THEORY OF OPERATION SECTION C PAGE 1

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1 C1. SYSTEM COMPONENTS The DemandWorks Wrapping System One consists of the following components: sensors Turbo-code automated in-line mailing (AIM) module collating table rotary drum feeders Datalogic Matrix-2000 barcode readers JETVision reading system R3P roll unwinder wrapping module Robatech gluer Scitex inkjet printers ink dryer R2L bypass module RA5Z conveyor PC_Add PC_bh A.R.C. software PLC/control electronics C. C There are three applications for the machine: documents only checks only documents-plus-checks These can go into a a closed-face (no window) or openfaced (windowed) envelope. The AIM module accumulates, collates and folds documents. When using variable collation, the set is accumulated based on having the same account number in the 2D barcode on the documents. There is no set sequence code. The documents are folded in one of two types of C-folds depending upon whether the document will go into a closedface or open-faced envelope. There are two 2D barcodes with duplicate information, so that one is on the outside of the folded document set for scanning regardless of the fold type (see Figure C 1). SECTION C PAGE 1

2 SECTION C PAGE 2 Address Closed-faced C-fold PC_Add. For check-only applications, the account number is read from the barcode and sent to PC_Add to obtain the address which is sent to the Scitex printers (see Figure C 2). 2D Barcode Open-faced C-fold Address 2D Barcode Document and Folds Illustration Figure C 1 The document set is then passed to the first feeder where the same barcode read by the AIM module is read again by either the barcode reader on the back of feeder (for openface applications), or on the exit belts (for closed-faced applications). The account number read from the barcode is then sent to PC_Add and the corresponding address is looked up in a database and this information is sent to the Scitex printers. When checks are being processed, they are fed from the second (reverse) feeder. For check-plus-document applications, the account number read from the barcode on the check and document is compared for a match by Check Illustration Figure C 2 If included in the job, additional inserts are fed from the third and fourth feeders. For closed-face applications, the printers print the address and other fixed data (return address, indicia, promotional slogans) on the web fed from the unwinder. For open-faced applications, only the fixed data is printed. A dryer blows hot air on the ink to speed drying. In closed-face applications prior to wrapping, the JETVision system reads and compares the account number printed on the envelope (see Figure C 3) to the account number read by the barcode reader on either the first feeder (document-only and check-plus-document applications) or the second feeder (check-only applications). If a mismatch is detected, then JETVision sends a signal to PC_Add and the

3 system stops. If the JETVision camera fails to read the data, then the mailpiece is diverted. Address Account Number Closed face Envelope Illustration Figure C 3 The documents and inserts are sent to the wrapper where the newly printed paper from the unwinder is formed around them, and cut and sealed into an envelope. The finished mailpieces then pass through the R2L bypass module where they are either rejected and dropped through the bypass gate, or accepted and sent to the RA5Z conveyor. The programmable pneumatic arm on the RA5Z conveyor separates the mailpieces into groups by ZIP code or quantity. See Sections C2. through C18. for more detailed information on the behavior of each component. C2. SENSORS The Wrapping System One has a variety of sensors for different tasks that operate under different principles. C2.a. DOUBLE DETECTION Double detection senses when two or more pieces of paper pass through an area of the machine where only one should. There are two kinds of double detection sensors: mechanical infrared C2.a1. Mechanical Proximity Sensor NOTE: The mechanical double detect is not currently used. The mechanical system for double detection uses a proximity detector that detects the presence or absence of a lever arm. As an insert passes over the feeder drum, it pushes the lever arm away from the proximity detector. When a single insert passes through, the displacement of the arm is small enough that the proximity detector can still sense the arm s presence. However, when two inserts pass through together, the lever arm is pushed too far from the detector and a double is detected. A blinking red light on the alarm light tower next to the feeder signals a double. SECTION C PAGE 3

