Patent Document

TECHNICAL FIELD 
       [0001]    The present invention relates generally to system, apparatus, and method for removing pressure adhesive indicia from their backing and affixing the same to a target substrate. 
       BACKGROUND 
       [0002]    Currently, there is a need to remove fee indicia, such as stamps, from a sheet, or pane, by hand and affix the same to a target substrate, such as an envelope, by hand. Both the speed of this operation and the accuracy of the stamp affixation placement is limited by human capacity. In some circumstances, the need for precision placement contributes dramatically to the labor time required to affix the stamps to the target substrate. 
         [0003]    For example, precise placement of the stamp on the target substrate is desired on philatelic items. Philately, that is stamp collecting, is an extremely popular hobby, recognized by many as the most popular hobby in the world. National postal administrations, as well as private sector companies, create items bearing significant postmarks specifically to appeal to those who participate in stamp collecting. In order to be regarded as collectible quality, the stamps must be affixed precisely in a specific placement on the target substrate. 
         [0004]    To meet philatelic standards, stamps are, on the average, manually removed and affixed to the target substrate with precision placement at a rate of 150 stamps per man-hour. In fact, the precision placement contributes significantly to the time requirements. Stamps must by placed in a consistent location on the target substrate, in a specific orientation and, when more than one stamp is to be affixed, they must be grouped in a specific configuration and spaced precisely from one another. The placement surface of the target substrate necessarily varies as well, such as a small envelope, a large document envelope, or a package. This variability contributes to the demands of manual-stamp placement. 
         [0005]    In addition to the arena of stamp collecting, other applications exist in which removal of pressure adhesive indicia, delivery labels for example, from sheets or sheets and subsequent precise placement is desirable. An increase in production rate of this process would benefit any high volume delivery service. Precise placement can contribute to the ease and speed of future target substrate processing, such as cancelling of delivery fee indicia and verifying delivery fee amount. Precise placement of labels has aesthetic appeal and can contribute to product marketability and sales. 
         [0006]    The application for automated removal, affixation, and canceling of self-adhesive indicia is broader than delivery of goods. Other examples include cigarette packages which are labeled, and then the affixed label is cancelled for tax purposes. Presently, this labeling and cancelling stamp by tax stamp is performed by hand. The invention provided herein could readily be utilized by for such practices improving speed and efficiency of the process. 
         [0007]    Accordingly, a need exists to reduce the labor requirements while increasing the speed and accuracy of removing pressure adhesive indicia, such as labels, from backing sheets and precisely affixing the same to a target substrate. 
       SUMMARY 
       [0008]    Any reference to self-adhesive indicia, pressure adhesive indicia, labels, and stamps is merely exemplary, any of which could be used in place of another. Consistent with one aspect of the invention, apparatus is provided for precise automated stamp placement upon a target substrate. Consistent with another aspect of the invention is an apparatus for the automated removal of stamps or labels from a backing material. The backing and stamps can be, for example, in an individual sheet, or the sheets can be folded into a booklet configuration. 
         [0009]    Consistent with another aspect of the invention, a computer-readable medium storing program instructions is provided which, when executed, enables the user to select a desired stamp or multiple stamps from a given sheet for placement on a target substrate. The user can select the target substrate, the dimensions thereof, and the desired placement location and configuration for the desired stamps. Alternatively, the executed program will select the location and configuration of stamp placement based on at least one of the selected stamps and the selected target substrate. The user can select a sheet of stamps from a collection of the same and further select the desired stamps contained therein. Alternatively to selecting a target substrate from a group, the user can define the dimensions of the target substrate. Also, the user can select printing of a postmark onto a stamp-affixed-target substrate. 
         [0010]    Consistent with another aspect of the invention, a method is provided for removing pressure adhesive indicia from their backing sheet and affixing the removed labels to a target substrate. Consistent with another aspect of the invention there is provided a method for returning removed adhesive indicia, e.g. stamps, which are not affixed to a substrate, to a second backing for future use and or accounting purposes. A second backing is of course, not essential, and placement of adhesive indicia upon any paper which is fed out to an accounting and salvage station is commensurate with aspects of the invention. 
