Rotatable Insertion Horns for Envelope Collation Handling
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Solution Overview
Problem
Existing multi-station document inserting systems face difficulties in efficiently inserting documents into envelopes due to the angle of mechanical paper guides, which restricts the maximum collation width and can cause the addressing information to shift or become hidden.
Innovation Solution
A rotatable insertion horn system is employed, where a pair of horns rotate into the envelope to form a clear channel for document insertion, allowing maximum width accommodation and preventing catching on upstream edges, and then relax to reduce friction for easy envelope extraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the horn is angled inwards to create a tunneling effect, then the collation does not catch on entry to the horn, but the maximum collation width that can be run is reduced
Solution Approach 1:
The horn is made rotatable about a pivot axis, allowing it to dynamically change its angle relative to the envelope. The horn can be positioned at different angles depending on the collation width being inserted, providing both the tunneling effect for reliable insertion and the maximum width capacity when needed.
Solution Approach 2:
The angle of the horn relative to the envelope is changed as a variable parameter. By adjusting the horn's angular position, the system can optimize for either tunneling effect (narrower angle) or maximum width capacity (wider angle), resolving the contradiction between insertion reliability and width adaptability.
2Reliability
If the horn extends into the envelope to shield the collation, then the collation is protected from inside edges, but friction increases making envelope extraction difficult
Solution Approach 1:
The horn's position is made dynamic through rotation. It extends into the envelope during insertion to provide shielding and protection, then rotates to a retracted position after insertion to reduce friction and facilitate easy envelope extraction.
Solution Approach 2:
The horn performs periodic extension and retraction movements. It extends before and during collation insertion to provide protection, then retracts periodically after insertion to reduce friction for envelope extraction, creating a cyclical pattern of protection and ease of removal.
3Device complexity
If a fixed angle horn is used for insertion, then the structure is simple, but the system cannot accommodate varying collation widths efficiently
Solution Approach 1:
The horn is made rotatable about a pivot axis, allowing it to dynamically change its angle relative to the envelope. The horn can be positioned at different angles depending on the collation width being inserted, providing both the tunneling effect for reliable insertion and the maximum width capacity when needed.
Data Source
AI summary
A method is provided for using a rotatable insertion horn to open an envelope prior to insertion of documents. A pair of insertion horns is positioned at the sides of an envelope inserting station. An envelope is fed into the envelope inserting station with its flap open. The collation of documents is pushed into the open end of the envelope. The insertion horns are positioned in an initial position that is fully outside the envelope, prior to arrival of the collation. The insertion horns are controlled to simultaneously rotate into the envelope as the collation passes between the insertion horns. Preferably, rotation of the insertion horns into the envelope does not begin until a lead edge of the collation is in a region between the insertion horns. This facilitates insertion of the collation without catching on an upstream edge of the insertion horns.