop commercial sized envelopes RE 1 , RE 2  after the envelopes RE 1 , RE 2  are fed into the process path  30  by an envelope feeder EF. The commercial sized envelopes RE 1 , RE 2  are designed to receive small or folded sheet articles such as folded letter-sized paper. Thus, the support carriage  52  in  FIGS. 7-10  positions the actuator  10  close to the envelope feeder EF. In  FIGS. 11-14 , the envelopes being processed are catalog sized envelopes LE 1 , LE 2  into which an unfolded sheet article or other type of larger insert material can be inserted. The support carriage  52  positions the actuator  10  in a location to stop catalog sized envelopes LE 1 , LE 2  after the envelopes LE 1 , LE 2  are fed into the process path  30  by an envelope feeder EF. The support carriage  52  in  FIGS. 11-14  positions the actuator  10  farther away from the envelope feeder EF and farther down the process path  30  than the position of the actuator  10  within the support carriage  52  in  FIGS. 7-10 . The support carriage  52  can be fixed so that the actuator  10  is in a fixed, stationary position that is not adjustable. Alternatively, at least portions of the support carriage  52  can be moveable to allow the position of the actuator  10  to be adjustable. An embodiment of an adjustable support carriage  52  as shown in  FIGS. 7-14  will be described in more detail below. 
     Controller  20  can also be included in the system  40  and can be used to control the inserting station  50 . Controller  20  can be a computer, a microcomputer, a programmable logic controller, or the like. Controller  20  can be a controller for the entire inserting system of which the inserting station is a part. Alternatively, the controller  20  can be for just the inserting station  50  or the actuator  10 . Controller  20  can control the movement of the arm  14  with the solenoid by pulse-width modulation. As described above, the controller  20  can provide a high pulse-width modulation duty cycle to the solenoid to provide a maximum force on the arm  14  to position the arm  14  in the process path to register the envelopes RE 1 , RE 2 , LE 1 , LE 2  against the arm  14  to align the envelopes RE Q , RE 2 , LE 1 , LE 2  in a position to receive insert material I. The controller  20  can also provide a low pulse-width modulation duty cycle to the solenoid to provide a less resistive force on the arm  14  to permit the envelopes RE 1 , RE 2 , LE 1 , LE 2  to push past the arm  14  along the process path  30 . 
     The process path  30  can comprise one or more openings  32  into which the arm  14  can extend upon application of force by the solenoid. In particular, the process path  30  can comprise one or more decks  36  that form the openings  32 . One or more pusher members  34  (See  FIGS. 10 and 14 ) for moving the sheet article along the process path  30  can also be provided. The pusher members  34  can travel along the openings  32  in the process path  30 . The pusher members  34  can be moved along the process path  30  by one or more movable conveyor devices, such as a chain  38 . Other movable conveyor devices such as belts can also be used. The pusher members  34  can be fixedly attached to the chain  38 . Alternatively, the pusher members  34  can be pivotally attached to the chain  38 . In the inserting station  50 , the pusher members  34  can be used to push insert material I along the process path  30  and into the envelopes RE 1 , RE 2 , LE 1 , LE 2  after the envelopes RE 1 , RE 2 , LE 1 , LE 2  are fed onto the process path  30  by the envelope feeder EF and registered against the arm  14  of the actuator  10 . As stated above, the insert material I can comprise sheet articles and mail articles that form document sets to be inserted into the envelopes RE 1 , RE 2 , LE 1 , LE 2 . 