4 SECTION C PAGE 4 Examples and Locations: back of each feeder C2.a2. Infrared DoubleSense III Sensor The DoubleSense III sensor transmits an infrared beam through the paper to read its opacity (reduction of detected infrared light). When the DoubleSense III detector has been calibrated for the type of paper being used, it will sense a double when it reads approximately half of the light compared to the light received during the calibration. The red DOUBLE LED on the DoubleSense panel lights to signal a double (see Figure C 1). Red DOUBLE LED DoubleSense Operator Panel Figure C 1 Examples and Locations: exit of each feeder exit of the sheet feeder C2.b. PRESENCE DETECTION Presence detection sensors signal the presence or absence of paper. There are four types of presence sensors: interrupted point-to-point beam photosensor and reflector interrupted loop beam ambient light detection C2.b1. Interrupted Point-to-Point Beam This type of presence sensor transmits and receives a beam of light. The sensor detects the passage of a piece of paper by sensing an interruption of this beam. Examples and Locations: LS2 tractor belt sensor (left side of bulk loader) B11.1 barcode reader trigger sensor (accumulator entrance) B9C.1 accumulator entry sensor (accumulator entrance) B13.2 storage sensor (accumulator exit) B13.3 exit sensor (accumulator exit) B13.1 count down sensor (center of accumulator) B16.1 activate reject sensor (common belt interface section entrance)

5 C2.b2. Interrupted Loop Beam This type of presence sensor has a single transmitter/receiver that detects a break in the light loop. Examples and Locations: LS3 gap jam detection sensor (bulk loader transfer arm) B16.4 confirm reject sensor (common belt interface section entrance) C2.b3. Photosensor and Reflector This type of presence sensor looks for a reflection of itself, which occurs when the area between the photosensor and reflector is clear, indicating the absence of paper. When the sensor cannot see itself, which occurs when the reflector is blocked, paper is present. The reflectors for the sensors on the first feeder are the metal guides on the document table. Examples and Locations: LS5 low stack level sensor (left side of bulk loader) B16.2 jam sensor (top of first feeder) B16.3 full sensor (top of first feeder document table) B102.2 reduce AIM speed sensor (middle of first feeder document table) B102.1 low level sensor (bottom of first feeder document table) missing insert sensor (back of each feeder) B144.1 product presence sensor (end of the collating track) B18.1, B18.2 unseparated product sensors (bypass module) B17.1 product count sensor (end of bypass module) C2.b4. Ambient Light Detection This type of presence sensor detects the reflected ambient light from the surface of paper. When paper is close enough to the sensor, the reflected light is detected; when the paper is too far away, there is reduced reflected light. Examples and Locations: B9C.3 load feeder sensor (right side of sheet feeder) B9C.2 feeder empty sensor (right side of sheet feeder) C2.c. WHISKER SWITCHES Whisker switches detect product jams (see Figure C 2). When product piles on top of itself, it pushes the needle on the switch upward, signaling a jam condition. Blinking blue and red lights on an alarm tower next to a feeder, or a yellow light on the AIM module alarm tower signals a jam. SECTION C PAGE 5

6 SECTION C PAGE 6 C2.c1. Thermal Sensor The wrapping section includes a thermal sensor to detect heat from the newly glued envelope (see Figure C 3). If the sensor detects insufficient heat this indicates: the glue is not hot enough to properly seal the envelope the inserts have shifted forward and are covering the glue strip and thus may be cut by the rotary knife Whisker Switch Glue Thermal Sensor Whisker Switch Figure C 2 Examples and Locations: entrance of the interface belt section after each feeder before the wrapping module pressure roller after the rotary knife in the wrapping section on the bypass module Thermal Sensor Figure C 3 Examples and Locations: entrance to wrapping module

7 C3. AIM The AIM module (see Figure C 4) consists of several components (moving from upstream to downstream): single-sheet bulk autoloader vacuum sheet feeder high-speed single deck accumulator high-speed folding unit interface belt Sheet Feeder Accumulator Bulk Loader AIM Module Figure C 4 SECTION C PAGE 7

8 SECTION C PAGE 8 C3.a. BULK LOADER The bulk loader (see Figure C 5) continuously loads sheets from a bulk stack and sends them to the sheet feeder by the transfer arm (see Figure C 6). The bulk loader s stack transport holds about 4,000 sheets. LS3 Gap Jam Detection Sensor Transfer Arm Bulk Loader Sheet Feeder Bulk Loader Figure C 5 Transfer Arm with Jam Sensor Figure C 6 The low stack level sensor (LS5) generates a signal when uncovered by the paper stack, indicating that the operator should load more paper (see Figure C 7).