         [0011]    Consistent with another aspect of the invention there is provided a system for removing pressure adhesive stamps from their backing sheet and affixing the same to a target substrate. The automated system affixes stamps to the target substrate with both speed and precision of placement. Desired stamps can be removed from a backing, can be placed on variable locations upon the target substrate, and can be affixed in the desired orientation with precise spacing between stamps. The precision of affixation afforded by this system is commensurate with philatelic standards and is suitable for all pressure adhesive labels where rapid and precise placement is desired for cosmetic or other reasons. 
         [0012]    The system enables loading of target substrates at large into a hopper, feeder, or large collecting container. Target substrates are automatically, guided and moved throughout the system being positioned with accuracy in an affixing station and being subsequently transported to an outfeed area upon processing completion, where processing may include printing of a postmark upon affixed stamps. A magazine, hopper, or other storage apparatus is loaded with sheets of stamps for subsequent feeding to the removal apparatus. 
         [0013]    It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and together with the description, serve to explain the principles of the invention. 
           [0015]      FIG. 1  is perspective view of a system for removing pressure adhesive labels from a backing and affixing labels to a target substrate, consistent with the present invention. 
           [0016]      FIG. 2  is block diagram of a system consistent with the present invention. 
           [0017]      FIG. 3  shows a substrate feeder consistent with the present invention. 
           [0018]      FIG. 4  shows a pair of sheet units. 
           [0019]      FIGS. 5   a  to  5   d  illustrate the various components of a pickup unit consistent with the present invention. 
           [0020]      FIG. 6  shows a suction plate, consistent with the present invention. 
           [0021]      FIG. 7  shows a suction unit consistent with the present invention. 
           [0022]      FIG. 8  illustrates components in a peeling area, consistent with the present invention. 
           [0023]      FIG. 9  shows an affixing unit consistent with the present invention. 
           [0024]      FIG. 10  shows one of a pair of salvage units consistent with the present invention. 
           [0025]      FIG. 11  shows a cancellation unit  600  consistent with the present invention. 
           [0026]      FIG. 12  shows an output unit  700  consistent with the present invention. 
           [0027]      FIG. 13  shows an inspection system  800  consistent with the present invention. 
           [0028]      FIG. 14  shows a flow diagram of the operator interface protocol for the system of removing pressure adhesive stamps and affixing the stamps to a target substrate performed by a processor when executing program instructions stored on a computer-readable medium. 
           [0029]      FIG. 15  is an illustration showing a method of pressure adhesive stamp removal, consistent with an exemplary embodiment of the present invention. 
       
    
    
     DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0030]      FIG. 1  is perspective view of an automated system  10  for removing pressure adhesive labels from a backing and affixing labels to a target substrate, consistent with the present invention.  FIG. 1  shows the major areas and units of system  10  and their physical positions relative to each other in one embodiment. 
         [0031]    Consistent with the invention,  FIG. 2  is block diagram of an automated system  10  for removing labels, such as stamps, from a backing and affixing them to a target substrate, such as an envelope. System  10  may include a target substrate feeder unit  100 , which may be a hopper or large collector apparatus. System  10  may also include a pair of sheet units, or stamp sheet units,  200  and an affixing station  300 . System  10  may further include a pair of salvage units  400 , a cancellation unit  500 , an output unit  600 , and an inspection unit  700 . A control unit may be provided and coupled to substrate feeder unit  100 , sheet units  200 , stamp affixing unit  300 , salvage units  400 , cancellation unit  500 , output unit  600 , and inspection unit  700  by connections, not shown. 
         [0032]    In general operation of one embodiment consistent with the invention, a sheet unit  200  picks up a sheet of stamps and removes the backing from the sheet, while holding the individual stamps. The stamps are then transported to affixing station  300 , where the stamps, either individually or in groups, are affixed to envelopes supplied from substrate feeder unit  100  by a transport system. The envelopes with affixed stamps may then be transported to cancellation unit  500  where an imprint, such as a cancellation, is place on the envelopes. After passing through inspection unit  700 , the envelopes, with affixed stamps, are transported to output unit  600 , which processes the envelopes into a form suitable for packaging. One sheet unit  200  may operate as described above, while the other sheet unit  200  is off-line, being configured to handle a different size sheet, as will be described below in greater detail. In alternate embodiments, system  10  may include only a single sheet unit  200  and salvage unit  400 . 