     The arm  14  can be rotatable into an active position in the process path  30  upon providing a high pulse-width modulation duty cycle from the controller  20  to the solenoid. The torque on the solenoid created by the high pulse-width modulation duty cycle DC H  can be strong enough to force the arm  14  to rotate into the active position and hold the arm  14  in the active position during registration of the envelopes RE 1 , RE 2 , LE 1 , LE 2  and insertion of the insert material I. The arm  14  can be configured to be movable to a passive position during a low pulse-width modulation duty cycle to the solenoid by letting the pusher members  34  push the envelopes RE 1 , RE 2 , LE 1 , LE 2  past the arm  14 , thereby moving the arm  14  upward and out of the process path  30 . The arm  14  in this manner can be rotatable out of the process path  30  by the movement of the envelopes RE 1 , RE 2 , LE 1 , LE 2  during the period when a less resistive force in the form of torque on the solenoid is applied. In such an embodiment, the actuator  10  does not need a return spring mechanism for returning the arm  14  from an active position because the envelope and pusher members  34  operate to move the arm to a passive position to allow passage of the envelopes RE 1 , RE 2 , LE 1 , LE 2 . After each envelope passes, the controller  20  can again apply a high pulse-width modulation duty cycle to the solenoid of the actuator  10  to ensure that the arm  14  returns to the active position from the passive position for registration of the next envelope. 
     As stated above, the support carriage  52  can be adjustable to allow the location of the actuator  10  along the process path  30  to be moveable. In particular, in the embodiment shown, the location of the actuator  10  relative to the envelope feeder EF can be changed. As shown in  FIGS. 7-14 , this allows for processing different sized envelopes and insert materials I. The support carriage  52  can comprise a frame  54  that holds an actuator carrier  56  between guide rails  58 . The solenoid carrier  56  has the actuator  10  installed therein so that the arms  14  are rotatable into the process path  30 . An adjuster  60  can be provided that permits the movement of the actuator carrier  56  within the frame  54  of the support carriage  52 . The adjuster  60  can comprise a rod  62  that is retained by the frame  54  and is rotatable within the frame  54 . The rod  62  can pass through an aperture (not shown) in the actuator carrier  56 . Both the rod  62  and the aperture in the actuator carrier  56  can be threaded so that as the rod  62  rotates the actuator carrier  56  moves up and down the rod  62  depending on the direction of rotation of the rod  62 . The guide rails  58  prevent the rotation of the actuator carrier  56  with the rotation of the rod  62  to cause the actuator carrier  56  to move up and down the rod  62  depending on the direction of rotation of the rod  62 . 
     The adjuster  60  can also comprise a handle  64  that can be used to turn, or rotate, the rod  62 . The handle  64  can be positioned at different locations on the support carriage  52 . For example, the handle  64  can be located on the side of frame  54  (not shown) and can be directly attached to the end of the rod  62  so that the turning of the handle  64  will result directly in the turning of the rod  62 . Alternatively, the handle  64  can extend upward from the frame  54  at an angle to rod  62  as shown in  FIGS. 10 and 14 . In such an embodiment, the handle  64  can be attached to a gearing arrangement  66  to transfer the rotation of the handle  64  to the rod  62 . For example, the handle  64  can be at approximately a right angle to the rod  62  and bevel gears  66 A and  66 B in the gearing arrangement  66  can translate the turning of the handle  64  to the turning of the rod  62 . With the turning of the rod  62 , the actuator carrier  56  will move along the rod  62  depending on the direction rotation of the handle  64  and the rod  62 . In this manner, the actuator  10  within the actuator carrier  56  can be moved into a position where the actuator  10  can properly register the envelopes and hold the envelopes in position to be stuffed with insert material I depending on the size of the envelopes being processed. 
     Thus, the support carrier  52 , as shown in the embodiment illustrated in  FIGS. 7-14 , can permit the adjustment of the location of actuator  10  along the process path  30  to fit the size of the envelopes RE 1 , RE 2 , LE 1 , LE 2 . In the embodiment shown, the envelope feeder can be positioned above the process path  30  to feed the envelopes onto the process path  30 . The actuator  10  is positioned close enough to the envelope feeder EF so that a top flap TF of the envelope RE 2 , LE I  that is registered against the arm  14  of the actuator  10  when the arm  14  is in the active position resides on a portion of the envelope feeder EF to hold the envelope in an open position for insertion of the insert material I into the envelope. To accomplish this as shown in  FIGS. 10 and 14 , the position of the actuator  10  relative to the envelope feeder EF can be changed depending on the size of the envelope. 