9 The conveyor tractor runs only when the tractor belt sensor (LS2) detects an uninterrupted beam (see Figure C 7), indicating the presence of paper to transport. LS2 Tractor Belt There are two sensors that monitor the height of the paper stack (see Figure C 8). The upper sensor (B9C.3) signals that the feeder is low and requests more product from the bulk loader. The lower sensor (B9C.2) indicates that the feeder is critically low and generates an alarm and stops the machine. B9C.3 Load Feeder LS5 Low Stack Level B9C.2 Feeder Empty Bulk Loader Sensors Figure C 7 The gap jam sensor (LS3), on the transfer arm, detects breaks in the material flow caused by paper jams (see Figure C 6). C3.b. SHEET FEEDER The sheet feeder receives paper from the bulk loader and stores it in a stack. A rotary vacuum drum separates the sheets from the bottom of the stack, and pinch rollers feed the sheets to the accumulator. The sequence of sheets is always maintained. Sheet Feeder Figure C 8 C3.c. ACCUMULATOR The accumulator receives documents from the sheet feeder and, based on barcode data or a fixed value, collates the document into sets and then sends them to the folder. Upon entering the accumulator a document triggers the entry sensor (B9C.1). Another sensor detects doubles by sensing the opacity of the paper (see Section C2.a2. for details). A third sensor (B11.1) at the entrance triggers the barcode reader to scan. Additionally, a sensor (B13.1) in the middle of the deck counts the accumulating sheets until SECTION C PAGE 9

10 SECTION C PAGE 10 the required number is detected and then signals the sheet feeder to stop feeding (see Figure C 9). Double Detect B13.1 Count down B11.1 Barcode Reader Trigger Accumulator Deck Figure C 9 At the end of the accumulator deck there are two more sensors (see Figure C 10). The storage sensor (B13.2) detects when product is present in the accumulator. The control panel indicates an error if this sensor is blocked when no material is expected, or the sensor is clear when material is expected. Finally, there is an exit sensor (B13.3) which senses when a set has cleared the accumulator. Normally, the feeding of the next document set is controlled by the current set clearing the exit sensor. However, there is a rush job option that uses the storage sensor to trigger feeding of the next set (see Section E4.e1.). B13.3 Exit B13.2 Storage B9C.1 Accumulator Entry Accumulator Exit Figure C 10

11 C3.d. FOLDER The GUK FA30/4 folder can process sets of up to eight sheets from the accumulator. The folder supports Z-, C-, and half-fold types (see Figure C 11). The entrance rollers drive the set into the first fold plate segments. As the set continues to be forced through, it buckles and the buckled edge is driven through the first fold plate rollers forming a fold (see Figure C 12). The set will continue into other fold plates and their rollers, depending upon the fold type. Deflectors are set up at unused fold plates to force the set to bypass them (see Figure C 12). Entrance Rollers Paper Flow Fold Plate Segments Fold Plate 1 Roller Pair 1 Roller Pair 2 Fold Plate Segments Fold Plate 2 Deflectors Folder Figure C 11 Folder Operation Figure C 12 SECTION C PAGE 11

12 SECTION C PAGE 12 C3.e. INTERFACE BELT The interface belt moves the folded documents from the folder to the first feeder (see Figure C 13). Interface Belt sets exiting from the folder. This sensor triggers the AIM module bypass gate if the set has an incorrect count. The second sensor (B16.4) confirms that the set was successfully rejected. A whisker switch detects paper jams (see Figure C 14). B16.4 Confirm Reject Sensor AIM Bypass Gate Folder AIM Interface Belt Figure C 13 There are two sensors on the first section of the interface belt (see Figure C 14). The first sensor (B16.1) detects Jam Detection B16.1 Activate Reject Sensor Interface Belt Sensors Figure C 14

13 C4. COLLATING TABLE The collating table includes the raceway track and feeders (see Figure C 15). B144.1 Product Presence Sensor Raceway Track Feeders Collating Table Figure C 15 The feeders drop their inserts on the raceway between the pusher pins on the conveyor belt forming collated stacks. Blue lamps on the table and bypass module indicate machine zero position for coordinating timing. At the end of the collating table, there is a photosensor (B144.1) to detect the presence of product (see Figure C 16). End of Collating Table Product Presence Sensor Figure C 16 C5. ROTARY DRUM FEEDERS There are four A14 feeders. Inserts are loaded into the top of the feeder and taken individually over the feeder drum and passed onto the raceway. The feeders must be synchronized with the raceway so that they drop inserts between the vertical pusher pins on the track. The first feeder is a a SEP1 unit which has a separation disk to separate inserts. The AIM module feeds document sets into this feeder. The second feeder (reverse) feeds the face-down checks from a bin on the back, singulates them SECTION C PAGE 13

