Method and system to feed inserts with a rotary and gripper system

1. A rotary insert feeder for feeding a plurality of stacked inserts to a collating track of document processing equipment, the rotary insert feeder comprising:

a stacker for containing a vertical stack of the plurality of inserts, the stacker comprising vertical side supports and a bottom plate;

a plurality of rotary drums positioned below the bottom plate of the stacker;

a separator hook positioned above the rotary drums, the separator hook configured to pivot from a first position such that a leading edge of the separator hook is at least partially disposed between a bottommost insert and a second bottommost insert, to a second position away from the bottom plate and the rotary drums; and

a plurality of gripper assemblies for removing a bottommost insert from the vertical stack of inserts, the plurality of gripper assemblies operably attached to a side surface of a respective one of the rotary drums, each gripper assembly including: a movable gripper finger and a spring loaded and movable bottom seat, wherein:

when the separator hook is in the first position, a leading edge of the bottommost insert is engaged between the gripper seat and the spring loaded bottom seat during a closing operation of each gripper assembly such that the bottommost insert is removed from the vertical stack, and

the gripper assemblies are driven synchronously, and each gripper assembly is configured to operate with an independent gripping force based on at least a thickness of the bottommost insert.

2. The rotary insert feeder according to claim 1 , further comprising:

a control processor for operational control of rotary insert feeder.

3. The rotary insert feeder according to claim 1 , wherein:

as the bottommost insert is pulled out from the stack by the rotation of the rotary drums, a proportion of force needed to overcome friction between the bottommost insert and the stack is transferred through the bottom seat to the spring associated with the bottom seat,

the spring configured to compress transfer additional gripping force between the gripper finger and the bottom seat, and

the gripping force increases as the force needed to pull the bottom insert out of the stack increases.

4. The rotary insert feeder according to claim 1 , further comprising;

a vacuum belt assembly positioned below the rotary drums for delivering the bottommost insert to the collating track.

5. A method for processing a plurality of stacked inserts on a rotary insert feeder, the method comprising steps of:

providing a vertical stack of the plurality of inserts in a stacker including a bottom plate;

advancing a leading edge of a bottommost insert from the stacked inserts;

rotating a plurality of rotary drums positioned below the bottom plate of the stacker;

advancing a separator hook to a position such that a leading edge of the separator hook is at least partially disposed between a bottommost insert and a second bottommost insert, and the leading edge of the bottommost insert is held in proximity to the rotating rotary drums;

engaging a leading edge of the bottommost insert by way of a plurality of gripper assemblies, the leading edge of the bottommost insert engaged between a gripper seat and a spring loaded bottom seat of each gripper assembly, wherein the gripper assemblies are driven synchronously, and each gripper assembly is configured to operate with an independent gripping force on the insert based on at least a thickness of the bottommost insert; and

removing the bottommost insert from the vertical stack for delivery to a collating track positioned below the rotary drums.

6. The method according to claim 5 , wherein:

as the bottommost insert is removed from the vertical stack by the rotation of the rotary drums, a proportion of force needed to overcome friction between the bottommost insert and the stack is transferred through the bottom seat to a spring associated with the bottom seat,

the spring compresses in order to transfer additional gripping force between the gripper finger and the bottom seat, and

increasing the gripping force as the force needed to pull the bottom insert out of the stack increases.

7. The method according to claim 5 , further comprising the step of:

delivering the bottommost insert to a vacuum belt assembly positioned below the rotary drums for delivery of the bottommost insert to the collating track.

8. A rotary insert feeder for feeding a plurality of inserts to a collating track of document processing equipment, the rotary insert feeder comprising:

a stacker for containing a vertical stack of the plurality of inserts, the stacker comprising vertical side supports and a bottom plate;

a plurality of rotary drums positioned below the bottom plate of the stacker;

a separator hook positioned above the rotary drums, the separator hook configured to pivot from a first position away from the bottom plate and the rotary drums to a second position such that a leading edge of the separator hook is at least partially disposed between a bottommost insert and a second bottommost insert;

a plurality of gripper assemblies for removing a bottommost insert from the vertical stack of inserts, the plurality of gripper assemblies operably attached to a side surface of a respective one of the rotary drums, each gripper assembly including: a movable gripper finger and a spring loaded and movable bottom seat; and

a vacuum mechanism positioned between the plurality of rotary drums, the vacuum mechanism configured to contact a leading edge of the bottommost insert and move the bottommost insert in a downward direction toward to the rotary drums when the separator hook is in the first position, wherein the vacuum mechanism is configured to move between a first position above an upper surface of each rotary drum and in contact with the leading edge of the bottommost insert, to a second position below the upper surface of each rotary drum, and release the vacuum upon contact of the leading edge of the bottommost insert with the rotary drums,

wherein when the separator hook is in the second position, the leading edge of the bottommost insert is engaged between the gripper seat and the spring loaded bottom seat during a closing operation of each gripper assembly such that the bottommost insert is removed from the vertical stack.

9. The rotary insert feeder according to claim 8 , further comprising a control processor for operational control of rotary insert feeder.

10. The rotary insert feeder according to claim 8 , further comprising a vacuum belt assembly positioned below the rotary drums for delivering the bottommost insert to the collating track.

11. The rotary insert feeder according to claim 8 , wherein the vacuum mechanism comprises a sucker cup.

12. The rotary insert feeder according to claim 8 , wherein the separator hook includes two hooks inwardly facing the stacker, wherein each hook includes an outwardly facing curved surface.

13. A method for processing a plurality of inserts on a rotary insert feeder, the method comprising steps of:

providing a vertical stack of the plurality of inserts in a stacker including a bottom plate;

rotating a plurality of rotary drums positioned below the bottom plate of the stacker;

applying a vacuum, by way of a vacuum mechanism, to a leading edge of a bottommost insert of the vertical stack such that the leading edge of the insert is lowered in a direction toward the rotating rotary drums;

advancing a separator hook to a position such that a leading edge of the separator hook is at least partially disposed between the bottommost insert and a second bottommost insert, and the bottommost insert is supported in close proximity to an upper surface of each rotary drum;

releasing the vacuum applied to the leading edge of the insert and lowering the vacuum mechanism from a first position above an upper surface of each rotary drum and in contact with the leading edge of the bottommost insert, to a second position below the upper surface of each rotary drum;

engaging the leading edge of the bottommost insert by way of a plurality of gripper assemblies, the leading edge of the bottommost insert engaged between a gripper seat and a bottom seat of each gripper assembly; and

removing the bottommost insert from the vertical stack along the outer diameter surface of the rotating rotary drums.

14. The method according to claim 13 , wherein the applying step includes:

moving a sucker cup between a first position below an upper surface of each rotary drum to a second position above the upper surface of each rotary drum to contact the leading edge of the bottommost insert.