         [0033]      FIGS. 3-13  provide a more detailed view of respective major components shown in  FIGS. 1 and 2 .  FIG. 3  is an illustration of a substrate feeder  100  which includes a substrate hopper  110  and a first transport mechanism  120 . In one embodiment, the first transport mechanism maybe an indexing belt. In other embodiments, the substrate feeder comprises a large collector apparatus, and in yet another substrate hopper  110  is a friction feeder. In various embodiments, the target substrate maybe an envelope, a card, or a package. Still further, the package could be a package of consumable goods. The substrate feeder supplies a single substrate to affixing station  300  at an affixing location. Substrates are fed onto transport mechanism  120  singly and then move up the transport line to the point where affixing occurs. 
         [0034]    One or more indexing belts, as shown for example in  FIG. 3 , move the target substrate through system  10  ( FIG. 1 ). These belts may travel just below the surface upon which the substrate rides. The separation of the belts may be adjustable by use of various size magnetic spacer plates (not shown) Pusher members, or “flights,” mounted in the belt push the substrate along. In affixation station  300 , a front pin, not shown, restricts forward movement of the substrate when positioning the same for affixing the stamps. The indexing belts maybe driven by timing pulleys, with the drive pulleys at the output unit  600  end of the machine and idler pulleys at the substrate feeder unit  100  end. Both drive and idler pulleys maybe attached to timing hubs which are mounted on keyed shafts. The pulleys maybe adjustable along their respective shafts to accommodate different widths of target substrates and different belt separations. Generally, it is sufficient to move the belt closest to the feeder only. 
         [0035]    Guide rails (not shown) run along the whole length of the system and maybe magnetically attached to the top plates. The position of the rails should be adjusted to accommodate different target substrate sizes. The rails maybe made in short lengths, such that excessive magnetic force does not oppose desired movement or repositioning. The rails maybe mounted end to end, forming a smooth connection from one rail piece to the next. 
         [0036]    Sheet units  200  may comprise a drawer frame  202  and a lifter  204 , as shown in  FIGS. 4   a  and  b,  respectively.  FIG. 4   a  is a top view of a three dimensional frame while  FIG. 4   b  is a side cross-section view. The hopper drawers  20  and  25  ( FIG. 1 ) may slide into the front and back drawer frames  202  ( FIG. 4   a ). Sheets of stamps maybe inserted into a drawer  20  or  25  by an operator as a stack on a lift plate  206  ( FIG. 4   a ).  FIG. 4   c  shows lifter  204  from a front cross sectional view. 
         [0037]    Drawer  20  or  25  ( FIG. 1 ) has a secondary container (not shown) inside, which is mounted on slides that allow it to be moved backwards and forward within the drawer. Within the secondary container are a number of vertical retainers (not shown) which allows various size lift plates  206  ( FIG. 4   a ) to be fitted, to accommodate various sizes of sheets. 
         [0038]    Lifter  204  operates from beneath the lift plate  206  and raises lift plate  206  supporting the stack of sheets to a position where a pickup unit (described below) can remove a single sheet from the stack. Drawer  20 ,  25 , is locked in the closed position by a pneumatic plunger and maybe released and allowed to open via a push button (not shown). This push button maybe on a safety circuit to prevent release of the drawer during certain periods of the system operation cycle. 
         [0039]      FIG. 5   a  shows a cross section of a pickup unit  250  consistent with the present invention. Although the embodiment of system  10  shown in  FIGS. 1 and 2  operates with a pair of pickup units at either side of feeder unit  200 ,  FIG. 5   a  shows a single pickup unit  250 . The purpose of pickup unit  250  is to pick up and transfer a sheet of stamps from lift plate  206  to a peel unit (peel areas  60 ,  65 ,  FIG. 2 ), to the affixing station  300  ( FIG. 1 ), and then return to the salvage unit  400  ( FIG. 1 ) where it deposits any unused stamps and the sheet margins. 