14 SECTION C PAGE 14 with a separation foot, and delivers them face-down onto the track. This is required for applications where checks need to be matched to documents and where the check face must show through a windowed envelope. The next two feeders (3rd and 4th), like the reverse feeder, use a separator foot for singulation. These feeders deliver miscellaneous inserts. C5.a. SEP1 FEEDER (1ST FEEDER) The first feeder has two jogger arms for straightening the document stack and four sensors (see Figure C 17). B16.3 Full Sensor B16.2 Jam Sensor B102.2 Reduce AIM Speed Sensor B102.1 Low Level Sensor Jogger Arms SEP1 Feeder Sensors and Jogger Arms Figure C 17 The jam sensor (B16.2) stops the machine when it detects documents that have fallen at an angle in the feeder table. The full sensor (B16.3) detects when the document stack is too high and stops the AIM. The reduce AIM speed sensor (B102.2) detects when the document stack is becoming too high and signals the AIM to slow down. The low level sensor

15 (B102.1) indicates when the feeder is low and stops the machine. When a feeder is properly phased, the suction cup arm rises until it is level with the insert table and the suction cup is touching the left, front corner of the insert. The vacuum to the suction cup turns on allowing the cup to grab the insert. As the cup starts to descend, the singulation disk passes over the insert separating it from the stack (see Figure C 18). As the cup continues to descend, the gripper fingers (see Figure C 19) extend and close down on the insert clamping it to the drum. At the bottom of the suction cup arm stroke, the suction cup vacuum turns off releasing the insert so that it can pass over the feeder drum, and then onto the track. Insert Flow Singulation Disk Suction Cup Insert Gripper Finger Insert Passing Through SEP1 Feeder Figure C 18 SECTION C PAGE 15

16 SECTION C PAGE 16 Suction Cup The reverse feeder uses a separator foot instead of a disk to provide singulation (see Figure C 20). Separator Foot Gripper Finger Overhead View of SEP1 Feeder Figure C 19 C5.b. REVERSE FEEDER (SECOND) The second feeder receives checks facedown and delivers them on the track that way. This is different from the other feeders, which flip the inserts. This type of feeder is necessary for an application where the check needs to be matched to a document or where the check face needs to show through a windowed envelope. Feeder Separator Foot Figure C 20 The feeding action is similar to the SEP1 feeder except that the check passes from the table which is mounted on the back of the feeder, and then over the front of the drum, and then passes out of the exit belts onto the track. C5.c. NON SEP1 FEEDERS (THIRD AND FOURTH) The third and fourth feeders are non SEP1 feeders which use a separator foot instead of a disk to provide singulation (see Figure C 20). They also have a second suction cup that provides downward force on the insert corner that would otherwise be forced down by the separation disk. Otherwise, the action of the feeder is the same as for the SEP1.

17 C6. DATALOGIC BARCODE READERS There are four barcode readers (see Figure C 21) in following locations: AIM module, just before the sheet feeder (see Figure C 21) back of the first feeder (see Figure C 22) exit of the first feeder (see Figure C 23) back of the second feeder (see Figure C 24) Barcode Reader Barcode Reader on the Back of the First Feeder Figure C 22 Barcode Reader Barcode Reader on the AIM Module Figure C 21 SECTION C PAGE 17

18 SECTION C PAGE 18 reader on the exit belts of the feeder reads (see Figure C 23). The barcode provides the account number for integrity matching and addressing. The fourth reader readers the 2D barcode on the checks in the second feeder (see Figure C 24). This information is used for matching in document-plus-checks applications and addressing for checks-only applications. Barcode Reader Barcode Reader Barcode Reader on the Exit of the First Feeder Figure C 23 The first reader (on the AIM module) reads the account number from the 2D barcode on the documents. Document sets are accumulated based on having the same account number. There is no set sequence code in the 2D barcode. The second and third readers on the first feeder read the same barcode on the document. In the case of open-face applications, the barcode reader on the back of the feeder reads (see Figure C 22). For closed-face applications, the Barcode Reader on the Back of the Second Feeder Figure C 24 The barcode on the checks is visible to the barcode reader through a window in the feeder table (see Figure C 25).

