Reconfigurable Stitcher for Variable Thickness Collations
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Solution Overview
Problem
Existing mailpiece inserter systems face challenges in efficiently binding consecutive multi-sheet collations of varying thickness due to misalignment issues and the need for manual adjustment of binding mechanisms, which limits throughput and increases mechanical complexity.
Innovation Solution
A reconfigurable stitcher/stapler system that determines the thickness of multi-sheet collations and uses a processor to control actuators to form variable-length stitches or staples, align edges, and bind collations using a transport and alignment system with adjustable registration mechanisms and repositionable alignment devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual adjustment of binding mechanisms is used, then adaptability to variable thickness is improved, but device complexity and labor requirements increase
Solution Approach 1:
The stitcher employs dynamically adjustable components including a movable anvil positioned by an actuator, and a stitch wire feed mechanism with variable wire length control. These dynamic elements allow the binding mechanism to adapt to different collation thicknesses automatically, eliminating the need for manual reconfiguration while maintaining versatility.
Solution Approach 2:
The system changes critical parameters such as stitch wire length, anvil position, and clinching force based on detected collation thickness. The processor receives thickness information and automatically adjusts these parameters to optimize binding for each specific collation, achieving adaptability through parameter variation rather than mechanical reconfiguration.
2Device complexity
If fixed-length stitches are used, then device simplicity is maintained, but binding effectiveness for variable thickness collations deteriorates
Solution Approach 1:
The stitch wire feed mechanism is designed to dynamically adjust wire length based on collation thickness. The system feeds varying lengths of stitch wire from a supply spool, ensuring adequate penetration depth for thick collations while using appropriate lengths for thinner ones, thereby maintaining binding effectiveness across variable thicknesses.
Solution Approach 2:
The system incorporates a thickness detection mechanism that provides feedback to the processor about each collation's thickness. This feedback loop enables the system to automatically determine the appropriate stitch wire length and binding parameters, ensuring reliable binding effectiveness without requiring complex mechanical adjustments.
3Manufacturing precision
If alignment mechanisms are added to handle variable thickness, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system replaces complex mechanical alignment mechanisms with a transport deck featuring registered indicia (such as markings or patterns) that guide collation positioning. The collations are aligned by matching these indicia rather than through mechanical guides, significantly reducing mechanical complexity while maintaining high alignment precision.
Solution Approach 2:
The registered indicia on the transport deck serve as an intermediary alignment system. Instead of direct mechanical contact between alignment mechanisms and collations, the indicia provide a reference framework that facilitates precise positioning, reducing the need for complex mechanical adjustment components.
Data Source
AI summary
A stitcher for binding variable thickness collations including a means for determining the thickness of a multi-sheet collation, a stitch head operative to drive a stitch through the multi-sheet collation, an anvil operative to clinch the stitch to bind the sheets of the collation and a plurality of actuators operative to displace forming elements of the stitch head to form the stitch, position the stitch head and anvil against opposite surfaces of the multi-sheet collation, drive the stitch through the collation and clinch the ends of the stitch. A processor, responsive to the thickness value signal, controls the actuators to form the stitch and bind the collation.