         [0040]    Referring to  FIG. 5   a,  pickup unit  250  may include a suction plate  252  and a plurality of suction units  256  mounted thereon. Turning to  FIG. 5   b,  a top view of the suction plate  252  shows suction units  256  mounted thereon as well as a plurality of miniature electrically-operated vacuum valves  254  and a plurality of connection hoses  258  which connect valves  254  to suction units  256 . Pickup unit  250  may also include a pickup plate  258 , and a transport system  260  (shown in  FIG. 5   a ). Valves  254  ( FIG. 5   b ) may be arranged in three banks, each parallel to one side of suction plate  252 , where  FIG. 5   b  shows two valve banks with hoses  258  extending towards these two banks and towards a third side of the suction plate  252 . Suction units  256  may be arranged in an array of, for example, sixty suction units formed as five columns of twelve units. Connection hoses may be removably attached to respective valves  254  and suction units  256  to provide different configurations, as desired for various operational runs of system  10  to process various types of sheets. 
         [0041]    Turning to  FIG. 5   c,  each bank of valves  254  may be connected to a vacuum manifold  255 , which may in turn include a component for removable attachment to a vacuum source. Similarly, each valve  254  may be electrically connected to a connection fitting and removably connected to terminals of control system  800  ( FIG. 2 ). The entire suction plate  252 , with included valves  254  and suction units  256  may thus be quickly and conveniently removed from pickup unit  250  and replaced with another suction plate  252  having a different configuration of valves  254  and suction units  256 . 
         [0042]    As may be seen more clearly in  FIG. 7 , suction units  256  may be formed of a suction block  260  including a vacuum port for receiving a connection hose  258 , one or more suction tubes  262 , and a suction cup  264 , formed as a unit. A pneumatic passage is formed from the vacuum port of suction block  260 , through suction tubes  262 , to suction cup  264 . Suction cups  264  are preferably bellows-type suction cups 
         [0043]    Each suction unit  256  may also include a contact nub  266  and a spring  268 , to provide a spring-loaded mounting of suction unit  256  to suction plate  252 . That is, suction tubes  262  movably extend through suction plate  252 , with suction cup  264  and suction block  260  on opposite sides of suction plate  252 . Spring  268  maintains suction cup  264  in proximity to suction plate  252 . However, downward pressure against nub  266  will cause suction cup  266  to move to a second position spaced away from suction plate  252 . Contact nub  266  may be a nylon domed nut. 
         [0044]    Referring now to  FIG. 6 , pickup unit  250  includes an X-Y transport mechanism  280 , which enables the suction plate  252  to move with precision in a horizontal plane from a position over the stack of sheets on lifter  204  ( FIG. 4   a ) and to a position in affixing station  300  over the target substrate. Stamps separated from their backing are moved into position via the X-Y transport system of the pickup unit, shown in  FIG. 6 , to the affixing station  300  ( FIG. 1 ). 
         [0045]    Under control of control unit  800 , transport mechanism  280  positions pickup unit  250  over the stack of sheets in lifter  204 . A pickup plate  277 , above and parallel to suction plate  252  is then lowered by control unit  800  into contact with nubs  266  of suction units  256 . Pickup plate  277  continues to descend, compressing springs  268  of suction units  256  until suction cups  264  come into contact with the top sheet on lifter  204 . Control unit  800  then actuates vacuum valves  254  to deliver suction to suction units  256 , causing the top sheet to be held by vacuum against suction cups  264 . Control unit  800  then raises pickup plate  277 , allowing springs  268  to raise suction cups  264  into proximity with suction plate  252 , raising the sheet of stamps. 
         [0046]    After being removed from the lifter and before being transported to the affixing station, the sheet of stamps is “peeled,” separating the stamps from the sheet backing. Turning to  FIG. 8 , the peeling area may include grippers  284 ,  285 , a pickup plate  258 , and peel plate  270 . To initiate separating a backing sheet from stamps, a pickup unit  250  is controlled by control unit  800  ( FIG. 2 ) to move a sheet of stamps to the peeling area  60 ,  65  ( FIG. 1 ) onto a peel plate  270  ( FIG. 8 ). While the suction cups  264  maintain control of the stamps, one or more grippers, for example, grippers  284 ,  285  of pickup unit  250  clamp onto the selvage, or border area, of the sheet where no stamps are present. Grippers  284 ,  285  clamp onto opposite sides of the sheet. Briefly, gripper  284  pulls the backing sheet in a downward direction along an edge of peel plate  270 , removing the backing from the stamps, which are still held by vacuum to the suction cups. Exemplary peeling operations will be described in greater detail below. 