19 Barcode on Check Barcode Reader Window C7. JETVISION READING SYSTEM In closed-face applications prior to wrapping, the JETVision system reads and compares the account number printed on the envelope to the account number read by the barcode reader on either the first feeder (document-only and checkplus-document applications) or the second feeder (checkonly applications). If a mismatch is detected, then JETVision sends a signal to PC_Add and the system stops. The operator can then review the error, and if it is a true mismatch, acknowledge the error and restart the system. The mismatched mailpiece is then diverted. If the JETVision camera fails to read the data, then the mailpiece is diverted. The JETVision camera is mounted under the chassis of the wrapping section just after the dryer (see Figure C 26). JETVision Camera Checks in Second Feeder Figure C 25 JETVision Camera Figure C 26 SECTION C PAGE 19

20 SECTION C PAGE 20 C8. R3P ROLL UNWINDER The R3P unwinder holds a roll of paper web that is used to create an envelope around the collated product (see Figure C 28). JETVision Gold Series Figure C 27 R3P Roll Unwinder Figure C 28 The unwinder needs to follow the speed of the main system in order to smoothly supply it with paper. This is accom-

21 plished with a combination potentiometer/tachometer (see Figure C 29). This device delivers the web at a steady rate by continuously adjusting the power output of the AC brushless motor to compensate for the decreasing roll size. Upper Proximity Detector web wound through its rollers) to rise to a position that is approximately 45 from the floor (see Figure C 30). The potentiometer/tachometer monitors the position of the dancer bar and adjusts the speed of the unwinder motor accordingly. Dancer Bar Potentiometer/ Tachometer Lower Proximity Detector Dancer Bar R3P Roll Unwinder Potentiometer/Tachometer and Proximity Sensors Figure C 29 When the unwinder is delivering the web at the correct rate the tension on the web raises the dancer bar (which has the Unwinder Dancer Bar Figure C 30 There are two proximity detectors on the unwinder to detect excessive positions of the dancer bar (see Figure C 29). The upper proximity detector signals when the dancer bar is too high. This occurs when the unwinder is not turning fast enough to keep up with the rest of the system. The lower proximity detector signals when the dancer bar is too low, indicating that the web has finished unwinding, or has broken. SECTION C PAGE 21

22 SECTION C PAGE 22 C9. WRAPPING MODULE Paper from the unwinder feeds into the wrapping module where it is folded around the collated product, sealed, and then cut into an envelope. Before the web is folded around the collated product, it is sprayed with strips of glue to seal the envelope. After the web has passed the gluer, the corners of the metal anvil score the paper lengthwise so that it will fold easily. The finger guides then form the web lengthwise around the collated product (see Figure C 31). The pressure belt assembly presses the glue strips against the wrapper, sealing the envelope down the center and at both ends. The rotary knife then cuts the envelopes apart (see Figure C 32). Finger Guides Pressure Belt Assembly Rotary Knife Paper Web Pressure Belt Assembly and Rotary Knife Figure C 32 Anvil Corner (under paper) Wrapper Forming Around Product Figure C 31

23 C10. ROBATECH GLUER The Robatech gluer applies glue to seal the envelope constructed from the paper web. The gluer system consists of: a tank for storing and initially heating the glue hoses to transport the melted glue from the tank and heads, at the end of the hoses, to spray the glue Each part of the system can be set to a different temperature. Generally, the system is set up so that the glue gets progressively hotter as it passes from the tank, through the hoses, and to the heads. Four glue heads spray glue on the paper web lengthwise and crosswise. The gluer control panel controls the timing and length of glue spraying. When the wrapper web has pre-print registration marks, a photosensor detects these marks, and passes that information to the gluer control. Values entered into the gluer control panel dictate when the glue heads begin and end spraying from the registration mark. If the wrapper web does not have pre-print registration marks, then the gluer control panel uses encoder information from a main system tachometer to determine the wrapper speed. In this mode, the start and end of glue spraying, and the offset number for centering the glue strip lengthwise on the envelope, are required. C11. SCITEX INKJET PRINTERS The Wrapping System One has five Scitex inkjet printers that can print on both sides of the envelope. For closed-face applications, the printers print the address and other fixed data (return address, indicia, promotional slogans) on the web fed from the unwinder. For open-faced applications, only the fixed data is printed. Each printer head contains 256 openings that spray very fine droplets of ink to create text. These openings create a matrix where letters are formed by the presence or absence of ink droplets on the paper. The resolution is 120 x 240 dpi. Ink is driven into the printer heads under pressure (19.5 psi). A current applied to the print head crystals induces them to vibrate. The combination of pressure and vibration makes ink droplets form that pass out of the orifice plate. Droplets that are not intended to land on the paper are given a negative charge, while droplets that are intended to land on the paper are left uncharged. A positively charged plate below the orifice plate attracts the negatively charged droplets and pulls them back into the system by a vacuum for reuse. SECTION C PAGE 23

