A device for distributing cards on a carrier.

Abstract

The device provides a mechanism for distributing cards on a carrier. [Solution] The apparatus 500 includes a first transport line 10 for transporting individual carriers 110 from an inlet to an outlet, a second transport line 20 for transporting individual cards, an inlet check station 160 suitable for checking all data printed on the carriers 110 and for performing checks on the data printed on the incoming carriers 110, a transport device for moving the incoming unloaded carriers 110 in a configuration suitable for matching with cards on the upper exposed surface of the incoming unloaded carriers 110, and a matching station, the robotic device 6 suitable for picking individual cards and placing them on the target surface of the target carrier 110.

Description

Technical Field

[0001] The present invention relates to an apparatus for dispensing cards onto a carrier, which carrier may in some cases consist of a paper carrier or paper substrate for one or more cards used for direct mail of the cards, or simply a single sheet of paper used as a carrier.

Background Art

[0002] This type of apparatus comprises a first transport line for transporting individual carriers, i.e., paper documents on which all the required data has already been printed, from an inlet to an outlet of the apparatus, and at least one second transport line for transporting individual cards that are collated individually with the incoming carriers.

[0003] Direct mail is known to be an important tool for companies to communicate with customers and to meet the need to distribute by mail to individuals debit cards or credit cards, business cards, identity verification documents such as identity cards or driver's licenses, or cards such as membership cards.

[0004] These cards are inserted into envelopes addressed to the appropriate recipients and may be sent individually to the individuals or as part of a single package combined with other inserts or components of the mailing, all of which make the preparation of such mailings laborious and time-consuming.

[0005] Hereafter, the term “card” means a substantially rigid card having a basically rectangular shape and made of plastic or other plasticizing material, which may include, in some cases, identification information, biometric data, images, alphanumeric characters, QR (Quick Response) codes or barcodes, readable characters of an International Civil Aviation Organization (ICAO) Machine-Readable Travel Document (MRTD) or electronic Machine-Readable Travel Document (eMRTD), RFID (Radio Frequency Identification) tags or NFC (Near Field Communication) tags, and magnetic stripes.

[0006] These types of cards typically have formats defined according to ISO standards 7810, 7811, 7813, 7816, and 14443, or formats A7, A8, B7, B8, C7, and C8 according to ISO standard 216. These card formats can also be used for magnetic or optical memory, toy cards, collectible cards, badges, smart lock access keys, and the like. All of these items fall within the definition of "card."

[0007] It is understood that, in addition to being hard or harder than regular paper, cards may be considered to be somewhat fragile or contain delicate parts.

[0008] Generally, such cards are attached to a paper carrier by adhesive, double-sided adhesive tape, or by fitting them into a frame with appropriate notches, and are mailed on the paper carrier. The recipient's address may be printed on the paper carrier so that it is visible through the envelope window, or directly on the envelope itself. The carrier, and in some cases the envelope, may also contain identification data that may allow for the secure coupling of only the intended cards.

[0009] The paper carrier has an exposed area to which one or more cards can be attached. The paper carrier is generally A4 or letter-sheet format and must be folded in two or three folds before being inserted into the associated envelope, the latter having a Z-fold or C-fold.

[0010] Mail preparation and finishing systems increase efficiency by automating the printing, folding, and insertion processes. However, the distribution of individual cards addressed to specific carriers remains a crucial stage in the overall mailing process.

[0011] However, it is necessary to perform a faster distribution stage using robotic equipment by simultaneously checking the input and output of pre-printed carriers, which usually already have folds or creases to facilitate the subsequent encapsulation stage.

[0012] In reality, the various formats and folding configurations of carriers can hinder the accurate identification of personal data already present on the carrier, in which case the coupling between the carrier and the associated card can be affected by errors. This complicates the mailing process, forcing postal service providers to repeat the distribution stage multiple times.

[0013] Furthermore, in known devices, cards are fed into a first transport line by a suitable feeder, while carriers are fed through a second transport line to a card-paper carrier coupling station. Both transport lines must be equipped with reading stations to read identification data, considering the sensitivity and importance of the personal data contained on the cards, ensuring that the transport lines themselves are synchronized and that the coupling between the cards and individual carriers is an error-preventing measure. [Overview of the project] [Problems that the invention aims to solve]

[0014] The underlying technical problem of the present invention is to provide a device for distributing cards onto a carrier that eliminates the shortcomings mentioned by reference to known technologies. [Means for solving the problem]

[0015] The above-mentioned problem is then resolved by an apparatus as defined above and attached to claim 1.