     Any envelope feeder EF can be used that provides a feed of the envelopes at such an angle as to hold open the envelope within the process path for receipt of the insert material I therein. A generic envelope feeder EF is represented in  FIGS. 7-14 . A stack ES of envelopes can be placed in an envelope holder EH. A feeder wheel FW can pull individual envelopes into the envelope feeder EF which can then be grabbed by a feed belt FB that ejects the envelope onto process path  30 . The actuator  10  can be actuated so that the arm  14  is in the active position to stop and register the envelope at a position where the top flap TF of the envelope still resides on a lip FL of the envelope feeder EF. In this manner, the envelope can be held in an open position for insertion of the insert material therein. The upstream portion U of the process path that is before the support carriage  52  can be at a higher elevation as compared to the downstream portion D of the process path  30  to facilitate insertion of the insert material I into the envelope RE 2 , LE 1  as shown in  FIGS. 10 and 14 . 
     The operation of the inserting station  50  will be described in more detail below. As shown in  FIGS. 7 and 11 , the actuator carrier  56  can be adjusted to an appropriate position so that the actuator  10 , when activated, will register the envelopes RE 1 , LE 1  and hold the envelopes RE 1 , LE 1  for insertion of insert material I. To rotate the actuator  10  into an active position, a pulse-width modulation having a high pulse-width modulation duty cycle can be supplied to the actuator  10  to provide a greater resistive force on the arm  14  to position the arm  14  in the process path  30 . The high pulse-width modulation duty cycle can occur be over-exciting the solenoid in the actuator  10 . For example, if the solenoid is rated for 6 volts, a supply of 24 volts can be provided for a very short time period to quickly move the arm  14  into the active position. In this active position, the arm  14  can extend through the process path  30 . For example, the arm  14  in the form of fingers  14 A can extend into the openings  32  in the process path  30  in which the pusher members  34  can travel as shown in  FIGS. 10 and 14 . The envelopes RE 1 , LE 1  can be held open as described above with the top flap of each envelopes RE 1 , LE 1  residing on a portion of the envelope feeder EF such as feeder lip FL. 
     As shown in  FIGS. 10 and 14 , the pusher members  34  can push insert material I from an upstream position U towards a downstream position D along the process path  30 . At this point, either during insertion or after insertion, a pulse-width modulation having a low pulse-width modulation duty cycle can be provided to the solenoid of the actuator  10  to provide a less resistive force on the arm  14  to permit the envelope RE 1 , LE 1  to pass by the arm  14 . The less resistive force can be such that it will permit the envelope RE 1 , LE 1  to be push past the arm  14  along the process path  30  by the pusher members  34  as shown in  FIGS. 8 and 12 . As stated above, the low pulse-width modulation duty cycle can be a fraction of the high pulse-width modulation duty cycle. After the first envelope RE 1 , LE 1  is stuffed and moved down stream from the actuator  10 , the solenoid of the actuator  10  can be over-excited again to provide a high pulse-width modulation duty cycle to provide a greater resistive force on the arm  14  to position the arm  14  in an active position again for the registration and holding of a second envelope RE 2 , LE 2  in the process path  30  as shown in  FIGS. 9 and 13 . 
     As stated above, the pulse-width modulation having the high pulse-width modulation duty cycle that creates a greater resistive force on arm  14  can be immediately followed by the low pulse-width modulation duty cycle that creates the less resistive force on arm  14 . Further, the steps of providing the pulse-width modulation having the high pulse-width modulation duty cycle and the low pulse-width modulation duty cycle can be continually repeated. 
     Embodiments of the present disclosure shown in the drawings and described above are exemplary of numerous embodiments that can be made within the scope of the above disclosure and appending claims. It is contemplated that the configurations of the pulse-width modulated actuator systems, apparatuses, and methods of using the same can comprise numerous configurations other than those specifically disclosed. The scope of a patent issuing from this disclosure will be defined by these appending claims.