24 SECTION C PAGE 24 C12. DRYER AND AIR KNIFE The dryer blows hot air on the freshly printed ink on the wrapper to speed the drying time. The dryer is located under the wrapping module chassis just after the Scitex printer heads (see Figure C 33). C13. R2L BYPASS MODULE Bypass Gate Dryer B18.1 & B18.2 Unseparated Product Photosensors Rejection Bin Air Knife Dryer and Air Knife Figure C 33 PC_Add must be on for the dryer to operate. Also, the dryer will not operate when the machine is running at speeds below 4000 pcs/hr to prevent overheating of the wrapper web. The air knife (see Figure C 33) blows cool air over the dryer to cool it down when the machine stops. R2L Bypass Module Figure C 34 The R2L bypass module diverts defective mailpieces. Rejection is controlled by parameters programmed into PC_Add. Pieces can be rejected for unsuccessful barcode reader and camera scans, integrity mismatches, and/or insert misses/doubles. The bypass module will also reject envelopes that were not properly separated by the rotary knife. Completed mailpieces pass between two photosensors that are spaced one mailpiece length apart (see Figure C 34). If both sensors are blocked when a mailpiece passes through, then the mailpiece is too long, indicating that it is actually two unseparated envelopes. When this occurs, the R2L activates its pneumatic gate and drops the faulty product off of the conveyor.

25 The bypass module can also be programmed to divert a mailpiece at an certain quantity interval for quality control inspection. Product that is not diverted by the bypass gate is detected by the product count sensor (see Figure C 35). C14. RA5Z CONVEYOR After completed mailpieces pass through the R2L bypass module, a rotating cone guides them onto the RA5Z conveyor. When the end of a ZIP code group (RA6 software required) or a programmed quantity is detected, a pneumatic arm extends forward, pushing a mailpiece out of line with previous mailpieces (see Figure C 36). The pneumatic arm can offset either the first mailpiece detected in a group, or the entire group. Pneumatic Arm B17.1 Product Count Sensor Bypass Module Product Count Sensor Figure C 35 The count from this sensor is displayed in the C1 (partial pieces) counter area on the main control panel (see Section E1.a and Figure E 2). This sensor also triggers the operation of the output conveyor. Cone RA5Z Conveyor Figure C 36 SECTION C PAGE 25

26 SECTION C PAGE 26 C15. PC_ADD manage integrity for checks-plus-documents applications, the account numbers read from the barcodes on the checks and documents are matched PC_Add PC_bh PC_Add and PC_bh Machines Figure C 37 The PC_Add functions include: support the JETVision system and barcode readers control selective insert feeding control printing on envelopes the system uses the account number read from the 2D barcode to look up the address and provide this to the Scitex printers. For closed-face applications, the account number printed on the envelope is read by JETVision and compared to the account number read from the barcode on either the checks or documents. If a mismatch is detected, JETVision signals PC_Add. program, store, and recall job settings C16. PC_BH The PC_bh functions include: log performance data the PC_bh machine stores all machine and PC_Add events, and information about finished and unfinished documents generate reports C17. A.R.C. SOFTWARE The A.R.C. software provides automatic gap recovery. Typically, the wrapping system must operate at a speed to accommodate the slowest feeder in order to avoid wrapping empty steps (individual spaces between pusher pins on the raceway). This must occur even when the slowest loading insert is used a small percentage of the time. To increase average throughput, the A.R.C. software controls the speed of the wrapping section independently from the collating section. On-the-fly adjustments are made to the wrapping section speed so that empty steps are passed over and not wrapped. This allows the wrapping module to

27 operate at the average insert speed rather than the slowest insert speed for increased average throughput. The A.R.C. software can also make on-the-fly error corrections if the first feeder fails to deliver an insert. The A.R.C. software will direct the downstream feeders to not feed, and the wrapper module will slow down and allow the empty step to pass unwrapped. Only jobs that don t use integrity matching can use the A.R.C. software. When a job involves matching documents or checks to envelopes, the A.R.C. software would incorrectly wrap the next document or check into the wrong envelope. C18. PLC AND ELECTRONIC CONTROLS The control system is based on the programmable logic controllers (PLC) that are contained within a separate control cabinet (see Figure C 38). The control system is connected to an operator panel used to enter system parameters and operate the machine. The control panel also displays system errors. Electrical Cabinet Interior Figure C 38 SECTION C PAGE 27