         [0047]    The suction plate X-Y mechanism  280  ( FIG. 6 ), moves the stamps under accurate control of control unit  800  in the X-Y direction in a horizontal plane, to a precise location directly over a substrate on the belt of transport mechanism  120 . Transport mechanism  120  has indexing capability, that is, it is capable of transporting and stopping the substrate, also in a precise location. 
         [0048]    Turning to  FIG. 9 , an affixing member  410  is mounted on a second X-Y transport mechanism  420 , which moves affixing member  410  to a precise location above pickup unit  250 , as determined by operator-entered commands supplied to control unit  800 . Affixing member  410  may be, for example, a pneumatically-operated plunger. 
         [0049]    Control unit  800  actuates affixing member  410 , causing it to descends into contact with a nub  266  of precisely selected suction unit  256 . Spring  268  of the selected suction unit  256  compresses and the respective suction cup  264  then descends, causing the respective stamp held by suction cup  264  to move into contact with a substrate  290 , resting on bed plate  295 . While the stamp is in contact with substrate  290 , control unit  800  actuates the valve  254  corresponding to the selected suction unit  256 , removing vacuum from the suction cup and releasing the stamp. The pressure adhesive of the stamp causes the stamp to be affixed to substrate  290 . Control unit  800  then actuates affixing member  410 , causing it to lift, allowing spring  268  to return suction cups  264  into position in proximity to suction plate  252 . 
         [0050]    Although the above operation was described with one suction cup per suction unit, in certain applications it may be desirable to provide a plurality of, for example, four, suction cups per suction unit. Similarly, in certain applications it may be desirable to provide affixing unit with a broad strike surface, such that it contacts more than one suction unit. 
         [0051]    The stamp affixing operation is programmable through an operator interface to hold substrate  290  in position as pickup unit  250  and affixing member are translated to precise desired locations to sequentially affix additional stamps on other locations of substrate  290 . This operation is particularly useful for instances when it is desired to affix multiple stamps from a given design or series of stamps. Alternately, programming commands may instruct the transport mechanism  120  to advance following each affixing step, precisely positioning the next substrate beneath the positioning member so that a single stamp may be affixed to each target material, each in the same position on the subsequent substrates. When the affixing procedure is completed on a substrate, it is transported away from affixing station  300  toward output unit  700 , where it may be dropped onto a conveyor belt running perpendicular to transport mechanism  120 . From this point, an operator may collect the finished product. 
         [0052]      FIG. 10  shows salvage unit  500 , which is used to collect unused stamps and sheet margins for operator disposal. After depositing the required number of stamps from the sheet onto target substrates at affixing station  300 , pickup unit  250  moves back toward sheet unit  200  to the salvage unit  400 . There, control unit  800  causes a pressure plate, activated by four (4) pneumatic cylinders, to descend onto suction plate  252  depressing all spring-loaded vacuum cups  264  onto a continuous roll of salvage paper that passes over a stamp deposit plate of salvage unit  400 . 
         [0053]    In another embodiment, stamps unaffixed to target substrates are affixed at salvage unit  400  to a second backing material. Stamps on this second backing material may be collected for accounting. In still another embodiment, sheets, rather than rolls can be used to mount unused stamps upon. 
         [0054]    In some embodiments, all stamps from a sheet may not be desired to be affixed onto a target substrate. This would often occur when affixing specific designs from a multiple design sheet or a specific configuration, such as a plate number block of four stamps. In such an embodiment, prior to pickup unit  250  returning to sheet unit  200  to pick up another sheet of stamps, it first drops the entire array of suction cups  264  onto a platform  504  to release any unused stamps. The platform  504  is covered with backing paper  564  for later reuse, or other paper, on a roller mechanism  574 ,  576 . Any remaining stamps are affixed to this paper on platform  504  which is automatically advanced by a take up roller. At the end of a run or affixing period, the roll of paper  564  may be retrieved and any reaffixed stamps counted. Since stamps have inherent monetary value, this controlled method of disposing of unused stamps allow appropriate accounting and inventory in the instance of non-backing paper and reuse in the case of backing paper. 
         [0055]      FIG. 11  shows cancellation units  600  which, in one embodiment, may comprise one or more Tampon printers  602 . A printing pad comprises an engraved image of, for example, a postmark. Alternatively, multiple pads may be combined to form an intricate postmark when printed in combination. In other embodiments a one or more digital printers  603  in cancellation unit  400 , may print a postmark on the target substrate and the affixed stamps. A series of postmarks may be imprinted or alternatively a series of printing stages may form a complex postmark. The digital printers can form black and white or multi-colored postmarks. Personalized postmarks are possible in accordance with another embodiment of the present invention. 
