Inserter with diverter for faulty members

Abstract

An in-line inserter device comprises envelope and insert feeding assemblies, an envelope inserting station assembly, a sealing and stacking assembly, and various diverter stations. The envelope feeding assembly withdraws envelopes from a hopper-held envelope stack and conveys them to the inserting station. Each modular insert feeding assembly comprises a hopper-held insert stack disposed above, along, and in line with an insert conveyor. The conveyor, along its track, carries inserts dispensed from the hopper-held insert stacks to the inserting station. Diverter stations are disposed ahead of the envelope inserting station for diversion of envelopes and inserts and ahead of the inserted envelope stacking assembly to divert inserted envelopes, for normal operational purposes and for rectification of sensed faults by rejection and extraction of processed faulty items. Such faults include paper jams, misalignments, absences of inserts, duplication of inserts and envelopes, incorrectly collated inserts, damaged inserts or envelopes, etc. Subsequently to inserting, insert-filled envelopes are conveyed from the inserting station, are sealed, turned, and stacked. Supervision and coordination of the operation of the various assemblies and stations in concert is provided by computer control to efficiently accomplish the inserting of the inserts into the envelopes, further processing and handling thereof, and conveyance of the items in and between subunits of the in-line inserter device.