JP2006528552A - Improved object feeder pretreatment system - Google Patents

Abstract

  A mail handling system having a supply conveyor (10), wherein the supply conveyor supplies a carrier (60) to an auxiliary platform (40), and the auxiliary platform supplies a carrier to a feeder (100).

Description

Background of the Invention
FIELD OF THE INVENTION The present invention relates generally to systems for handling mail and / or other items (including, for example, thin mail items, envelopes, letters, postcards and / or other mail items), among others. The preferred embodiment relates more particularly to an automated system for pre-processing thin mail handled by a thin mail sorting system.

Background Description Currently, various systems are used for handling thin objects such as thin mail and / or other objects such as mail. For example, the US Postal Service (USPS) uses a variety of systems to facilitate and improve the handling of thin mail items.

  For example, several exemplary mail handling systems are assigned to Northrop Grumman Corporation, entitled “Flats Bundle Collator”. No. 6,443,311 (the '311 patent), the disclosure of which is incorporated by reference in its entirety as if set forth in full herein.

  As another example, one exemplary mail handling system is the AFSM100 thin mail sorting system built by Northrop Grumman Corporation and the Rapistan System and used by the USPS. The AFSM100 thin mail sorting machine is a mail sorting system that can process a large amount of thin mail such as a large number of magazines. Each AFSM100 system has three mail supply units.

  In some of these existing mail processing systems, feeders are used to deliver mail to the processing system. In some illustrative and non-limiting examples, these feeders include a delivery section and a destack (eg, individualization) section. In such systems, mailpieces are typically placed in the delivery section and delivered to the destack section. In these exemplary systems, mail pieces are usually delivered separately to a sorting section (eg, usually having a fixed gap and / or a fixed pitch).

  In such systems, the operator typically loads the mail to be processed into the delivery section (eg, by hand from the mail storage basket) at the beginning of the operation. The operator typically continues to load the mail while the system processes the mail.

  In modern mail handling environments, sorting systems and other systems operate faster and longer than before. In particular, this can increase the burden on the operator supplying and / or operating the system. In many cases, the performance of mail handling equipment is increasingly dependent on the ability to support the operator's system.

  Accordingly, there is a need for a pre-processing system that can overcome the above and / or other problems, particularly with existing systems.

Overview of the Preferred Embodiments Various embodiments of the present invention can significantly improve existing systems and methods. In some preferred embodiments of the present invention, one or more of the above and / or other problems with existing systems can be overcome.

  According to some embodiments, a method for pre-processing mail sent to at least one mail feeder having a conveyor for supplying mail to a downstream system includes: a) at least one preparation operator Placing unbound mail on the carrier; b) delivering the carrier to the feeder through the delivery system without lifting the carrier; c) placing the mail on the carrier. Transloading from the feeder to the conveyor of the feeder. Preferably, the step of transshipping the mail piece includes causing the feeder operator to move the mail piece laterally to the conveyor of the feeder. In some embodiments, the method further includes providing the mail piece as a thin mail piece. In some embodiments, the method includes delivering a carrier from a plurality of preparatory operator locations to a common supply, and a carrier from the common supply to a plurality of supply operator locations near each mail feeder. And a step of sending. In some embodiments, the delivering step comprises delivering the carrier through the delivery system along a path that includes a lateral component such that the carrier is at least partially moved laterally, and / or Alternatively, delivering the carrier through the delivery system along a path that includes a generally vertical component such that the carrier is moved at least partially in a generally vertical direction.

  According to another embodiment, a method for pre-processing mail sent to at least one mail feeder having a conveyor for supplying mail to the system includes: a) mail at at least one preparatory operator location. B) unwinding the bundle; b) placing the unwrapped mail piece on at least one mail carrier; c) placing at least one mail carrier into at least one mail feeder; Sending through a delivery system that allows the supply operator to leave around each of the postal feeders. In some embodiments, the delivery system includes a conveyor and a movable platform. In some embodiments, the movable platform is movable between a position adjacent to the conveyor and a position adjacent to the feeder.

  According to another embodiment, a method for pre-processing and delivering an object to an object feeder includes: a) loading the object onto a plurality of carriers; and b) carrying the carrier to the object feeder with a supply conveyor. C) transporting at least one of the carriers from the conveyor to the feeder on a reciprocating transporter; d) transferring the objects from the at least one carrier to the feeder after transport; e) Placing at least one carrier onto a return conveyor after transshipment.

  According to another embodiment, the mail handling system includes a) a feeder for supplying mail, b) a plurality of mail carriers, and c) a transport capable of arranging at least one of the mail carriers. And d) the conveyor includes a movable platform that is movable along a path from a position adjacent to the feeder to a position away from the feeder to allow the supply operator to exit around the feeder. Including.

According to another embodiment, a thin object handling system includes: a) a feeder for supplying a thin object; b) a plurality of carriers carrying a plurality of thin objects; and c) a carrier for carrying the carrier to the feeder. A conveyor and d) a conveyor configured to convey at least one of the carriers from the conveyor to the feeder, the conveyor being movable to allow the supply operator to exit around the feeder It is. In the preferred embodiment, the thin object includes a mail piece.