         [0056]      FIG. 12  shows an output unit  600  consistent with the present invention. An outfeed unit can, in one embodiment, be programmed in control unit  800  to stack the affixed substrates. Both the number of substrates in a stack and an offset spacing between individual substrates within a stack can be specified, for example,  25  and  0 . 5  in, respectively. Discharge rollers of output unit  700  may be positioned at the end of system  10  and eject the finished product unto a discharge conveyer. The discharge rollers may run at a faster speed than transport mechanism  120 , which allows the product to be drawn away from the pushers on the indexing belt of transport mechanism  120 . 
         [0057]      FIG. 13  shows an inspection unit  700 , which may optionally be used with system  10 , consistent with the present invention.  FIG. 1  shows the physical location of inspection unit  700  in relation to other system components. Inspection unit  700  automatically inspects affixed (and, if applicable, postmarked) substrates for compliance with quality or inspection standards. These standards are maybe programmed into control unit  800  and the user can select the parameters to evaluate and the tolerances for each parameter. Parameters which can be inspected include: presence of a stamp, position of any or all stamps within 0.02 in of the desired placement with respect to the substrate and adjacent stamps, and the presence and positioning of a postmark. Alternatively, the inspection parameters may look at the presence and position of a block or group of stamps with or without a postmark as a whole. A digital camera  702  ( FIG. 13 ) mounted within the inspection station accommodates accurate evaluation of various sized target substrates and various stamp configurations. The sensitivity of the inspection is adjustable. For example, the programming user can adjust sensitivity by selection or input of acceptable tolerances. The depth of field or field of view of the camera can be varied by, among other means, changing the camera position relative to the substrate via adjustable-camera-mounting, or adjusting the camera aperture. The inspection station can even be programmed to reject the stamp itself, for example, if it is defective or torn. Access to inspection program parameters may be provided to the user in inspection unit  700  via a touch screen  705  ( FIG. 13 ). 
         [0058]    Control unit  800  may be a standard programmable industrial or personal computer. Control unit  800  may include a processor, a memory unit and a mass storage unit. As shown in  FIG. 2 , an operator interface screen  900  coupled to control unit  800  may provide the user with numerous options to program control unit  800 . The programmable instructions, which when executed by the processor, may perform a method which includes removing pressure adhesive stamps, and affixing the stamps to a target substrate, selecting a target substrate  410 , as shown for example in  FIG. 14 . The target substrate can be selected from a few or a multitude of substrate options to include a sheet of paper, an envelope, a card, or a package  415 . The operator can enter numerically  422  or choose by displayed options the dimensions of the target substrate in a stamp affixation plane  420 . 
         [0059]    The operator can also select a sheet of stamps from a collection of sheets or may specify the number of stamps, their size, and configuration  432  on the sheet  430 . Next, the operator can select any of or all of the stamps for affixing to the target substrate  435 . 
         [0060]    The operator can indicate the desired placement location of each selected stamp  440 . In another embodiment, the placement location is determined by characteristics of the target substrate and the selected stamp or group of stamps  445 . 
         [0061]    Other programmable options include, selecting a desired postmark application  450  and inputting the height of the target substrate, normal to the affixation plane  455 . 
         [0062]    In yet another embodiment, an outfeed unit  600  ( FIG. 12 ) and a rejection unit  95  ( FIG. 1 ) facilitate moving affixed substrates out of an automated system. These units are housed downstream of the inspection unit  90 , as shown in  FIG. 1 . The outfeed unit may comprise rollers and a convery and can, in one embodiment, be programmed to stack the affixed substrates. Both the number of substrates in a stack and an offset spacing between individual substrates within a stack can be specified, for example, 25 and 0.5 in, respectively. 
         [0063]    The rejection unit  95 , ejects substrates, which fail to meet inspection standards, out of the system into a collection apparatus before the substrate would enter the outfeed unit. 
         [0064]    In another embodiment, system  10 , as shown in  FIG. 1 , counts the number of target substrates loaded into the feeder, the number of acceptable affixed substrates that have been outfed and the number of substrates which have been rejected and ejected from system  10 . 