[0016] According to the present invention, a device for distributing cards onto a carrier can be simply referred to as a distribution device.

[0017] Accordingly, a preferred embodiment of the present invention includes an inlet check station at the inlet, which is suitable for performing checks on data printed on an incoming carrier.

[0018] At the entrance check station, the apparatus of the present invention has a transport device, which is configured to be suitable for matching with one or more cards on the upper exposed surface of the incoming carrier, and moves the incoming carrier across the entrance check station.

[0019] In this regard, the carrier may be in a flat configuration or partially folded, and as a result, the above data may be printed on the upper exposed surface, or otherwise on the hidden surface, i.e., downward.

[0020] The apparatus further comprises a matching station, and at least one robotic device is suitable for picking individual cards and positioning them on a portion of the target surface, i.e., the upper exposed surface, of the carrier to be targeted.

[0021] According to the present invention, the entrance check station comprises a check area having a transparent support plane, on which the arriving carrier is slidably guided to move across the check area by a conveying device by applying a driving force to the side end of the arriving carrier.

Advantages of the Invention

[0022] The main advantage of the device according to the present invention lies in the fact that all the data printed on the carrier can be checked regardless of whether the data is printed on the exposed surface or the downward surface. The present invention will be described below according to its preferred embodiments provided by way of example and not for the purpose of limitation, with reference to the following accompanying drawings.

Brief Description of the Drawings

[0023] [Figure 1] An axonometric projection view of an embodiment of the dispensing device according to the present invention is shown. [Figure 2] It is a front view of the dispensing device of FIG. 1. [Figure 3A] An axonometric projection view of the dispensing device of FIG. 1 is shown, with some outer parts excluded to show the inside. [Figure 3B] It is a partially exploded axonometric projection view of the inside of the device shown in FIG. 3A. [Figure 4] A partial axonometric projection view of the first functional group of the dispensing device of FIG. 1 is shown. [Figure 4A] An axonometric projection view of the functional group of FIG. 4 is shown, with some outer parts excluded. [Figure 4B] A rear view of the axonometric projection of the functional group of FIG. 4 is shown, with some outer parts excluded. [Figure 5] A broken view of the functional group of FIG. 4 is shown. [Figure 5A] An axonometric projection view of the enlarged details of the functional group of FIG. 4 is shown. [Figure 6A] A partial axonometric projection view of the second functional group of the dispensing device of FIG. 1 is shown. [Figure 6B]Figure 6A shows a partial view of the back surface of the isometric projection of the second functional group. [Figure 7A] Figure 1 shows an isometric projection diagram illustrating the operation of the distribution device. [Figure 7B] Figure 1 shows an isometric projection diagram illustrating the operation of the distribution device. [Modes for carrying out the invention]

[0024] Referring to the figure, the device for distributing cards onto a carrier, briefly referred to as a distribution device, is collectively denoted by the code 500.

[0025] Apparatus 1 of the present invention is substantially provided for receiving a flow of cards through a first transport line and a flow of flat carriers through a second transport line having an upward-facing target surface. Apparatus 1 is equipped with a checking system for performing a distribution process in which individual cards are individually picked by a robotic device and placed on the target surface of the carrier to be processed, and such couplings of cards and carriers are then transported to a subsequent station in which an encapsulation process is performed.

[0026] Generally speaking, the device 500 comprises a first transport line 10 for transporting individual carriers from an inlet 120 to an outlet 150, and a second transport line 20 for transporting individual cards 610.

[0027] The device 500 has a support frame built on a base platform 100, with a first support frame 170 positioned at the entrance 120, a second support frame 190 positioned at the exit 150, and a central frame positioned in the middle.

[0028] The support frame is structured to leave an empty space between the base platform 100 and the upper level on which the first conveyor line 10 is located.

[0029] The device 500 includes a first entrance check station 160 located at the entrance on a first support frame 170, on which an unloaded carrier 110 is moved to be checked before being matched with the corresponding individual cards 610, the unloaded carrier 110 being in a flat configuration but in some cases having a fold line 114 within it or being partially folded.

