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

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.

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.

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.