FI128079B

FI128079B - A sorting system and a method for sorting mail items

Info

Publication number: FI128079B
Application number: FI20175250A
Authority: FI
Inventors: Mikko Auranen; Janne Eteläaho
Original assignee: Notta Systems Oy
Priority date: 2017-03-20
Filing date: 2017-03-20
Publication date: 2019-09-13
Also published as: FI20175250A

Abstract

The present invention relates to a sorting system for mail items. The sorting system comprises a data processing apparatus implementing a sorting plan, a conveyor belt (1) and sequential stations (2) through which the conveyor belt (1) passes. Each station (2) comprises a frame (5), at least one tray (6) on the frame (5) and at least one device for identifying the mail items. The present invention also relates to a method for sorting the mail items provided with the address particulars by the sorting system.

Description

A SORTING SYSTEM AND A METHOD FOR SORTING MAIL ITEMS

FIELD OF THE INVENTION

The present invention relates to a sorting system for mail items. The present invention also relates to a method for sorting mail items.

BACKGROUND OF THE INVENTION

Known systems for sorting parcels are usually fully automatic. They comprise many problems which exist in different combinations in the existing systems. A read rate of an optical character recognition device in connection with small parcels may be inadequate. The sorting system may require a lot of space and it may be slow to assemble or disassemble. The sorting system is usually fixed and unscalable, thus making the sorting system inflexible. Further, the system may require a remarkable initial investment. The system may have many moving parts resulting in high maintenance costs and many wearing parts.

Publication US 2012296467 discloses techniques and equipment for processing mailpieces. Publication WO 2014087069 discloses a method for merging postal matter with sorted post. Publication EP 1371423 discloses a mail sorter with mail containers arranged in several layers. Publication EP 1535671 discloses a mail sorting and distributing transfer system. Publication WO 2015009660 discloses a sorter having bullpens with double runout lanes and a method for sorting to those bullpens. Publication EP 3115115 discloses a sorting system and a method for handling parcels using such a sorting system.

BRIEF DESCRIPTION OF THE INVENTION

An object of the present invention is to provide a system and a method so as to overcome the above problems. The objects of the invention are achieved by the system and the method which are characterized by what is stated in the independent claims. The preferred embodiments of the invention are disclosed in the dependent claims.

The invention is based on an idea to combine automatic and manual functions in such a manner that the outcome is more effective. There are certain automatic and manual functions which may be accomplished simultaneously so that time is saved. The sorting system is scalable, i.e. it is easy to increase capacity of the sorting system. Thus, the sorting system is very flexible and further, it is quick to assemble or disassemble. Any kind of mail items can be sorted, such as letters, boxes or parcels having irregular shapes. The worker does not need long training, experience or knowledge about postal routes but seasonal workers can be hired. The sorting system requires less space compared to the known systems. The initial investment is low. There are only a few moving parts in the system which makes its maintenance easy and there are less problems connected to wearing parts. However, the benefits of the invention may slightly vary as per the embodiments of the invention.

The sorting system comprises sequential stations through which a conveyor belt passes. The conveyor belt comprises an endless rotating belt, or the conveyor belt is formed of sequential endless rotating belts.

A frame for trays surrounds the station. The frame has a shape of a circular arch in the direction of the horizontal plane. The arch may be approximately three quarters of the circle in such a manner that a worker of the station has a working space inside the circle and a possibility to leave though an opening at the side of the frame for the trays. The curved shape of the frame is ergonomic because the worker has all the trays at the same distance.

The frame for the trays is designed in such a manner that the conveyor belt can pass through the station. In other words, there is enough space so that the conveyor belt can run and convey mail items through the frame.

The frame for the trays comprises predetermined positions for the trays. The trays may be placed to the frame side by side and one upon the other on shelves of the frame. There may be a visual indication device, such as an illuminating device, on the frame in front of each position. The illuminating device may be a LED lamp (light emitting diode), a row of LED lamps, or a LED band. The visual indication device can be besides the illuminating device any other suitable device giving a visual sign.

Each sorting station comprises devices for sorting the mail items but it is possible that all stations do not comprise all devices. Usual devices on the sorting station are a display comprising a graphical user interface, an integrated label printer (a label printer which is fixedly integrated to the sorting system), a camera unit, a laser pointer and a barcode scanner.

The sorting process starts by choosing a sorting plan according to which the mail items are sorted into the trays. The sorting plan may be selected by a centralized selection, or the sorting plan may be selected at each station. It is possible that the sorting stations are grouped in such a manner that there are more than one station working with the same part of the sorting plan, i.e. there are trays having the same destination on different stations. There maybe several such groups in the sorting system. It is also possible that all stations are working with the same part of the sorting plan. After the sorting plan is selected identifying labels of the trays are printed at each station. The printing of the identifying labels begins automatically.

The mail items to be sorted are fed first to a feeding device, such as a feed hopper, from which they are transferred to the conveyor belt. The stations need not to be physically sequentially placed but the conveyor belt may wind and the stations are placed one after the other in the direction in which the conveyor belt runs.