         [0065]    In another embodiment of system  10 , the substrate is tracked as it proceeds through the system, for example in the feeder  15 , the affixing unit  81 , in a first cancellation unit  80 , or in the inspection station  90  ( FIG. 1 ). 
         [0066]    MOVE to END After affixing the desired stamps, the target substrate is transported through a postmark station in the cancellation units  80 , where cancellation occurs if desired and programmed. Following the cancellation unit, substrates enter the inspection and rejection units,  290  and  295 , respectively. 
         [0067]    Embodiments of the stamp affixing system, apparatus, and method consistent with the invention may perform the task of backing removal and stamp affixing on the target material at a rate of 2400 stamps per hour, a significant improvement over the manual rate. 
         [0068]    Peeling Operation 
         [0069]      FIG. 8  shows grippers  384 ,  385  and peel plate  270  according to an embodiment of the apparatus operating in peel areas  60  and  65  ( FIG. 1 ). In this embodiment, suction units  264  not only translate horizontally with respect to peel plate  270  on which the sheet rests, but also slightly in a vertical direction, as shown in  FIG. 8 . This vertical movement is produced by a ramp portion  259  of pickup plate  258 . 
         [0070]    As suction plate  252  is translated horizontally to the right with respect to the stationary pickup plate  258 , by transport mechanism  280 , nubs  266  follow the upwardly curving surface of ramp portion  259 , at the edge  271  of peel plate  270 . The effect is to separate the column of stamps held by suction units  264  in contact with ramp portion  259  from the remainder of columns of stamps on the sheet. In another embodiment, a pivot mechanism  287  causes gripper  285  to move vertically downward with respect to peel plate  270  before translation of the stamps or the backing, causing a crease in the backing. 
         [0071]    Turning to  FIGS. 15A-D , an embodiment of the peeling process is shown in still greater detail. The stamps of the sheet are removed from backing  289  while the suction cups  264  hold the stamps. Backing  289  is gripped by grippers  284  and  285  on opposite sides of the sheet, on the border or selvage of the sheet. A slight force is applied to gripper  284  to pull it away from gripper  285  to put the sheet in tension. (Note that movement of the sheet is to the left in  FIGS. 15A ,  15 B,  15 C, and  15 D, the opposite direction from  FIG. 8 ) Gripper  284 , suction units  264 , and gripper  285  move at the same speed such that the stamps (held by suction cups  264 ) and backing  289  of the sheet move in parallel across peel plate  270 . As shown in  FIG. 8 , grippers  284  and  285  are driven by separate server motors. Perforations in the stamps of the sheet, when present, run parallel to the direction of translation of the stamps.  FIG. 15C  shows the backing  289  completed separated from the stamps  32  and each stamp secured to a suction cup  264 . 
         [0072]      FIG. 15D  shows the backing separated from the stamps and collected in backing dump sites, e.g.  70  and  75  in  FIG. 1 . The stamps and backing are separated at the edge  47  of the peel plate  270  ( FIGS. 8 and 15C ). 
         [0073]    A sensor detects the position of the affixing head before release of suction on the suction head or heads. 
         [0074]    In still another embodiment, the front gripper  284  which is mounted on a vertical slide, is pivoted 30° over a “knife” edge  47  of peel plate  270  ( FIG. 8 ), by a small pneumatic cylinder; this has the effect of separating the backing sheet from the stamps, which are still held on the vacuum cups of the pickup unit. Alternatively, the front gripper  284  is moved vertically down slightly, e.g. by 1 mm, putting tension on the stamp sheet and assisting in removing the backing sheet from the stamps. 
         [0075]    The front gripper, rear gripper, and pickup unit now move together to remove the complete backing sheet from the stamps. On reaching a position where the last stamps have been removed, the rear gripper jaws are opened and the front gripper jaws carry the backing sheet down to the ‘backing sheet dump’ drawer, were it is released. 
         [0076]    While  FIGS. 15A-D  show a one-by-three array of suction units, alternate embodiments include, but are not limited to, five by 12 arrays. Individual suction cups  264  can hold an individual stamp or more than one suction cup  264  can hold a single larger stamp. 
         [0077]    Other embodiments consistent the invention will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit of the invention being indicated by the following claims.

Technology Category: 7