[0030] The first inlet plate 246 is located at the inlet, and the first outlet plate 115 is located at the outlet of the inlet check station, connecting the first transport line to the subsequent station (Figure 3A).

[0031] Individual data or personal data 300 is printed on any unloaded carrier 110, and a subsequent check is performed to verify it against the corresponding card 610.

[0032] The first check station 160 comprises a check area having a transparent support plane 240, on which an unloaded carrier 110, also referred to as an incoming carrier, is guided to slide across the check area in a configuration suitable for matching with one or more cards on its upper exposed surface.

[0033] In this regard, the first check station 160 includes a separate first transport device 30 which moves the incoming carrier 110 on the transparent support plane 240 by applying a driving force to the side end of the incoming carrier 110.

[0034] The transparent plane 240 is suspended on the support frame 170, and the space beneath the transparent plane 240 remains virtually empty.

[0035] The entrance check station 160 comprises at least one upper detection device 130 suspended above the transparent plane 240 and a lower detection device 132 located in the space below the transparent plane 240.

[0036] The upper detection device 130 is a first digital camera having an upper vision volume 131 that contains the check area. Similarly, the first lower detection device 132 is a second digital camera that defines a lower vision volume 133 in an empty space, oriented toward a transparent support plane 240.

[0037] Furthermore, the device 500 includes an inlet optical sensor 320 located at the inlet and an outlet optical sensor 322 located at the output of the inlet check station and suspended on each arm, suitable for detecting the travel ends and tails of the carrier as it moves through the first check station 160.

[0038] The first conveying device 30 comprises each first endless belt 210 driven by a corresponding toothed drive wheel 205 mounted on the drive shaft of the first motor 200.

[0039] The endless belt is sometimes embodied by a toothed belt made of a rubber-like material to provide high friction on the sliding surface 305 of the support plane 240. The first endless belt 210 is positioned to form a drive segment extending from the associated inlet wheel 222 to the associated outlet wheel 220, which are located at the inlet and output of the inlet check station 160, respectively, thereby driving the drive segment to slide on the transparent support plane 240 to transmit driving force.

[0040] The path of the first endless belt 210 is also defined by the first tension wheel 215 and the second tension wheel 224 (Figure 5).

[0041] The conveying device 30 further comprises a plurality of pressing rollers 228 arranged along the drive segments of each first endless belt 210, the pressing rollers 228 being pivotally supported on bearings mounted on pressing levers 232 having a pivot point 213 which is integrated with the support frame member 40 in an idle state, the levers 232 being rotated by individual springs 218 connected to the frame member 40 by hooks 216.

[0042] Each pressure roller 228 is independent and separated from adjacent ones by a partition wall 212 integrated with the lever 232.

[0043] The frame members 40 positioned on each side of the support plane 240 are movable toward their centerline in a direction across the transparent support plane 240 with the help of a handle 41 or other suitable displacement device.

[0044] The device includes a coupling station 50 located between the inlet check station and the matching station, the coupling station 50 being suitable for applying individual coupling points to the upper exposed surface.

[0045] In the coupling station 50, the device 500 includes a second motor 450 for rotating a second drive wheel 595, which is a toothed wheel for pulling a second endless belt 468 that engages with two different tail wheels: a first tail wheel 461 connected to the end of a first lower shaft 476 and a second tail wheel 463 connected to the end of a second lower shaft 472.

[0046] The first lower shaft 476 has a first lower pinion 465 mounted on the first lower shaft at the same end of the first tail wheel 461, which engages with a first upper pinion 462 connected to the end of the first upper shaft 474. The pinions 465 and 462 have a 1:1 transmission ratio.

[0047] The lower and upper first shafts 476 and 474 are both pivotally supported on bearings mounted on a side frame plate 102, which acts as a side wall and shaft support plate on the opposite side of the device 1, and extend along them, suspended in a vertical position on a support frame constructed on the base platform 100, i.e., on the first support frame 170 and the second support frame 190, to form a central frame in the middle.

[0048] The lower and upper first shafts 476, 474 hold pairs of first upper tension rollers 455 and first lower tension rollers 456, respectively, which have the same diameter and rotate in opposite directions at the same speed and the same peripheral speed while remaining in contact with each other.