The worker of the sorting station picks a mail item from the conveyor belt running through the station. Then the worker sets the address particulars under the camera of the OCR device (optical character recognition) or any other device for identifying the mail items, such as different devices for reading bar codes, matrix codes, or QR codes, or devices for reading radio frequency identification labels or tags, or devices for reading any other wireless identification labels or tags. The right destination, i.e. the right tray, is shown on the display. Further, illuminating devices come on on the frame of the trays, thus showing the correct tray. The worker puts the mail item into the tray.

If the mail item to be sorted does not belong to a tray of the first sorting station a label is printed and attached to the item. The label includes a correct tray number and a correct rack number. The correct tray number may be printed in a 2D data matrix. After the label is attached to the item it is returned on the conveyor belt.

The labelled mail item is identified by the barcode scanner at each station through which it passes. When it reaches the station to which it belongs an alarm is given to the worker of that station. The alarm is usually a sound. The display of the graphical user interface shows information to which tray the mail item belongs. The information may be in a form of a pop-up notification. It should be notified that when a label comprising a barcode is attached to a mail item, it is possible to use a sorting station without an OCR device because a barcode scanner identifies the right destination.

If the address particulars are extremely unclear or inadequate it may be possible that the OCR device fails to read the address. As the worker removes the rejected item from the surface of the identification desk the system automatically prints a unique identification code, such as a 2D matrix identification code, which is stored in the database. The rejected item is placed on a separate reject

20175250 prh 16-01-2019 tray.

After the normal sorting is done the worker starts to sort the rejected items in a local process for handling rejected items. The worker selects from the graphical user interface an online video coding (VCS) mode, puts the rejected item 5 under the camera and starts to code. A video coded address is stored in the database, and the unique identification code is combined with the image and address data. The right destination, i.e. the right tray, is shown on the display of the graphical user interface as in the normal sorting process. If the rejected item does not belong to the sorting plan of the station in question the worker returns the item 10 on the conveyor belt in such a manner that the unique identification code is visible.

The unique identification code is identified on the next station. If the item belongs to the sorting plan of the station in question, the system notifies the worker of that station with a sound and shows information on the display that the 15 worker should remove the item from the belt. There is also simultaneously information about the tray number and possibly the image of the mail item on the display. The worker may pick up the item, or let it travel on the conveyor belt to the next station if there are more stations having the same destinations.

An alternative to the above-mentioned procedure is to provide the re20 jected item with a label comprising the tray and station number. Once the worker sees the item on the belt he/she picks and sorts it normally.

An alternative to the local process for handling rejected items is a remote process for handling rejected items. The difference between the local process and the remote process is that in the local process the rejected mail items can 25 be sorted on a local station but in the remote process the rejected mail items are sent to a separate station for sorting. It depends on the work load at each station which process is chosen for the rejected mail items.

If the rejected item is not identified despite the described attempts the unrecognised mail item ends up to the collection section of the conveyor belt. All 30 rejected items are collected from the belt and sent to further investigations.

The worker of the station removes the tray from the frame when it is full or there is another reason to remove the tray and lifts it on the conveyor belt. The worker puts a new tray to the frame for the trays. There is an area in the graphical user interface for receiving a piece of information of a new tray. When 35 the piece of information is received the label printer prints a label which identifies the tray and the rack. The worker attaches the label to the new tray and con tinues sorting. The full tray is transported by the conveyor belt to a collection section of the conveyor belt. The worker in the collection section picks up the tray from the belt and puts it to the correct rack.

Alternatively, another worker behind the sorting station can take a full tray from the frame via the backside of the frame and lift the tray to a rack.

The system controls the number of the trays at each station and a worker who is responsible for new empty trays is informed by a sign, such as an attention light, that more trays are required at the station. The worker unloads the empty trays from a rack and puts them under the belt in such a manner that a worker at the sorting station can reach the trays. A full rack is removed by the worker and a new empty rack is changed to its place.

BRIEF DESCRIPTION OF THE DRAWINGS

In the following the invention will be described in greater detail by means of preferred embodiments with reference to the attached drawings, in which

Figure 1 shows an overview of the sorting system in a perspective view;

Figure 2 shows a detail of the sorting system in a perspective view;

Figure 3 shows a further detail of the sorting system in a perspective view.

DETAILED DESCRIPTION OF THE INVENTION

Figure 1 shows an overview of the sorting system in a perspective view from above. The sorting system comprises a conveyor belt 1 and successive stations 2 (2a, 2b, 2c and 2d). The conveyor belt 1 may wind, as seen in Fig.l. When the conveyor belt 1 winds the corner may be a conveyor of a different type, such as a curved roller conveyor.

A data processing apparatus implements a sorting plan. The sorting plan may be divided between stations 2a, 2b, 2c and 2d in such a manner that each letter from a to d forms a group. For example, in Fig. 1 there are three stations 2a which may form a sorting group which shares the same sorting plan.

