Electrodynamic propulsion system for conveying sheet material

A chassis module for a mailpiece inserter, the chassis module operative to form a stacked collation of sheet material for insertion into a mailpiece envelope, at least one of the stacked collations having a length dimension which differs from the length dimension of another stacked collation, the chassis module comprising:

• a support deck having at least two elongate slots disposed along the length thereof;
• a plurality of longitudinally spaced abutment members defining a pocket for accepting the stacked collation of sheet material therebetween, each abutment member extending downwardly through one of the elongate slots of the support deck and operative to engage one of the leading and trailing edges of the stacked collation;
• an electro-dynamic propulsion system having a guideway corresponding to each of the elongate slots and a plurality of longitudinally spaced ferromagnetic elements;
• each guideway having a magnetic coil operative to produce a magnetic field having a variable flux density and polarity, the magnetic field operative to propel the ferromagnetic elements within the guideway;
• each ferromagnetic element disposed within one of the guideways and coupled to one of the abutment members, each ferromagnetic element, furthermore, being propelled within the respective guideway in response to the flux magnitude and polarity of the magnetic field;
• and,
• an array of sensors disposed along the feed path operative to sense an actual angular position of an edge of the stacked collation, and issuing an orientation signal indicative thereof, and
• a processor operative to (a) control the magnetic field of the electro-dynamic propulsion system to propel the ferromagnetic elements within the guideway to transport the stacked collation along the feed path, (b) control the spatial position of the ferromagnetic elements to vary the pocket dimension to accommodate collations of varying length dimension, and (c) store prescribed position data indicative of a desired angular position of the stacked collation respond to the orientation signal for (i) comparing the actual angular position to the desired angular position, (ii) calculating a difference value therebetween, and (iii) issuing an error correction signal, based upon the difference value, to the vary the position of the ferromagnetic elements thereby transposing the stacked collation to the desired angular position.