[0049] These dragging rollers are provided to capture the carrier's movement from its end at the exit of the first check station 160, thereby advancing the carrier beyond the coupling station 50.

[0050] The second lower shaft 472 has a second lower pinion 464 mounted on the second lower shaft at the same end of the second tail wheel 463, which engages with a second upper pinion 466 connected to the end of the second upper shaft 470. The pinions 464, 466 have a 1:1 transmission ratio.

[0051] The lower and upper first shafts 472 and 470 are both pivotally supported by bearings mounted on the side frame plate 102.

[0052] The second lower shaft 472 has individual second lower tension rollers 458, and the second upper shaft 470 has a plurality of upper tension rolls 460 having the same diameter as the second lower tension rollers 458, which are formed as wheels mounted at a certain distance from each other but rotate in opposite directions while remaining in contact with each other and rotating at the same speed and the same peripheral speed.

[0053] These additional tension rollers are arranged to cooperate with the first tension rollers, at a certain distance from the first tension rollers, to capture the carrier together as it passes through them, and to advance the carrier beyond the coupling station 50, thereby applying tension to the carrier at the coupling station.

[0054] In this regard, the bonding station 50 is provided with at least one adhesive gun for depositing adhesive points 484, 486 on the upper exposed surface to function as individual bonding points, and according to the drawings in Figures 6A and 6B, there are two adhesive guns schematically represented by arrows 480 and 482, and three upper tension rolls 460 are provided so that the two adhesive points 484, 486 do not come into contact with each other.

[0055] Note that at bonding station 50, according to the information captured by the first check station 160, the adhesive guns 480 and 482 will not operate within the area containing the relevant data 300.

[0056] At the exit of the coupling station 50, there is a rejection plate 248 suitable for diverting carriers that have been found not to conform to the system's expectations at the first check station 160 and directing them into a rejection box located below the first transport line.

[0057] Next, the unloaded carrier 110 moves forward through the matching station 140, where at least one robotic device is provided and suspended above the flow of carriers along the first conveyor line 10, and a second conveyor line 20 having its terminal for transporting individual cards 610, the robotic device is a pick-and-place robotic device suitable for picking individual cards so that the individual cards 610 are placed on the target surface of the unloaded carrier 110 in question, ultimately resulting in a loaded carrier 118.

[0058] In this embodiment, the robotic device is a delta robot having a plurality of articulated arms 62 supported by a suspended platform 61, each arm having a relative picking device 63 attached to its terminal working end, the picking device 63 being a suction-based device with a suction cup that is pneumatically operated to capture and release individual cards.

[0059] At the matching station 140, the device 500 is equipped with a rejection conveying line 528 for transporting cards that are not applicable to any carrier, supplied by a delta robot.

[0060] Furthermore, along the first transport line 10, the device 500 includes a second check station 180 which operates as an exit check station, the second check station suspended on a second support frame 190 and providing a second check area 116 which includes a separate second upper detection device 134 made by a third digital camera and a separate second lower detection device 136 made by a fourth digital camera.

[0061] The second inlet plate 117 is provided at the inlet of the second check station 180, and the second outlet plate 118 is provided at the outlet of the second check station as a connection to the first transport line (Figure 3A).

[0062] The exit check station is suspended on a separate support frame 190, leaving the space below the separate transparent plane substantially empty, where the second lower detection device 136 is located.

[0063] In this embodiment and according to the present invention, the first and second check stations 160, 180 have substantially the same structure and configuration, the check area is provided on separate transparent support planes, and the loaded carrier 118 to be shipped thereon is intended to be guided to slide across the check area by a second conveying device that applies a driving force to the side ends of the carrier to be shipped.

[0064] Accordingly, the first and second conveying devices are intended to have substantially the same structure and configuration, and as a result, the second conveying device comprises an endless belt, each driven by individual drive wheels, forming a drive segment extending from a related inlet wheel to a related outlet wheel, these wheels positioned at the inlet and output of the outlet check station, respectively, thereby driving the drive segment to slide on a transparent support plane to transmit driving force. These endless belts are again pressed by a plurality of idle-state pressing rollers, each pivoted on bearings mounted on levers having fulcrums integrated into individual frame members, the levers being rotated by individual springs connected to the frame members, and finally the frame members being movable in a direction traversing the transparent support plane toward their centerline.