Each station 2 comprises a frame 5 for trays 6 (see Fig. 2). According to one solution, the frame 5 may have space for 52 trays. If there are three stations in the group there are 156 trays for different postal areas.

If the mail item to be sorted belongs to a tray of the first sorting station of the group the worker of that station puts the mail item in the tray in question.

If the mail item to be sorted does not belong to a tray of the first sorting station of the group a label is printed and attached to the item. The label includes a correct rack number and a correct tray number. The correct tray number may be printed in a 2D data matrix. After the label is attached to the item it is returned on the conveyor belt 1. However, each station 2a may have its own sorting plan if it is reasonable to do so. Thus, it is easy to increase / decrease capacity just by changing the sorting plan and the system is ready to operate.

As can be seen from Fig.l, it is also easy to add more stations 2 along the conveyor belt 1. The conveyor belt 1 may comprise several successive belts so that its length and direction can be changed flexibly.

There may be a feed hopper 3 in the beginning of the conveyor belt 1. Mail items to be sorted, such as letters, boxes or parcels having irregular shapes, are fed in the feed hopper 3 and led to the conveyor belt 1. Racks 4 can be kept around the conveyor belt 1 in suitable locations, i.e. in such a manner that they are easy to reach.

Fig. 2 shows a detail of the sorting system in a perspective view. The mail items to be sorted, such as parcels, are fed to a feed hopper 3 from which they are transferred to a conveyor belt 1. The conveyor belt 1 passes through a station 2a, as seen in Fig. 2. The rotating direction of the conveyor belt is shown by an arrow D. A frame 5 for trays 6 surrounds the station 2a approximately in a shape of a circular arch in such a manner that a worker W1 has a working space 7 inside the circle and a possibility to leave though an opening 8 at the side of the frame 5 for the trays 6. An attention light 17 is on the frame.

Fig. 3 shows a further detail of the sorting system in a perspective view. A sorting station 2a comprises a frame 5 for trays 6 and devices for sorting. The devices for sorting comprise a display 9, a label printer 10, a desk 11, a keyboard 12, illuminating devices 13, a laser pointer 15 and a barcode scanner 16. The display 9 shows a graphical user interface including a touch screen. The label printer 10 is for printing bar codes. The desk 11 is for identifying parcels and comprises a scale. In the front edge of the frame 5 there are illuminating devices 13, such as LED lamps or LED bands. There is an illuminating device 13 in front of each tray 5 in such a manner that the illuminating device 13 shows to which tray 6 a parcel belongs, i.e. the illuminating device 13 comes on, thus showing the right place to the parcel after the address particulars of the parcel have been identified. The laser pointer, i.e. a laser R01 (region of interest), scans the region of interest,

i.e. the region from where the address particulars can be read. The barcode scanner 16 is above the conveyor belt 1, thus being capable of reading the address 5 particulars of the parcels which are conveyed on the conveyor belt 1.

As seen from Figs. 2 and 3, the conveyor belt 1 passes through the frame 5 of the sorting station 2. In such a manner it is possible to have stations 2 one after the other. Further, it is easy to assemble more stations 2 or disassemble stations 2 according to the current need. The distance between the stations 2 can 10 also be changed.

It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.

Claims

The claims

A sorting system for mailings, the sorting system comprising a data processing device for implementing a sorting plan, a conveyor belt (1) and successive stations (2) through which the conveyor belt (1) passes,

The station (2) comprises a frame (5), at least one shelf (6) in the frame (5) and at least one device for identifying the items to be mailed.

Sorting system according to Claim 1, characterized in that the device for identifying the items to be mailed is an optical character recognition device.

10

Sorting system according to Claim 1 or 2, characterized in that the device for identifying items to be mailed is a bar code reader (16).

Sorting system according to one of the preceding claims, characterized in that the frame (5) surrounds the station (2) and defines the sorting area.

15 (7J.

Sorting system according to one of the preceding claims, characterized in that the frame (5) has a circular arc in the horizontal direction.

Sorting system according to one of the preceding claims, characterized in that the frame (5) has shelves (6) for different postal areas.

Sorting system according to Claim 6, characterized in that the frame is provided with visible detection devices such as illumination devices (13), each visible detection device corresponding to a certain position of the shelf in the frame (5).

8. Method of mailing copies with address information

For sorting by a sorting system comprising successive stations (2) and a conveyor belt (1) passing through stations (2), each station (2) comprises at least one device for identifying mailable items and at least one shelf (6) disposed in a frame, the method comprising:

- programmatically selecting a sorting plan that defines the output of the mailed copy,

- transporting the mail item by conveyor belt (1),

- manually removing the mail item from the strap (1),

recognizing the address information of the mail item to be sorted, and

35 - manually place the item to be mailed on a predetermined shelf (6) or return it manually to the conveyor belt (1).

Method according to claim 8, characterized in that the body to be mailed is identified by an optical character recognition device.

Method according to claim 8 or 9, characterized in that the body to be mailed is identified by a bar code reader (16).