Pitney Bowes Inc.

Bristol Corporation

Paul Mayer

Michael J Shea

William G Hart, Jr

Eugene Pritchard

David A Glowny

Thomas H Rosenkranz

Xuedong Liu

Andrew J Nikolatos

Kenneth S Zaldo

Susan L Chapin

Jeremy A Freed

Jeffrey Barry McGaughey

A method and system for mail run balancing of critical documents on a sorter machine that comingles both critical and non-critical documents. A plan identifying a set of critical documents to be processed as part of a mail run is received at the sorter. The plan includes an individual identifier code for each critical document. Sets of critical and non-critical documents are sorted as part of the comingled mail run. A camera scans the documents for the individual identifier codes on the critical documents during sorting. The camera captures an image of the scanned critical documents. A list of scanned individual identifier codes of sorted critical documents is stored for later use, along with the captured images of the documents. The list of scanned individual identifier codes is compared to the identifier codes of the critical documents in the plan. Based on the comparison, a first comparison list of scanned identifiers that do not match any identifiers in the plan and a second comparison list of identifiers in the plan that are not matched to pieces scanned are generated. The first comparison list is reconciled with the second comparison list by, at least in part, displaying the captured images to assist in matching corresponding documents from the lists.

Mail run balancing using video capture

Methods and apparatus to detect leakage current in a resistance temperature detector are disclosed. An example method includes providing a resistance temperature detector circuit with a first resistance circuit and a second resistance circuit, measuring a first voltage at the first resistance circuit in response to applying a first current to the first resistance circuit, measuring a second voltage at the second resistance in response to applying a second current to the second resistance circuit, comparing the first and second voltages to determine a difference value, and determining that a current leak exists in the resistance temperature detector circuit when the difference value is not within a first range.

Methods and apparatus to detect leakage current in a resistance temperature detector

An integrated logic analyzer system that provides enhanced troubleshooting capabilities for an inserter machine. The system includes sensors positioned within the inserter machine. A controller is coupled to the sensors, and also provides control signals for operation of the machine. The controller generates error signals upon the occurrence of predetermined instances of sensor signals. A display coupled to the controller indicates machine status based on the signals from the plurality of sensors. An integrated logic analyzer is also coupled to the controller and to the plurality of sensors. The integrated logic analyzer provides a continuous readout of sensor signals from the sensors, and control and status signals from the controller. The controller provides a representation of the continuous readout to the display. In the preferred embodiment, the controller provides a visual representation of individually selectable modules of the inserter system. Machine status, from the controller, is displayed as vertical lines overlaying continuous readout at various points in time. In the preferred embodiments, the integrated logic analyzer further provides a continuous readout of control signals from the controller.

Inserter integrated method and system for logic analyzing error conditions

An inserter device including a plurality of modules for accumulating and assembling sheets into mail pieces. A controller computer is coupled to the plurality of modules and controls assembly of mail pieces in accordance with predetermined instructions. The controller computer receives the status data from the plurality of modules. Software based data processing objects process the inserter status data. The data processing objects pass processed status data directly to a network protocol object. Thereby status data is available for transmittal immediately, and there is no need for storage or a repository for periodic uploading. The inserter controller computer further includes a network port for directly transmitting the status data processed by the network protocol object to an external network, such as the Internet. The network port and the network protocol object accept incoming requests from the external network and immediately provide the requested information.

Web server integrated directly into an inserter system to provide status monitoring and configuration control

A method to reduce and manage the risks and costs associated with mail piece account balancing failures in connection with automated high speed mail production equipment. A mail run is divided into defined subsets of sequentially numbered mail pieces. Disposition of mail pieces is accounted for during the automated mail production process. Gaps in the subsets are identified. The number of subsets with gaps is tracked during automated processing of mail pieces. If the number of defective subsets exceeds a predetermined quantity, then the mail production equipment is stopped. In a further preferred embodiment, operators are notified of the occurrence of gaps in real-time, as they are detected, so that corrective action may be taken.

Method for balancing mail runs

An integrated remote control and integrated scanner () for use with a mail inserter (), including a user interface and device logic module (), a transceiver () for wirelessly communicating with the mail inserter (), and an (embedded) scanner (), all provided as a single hand-held device (). An operator can use the device () to send remote control commands to the mail inserter () and also operate the included scanner () (used, e.g., for obtaining scan codes of mail pieces so that the operator can indicate to the mail inserter () whether to recreate the mailpiece).

Mail inserter machine remote control with a scanner

A document assembly system with jam detection capability. The system including an accumulation chassis having a series of pusher fingers for pushing collations of documents. Above the chassis, document feeders release documents to the chassis to form the collations. A set of horizontal photo-sensors is positioned below the document feeder at a level substantially even with the tops of the pusher fingers on the chassis. The photo-sensors detect lead and trail edges of documents traveling in the flight path from the document feeder to the chassis. The sensors generate signals representing the lead and tail edges of documents breaking the line between the photo-sensors. A controller receives the signals from the photo-sensors and compares them to an expected profile calculated as a function the parameters of operation for the chassis and feeders. An error signal is generated when the compared signals are different from the expected profile by greater than a predetermined margin of error.

Jam detection method and system for an inserter

An apparatus for assembling mailpieces and a method for controlling such apparatus. The apparatus includes a document feeder for feeding sets of documents to a chassis for assembly into mailpieces a constant rate. Because the number of documents varies the time to assemble a set varies and it is possible that a set may not be available when the chassis is ready to cycle; resulting in a cycle in which no mailpiece is processed. To correct for this the average number of documents for a number of mailpieces to be processed is determined and a nominal chassis speed and cycling rate are determined correspondingly. The actual chassis speed is then periodically updated to approach the nominal speed.

Performance tuning of an inserter system based upon a rolling average of page counts for mailpieces to be processed

A method for controlling an inserter system having a chassis for assembling mailpieces, the chassis operating cyclically with successive accumulations advancing at the end of each cycle. The inserter system further includes a document feeder for feeding accumulations of documents to the chassis, the accumulations containing varying numbers of documents whereby the document feeder is operated at a first speed such that accumulations are available for input to the chassis at varying intervals substantially depending upon the number of documents in corresponding accumulations. And the chassis is operated at a selected speed, which speed is periodically updated in dependence upon the number of documents in the corresponding accumulations in the document feeder.

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Middlesbury, CT, United States of America

Paul Mayer