[0065] In summary, referring to Figure 7A, the apparatus 500, in a flat configuration, accepts an unloaded carrier 110 from any suitable supply source (1), and the advancing carrier is then checked by a first check station 160, which can observe all data imprinted on both carrier surfaces (2).

[0066] Next, the carrier optionally accepts coupling means that can be applied to the cards at the coupling station 50. The carrier then moves forward through the matching station 140, where the robotic device picks up the cards 610 from separate ends of dedicated transport lines and places them on the carrier with the associated coupling means (3).

[0067] Next, the loaded carrier 118 passes through a second check station 180, where the compatibility of the coupling between the card and the carrier is finally checked, and all data printed on the carrier and card is observed on both carrier surfaces (4), and if necessary, incorrect couplings are eliminated via the discharge line 680.

[0068] Finally, the loaded carrier 118 is released at the exit of the device 500(5).

[0069] Next, referring to Figure 7B, the device 500 receives an unloaded carrier 110 from any suitable source (1) in a folded configuration, i.e., having a flap hidden beneath the main part of the carrier 110, with the relevant data possibly printed on its downward-facing surface.

[0070] In either case, the forward carrier is checked by a first check station 160, which can observe all the data printed on both carrier surfaces (2).

[0071] Next, the carrier optionally accepts the coupling means, which may be applied to the card at the coupling station 50, only on its upward-facing side.

[0072] The carrier then moves forward through the matching station 140, where the robotic device picks up the cards 610 from separate terminals of dedicated transport lines and places them on the carrier using the associated coupling means (3).

[0073] Next, the loaded carrier 118 passes through a second check station 180, where the compatibility of the coupling between the card and the carrier is finally checked, and all data printed on the carrier and card is observed on both carrier surfaces (4), and if necessary, incorrect couplings are eliminated via the discharge line 680.

[0074] Finally, the loaded carrier 118 is released at the exit of the device 500(5).

[0075] All listed motors refer to electric motors that act as servo motors with electronic encoder-driven feedback, enabling the shafts connected to them to rotate at a controlled, precise speed. All of these motors, robots, and sensors provided throughout the apparatus 500 refer to control units with user interfaces.

[0076] Accordingly, the distribution device 500 can be monitored and controlled via this user interface, which may be physically mounted to the device or installed remotely. The user interface may be a touchscreen or other similar input device and may display parameters and operating conditions to the operator in order to control the functions of device 1.

[0077] The user interface is associated with at least one processor configured to control all scheduled operations of the device 500. The user interface may employ software, hardware, firmware, hardwiring, or a combination thereof. The features implementing the functionality may also be physically installed in various locations, including being distributed so that some of the functionality is implemented in different physical locations.

[0078] Aspects of the disclosure described herein, such as the speed and control of rollers, inclined chutes, and carrier guides as described above, as well as the monitoring and control of various parameters, can be performed using any type of computing device, such as a computer or programmable logic controller (PLC), including a processor, such as a central processing unit, or any combination of computing devices, each of which performs at least a part of the process or method. In some embodiments, the systems and methods described herein can be performed using a handheld device, such as a smart tablet, smartphone, or a dedicated device manufactured for the system.

[0079] Those skilled in the art can introduce several additional modifications and variations to the above-described apparatus for distributing cards on a carrier to meet additional and incidental needs, all of which fall within the scope of protection of the present invention as defined by the appended claims.

Claims

1. A device (500) for distributing cards (610) onto a carrier, comprising a first transport line (10) for transporting individual carriers from an inlet (120) to an outlet (150), and a second transport line (20) for transporting individual cards, The aforementioned device (500) An entrance check station (160) located at the entrance (120) is suitable for performing checks on data printed on incoming unloaded carriers (110), A transport device (30) that moves the incoming unloaded carrier (110) across the entrance check station (160) is configured to be suitable for matching with one or more cards (610) on the upper exposed surface of the incoming unloaded carrier (110), A matching station (140), wherein at least one robotic device (6) is suitable for picking individual cards (610) and placing them on the target surface of a target carrier, It further includes, The entrance check station (160) includes a check area (116) having a transparent support plane (240), and the incoming unloaded carrier (110) is guided to slide across the check area (116) by the conveying device (30) by applying a driving force to the side end of the incoming unloaded carrier (110).

2. The apparatus (500) according to claim 1, wherein the transparent support plane (240) is suspended on a support frame (170) with substantially empty space below the transparent support plane, and the entrance check station (160) comprises an upper detection device (130) suspended at least above the transparent plane and a lower detection device (132) positioned in the space below the transparent support plane (240).

3. The apparatus (500) according to claim 1 or 2, comprising an inlet optical sensor (320) located at the inlet section (120) and an outlet optical sensor (322) located at the output of the inlet check station (160).

4. The conveying device (30) comprises an individual endless belt (210) driven by individual drive wheels (205) and forming a drive segment extending from an associated inlet wheel (222) to an associated outlet wheel (220), wherein the inlet wheel and the outlet wheel are located at the inlet section (120) and the output of the inlet check station (160), respectively, and the drive segment is driven to slide on the transparent support plane (240) to transmit the driving force, the device (500) according to claim 1.

5. The conveying device (30) comprises a plurality of pressing rollers (228) arranged along the drive segments of each endless belt (210), according to claim 4 (500).

6. The apparatus (500) according to claim 5, wherein the pressing roller (228) is in an idle state and is pivotally supported by a bearing mounted on a lever (232) having a pivot point (213) integrated with a frame member, and the lever is rotated by individual springs (218) connected to the frame member.

7. The apparatus (500) according to claim 6, wherein the frame member is movable toward its centerline in a direction that crosses the transparent support plane (240).

8. The apparatus (500) according to claim 1, wherein a coupling station (50) is provided between the entrance check station (160) and the verification station (140), and the coupling station is suitable for applying individual coupling points (484, 486) to the upper exposed surface.

9. The apparatus (500) according to claim 8, wherein the bonding station (50) comprises at least one bonding gun (480, 482) for depositing bonding points on the upper exposed surface so as to function as individual bonding points (484, 486).

10. The coupling station (50) comprises a first pair of upper and lower tension rollers and a second pair of upper and lower tension rollers (455, 456, 458, 460) suitable for capturing the leading end of the carrier, wherein the first pair and the second pair are positioned at a predetermined distance from each other so that they can both capture the carrier, and the coupling point (484, 486) is applied between the first pair and the second pair, the apparatus (500) according to claim 8 or 9.

11. The apparatus (500) according to claim 1, wherein the robotic apparatus (6) is a delta robot.

12. The apparatus (500) according to claim 1, further comprising a rejection transport line (528) for transporting cards that are not applicable to any carrier.

13. The apparatus (500) according to claim 1, comprising: a further exit check station (180) suitable for performing checks on data printed on a loaded carrier (118) to be shipped and an associated card (610) applied thereto along the first transport line (10); and a separate transport device for moving the loaded carrier (118) to be shipped across the exit check station (180), wherein the exit check station (180) comprises a separate check area having a further transparent support plane, thereon the carrier to be shipped is guided by the transport device to slide across the check area by applying a driving force to the side end of the carrier to be shipped.

14. The apparatus (500) according to claim 13, wherein the transparent plane of the exit check station (180) is suspended on an individual support frame (190) leaving the space below the transparent plane substantially empty, and the exit check station (180) comprises an upper detection device (134) suspended at least above the transparent plane and a lower detection device (136) positioned in the space below the transparent plane.

15. The conveying device of the exit check station (180) comprises an individual endless belt driven by an individual drive wheel, forming a drive segment extending from a related inlet wheel to a related exit wheel, the inlet wheel and the exit wheel being located at the inlet and output of the exit check station (180), respectively, thereby driving the drive segment to slide on the transparent support plane to transmit the driving force, the apparatus (500) according to claim 13 or 14.

16. The conveying device (500) according to claim 15, comprising a plurality of pressing rollers arranged along the drive segment of each endless belt.

17. The apparatus (500) according to claim 16, wherein the pressing roller is idle and pivotally supported by a bearing mounted on a lever having a pivot point integrated with a frame member, the lever is rotated by an individual spring connected to the frame member, and the frame member is movable in a direction across the transparent support plane toward its centerline.

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