  The above and / or other aspects, features and / or advantages of various embodiments will be further appreciated in the following description in conjunction with the accompanying drawings. Various embodiments can include and / or exclude different aspects, features and / or advantages. In addition, various embodiments can combine one or more aspects or features from other embodiments. The descriptions of aspects, features and / or advantages of particular embodiments should not be construed as limiting other embodiments or the claims.

  The accompanying drawings are provided for purposes of illustration without limiting the broad scope of the invention or various other embodiments. In the drawings, like reference numbers indicate like or similar parts.

Various embodiments of the Detailed Description of the Invention The preferred embodiment can be used in a variety of systems and devices. In some non-limiting examples, embodiments of the present invention are similar to those shown in the '311 patent, for example, to improve processing at the feeder 10 shown in FIG. 1 of the' 311 patent. Can be used in the system. Furthermore, in other non-limiting examples, various embodiments of the present invention can be used for use with the AFSM100® thin mail sorting system.

  Preferred embodiments can be used to process mail items (including, for example, boxes, thin mail items, envelopes, letters, postcards and / or other mail items) and are most suitable for processing thin mail items. Although preferred embodiments can be used, various embodiments can be further used or alternatively used to process other objects (e.g., objects of any configuration). In a more preferred embodiment, the objects include thin objects such as sheets, cardboard, panels, magazines, paper products and / or other thin objects. In some preferred embodiments, thin mail pieces are handled. In certain preferred embodiments, a given system can handle a large number of thin objects (eg, thin mail pieces) of different sizes and / or shapes at a given time. However, thin objects are preferably included within a predetermined range of features.

For example, in certain preferred embodiments, the system can be adapted to handle thin mail pieces having one or more of the following features. In some embodiments, each thin mail piece is generally rectangular, a) about 12 to 5 inches in height, b) about 15 to 6 inches in length, and / or Or c) about 0.75 inches to 0.009 inches in thickness. Further, in some embodiments, each thin piece of mail has the following weight restrictions: a) less than about 13 ounces (eg, for first class mail), b) about 16 ounces (eg, for standard mail). Less than and / or c) less than about 20 ounces (eg, for periodicals and bundled prints). Further, in some embodiments, each thin piece of mail meets various postal service (eg, USPS) standards for “turning ability” and / or “deflection”. . Some preferred embodiments include the handling of thin mail pieces having features as described herein, but various other thin mail pieces configurations or specifications disclosed, for example, in the '311 patent. Numerous other embodiments can be used. The foregoing exemplary embodiments do not limit the broad applicability of the present invention to thin mail pieces and / or other objects or materials having other features that can vary widely depending on the particular situation.

  In some exemplary embodiments, a pre-processing system can be provided to assist one or more AFSM100® systems or other systems. This pre-processing system may be, for example, of a full carrier supply conveyor 10, an empty carrier return conveyor 20, a movable container tilter 30, a fixed auxiliary platform 40, a transfer slide 50, and / or a plurality of mail carriers 60. One or more, preferably all, can be included.

  In the illustrated embodiment, as shown in FIGS. 1 and 2, the bundled thin pieces of mail are unbundled and passed directly from the basket 30H to the mail piece carrier 60 at the inlet end 10A of the supply conveyor 10. Can be prepared. The full carrier 60 can then be lined up and transported to a fixed auxiliary platform 40 located between the conveyor 10 and the feeder 100. A full carrier 60 can be moved (eg, using a fixed auxiliary platform 40) to a receiving area 110 at the inlet end of the feeder. The operator OpF of the feeder preferably lowers the thin mail F to the feeder 100 and then places the empty carrier 60 on the empty carrier return conveyor 20.

  Some embodiments can be used with, for example, a feeder that supplies mail, but various other embodiments can also be used with feeders that supply other objects or materials. The term feeder includes “... a material feeding device” according to the Webster's II New Riverside Dictionary, and is supplied and / or supplied in any specific form. It is not limited to any particular object.

Supply Conveyor In some exemplary embodiments, a full carrier supply conveyor 10 aligns and prepares a full carrier operator OpP loading zone (see, for example, zone Z1 in FIG. 3 at the inlet end 10A of the conveyor). Electric rollers for transporting from one to a fixed auxiliary platform 40, zone-integrated conveyors may be included. The conveyor 10 may include, for example, a plurality of electric rollers 11. In other embodiments, any other conveyor can be used, such as, for example, one or more rotating belts, one or more pushers, one or more moving platforms, and / or other suitable conveyors. . The downstream end of the supply conveyor may be positioned adjacent to the location where delivery is desired, adjacent to the feeder 100 (eg, AFSM100 feeder, etc.). Preferably, there is a distance D1 of at least a few feet between the feeder or the like and the discharge end of the conveyor (eg to allow the operator to pass freely there between). This distance D1 may be about 3 to 5 feet in some exemplary embodiments, and may be about 4 feet, or more preferably about 46 inches in one exemplary embodiment. Can do.

In some exemplary embodiments, the supply conveyor can have a plurality of, such as two or more carriers, or more preferably three or more carriers, or more preferably five or more carriers, at a given time. It is made long enough to handle the carrier. In some exemplary embodiments, the conveyor may have a length DS of about 5 feet to 15 feet. In some exemplary embodiments, the conveyor width may be about 1 to 3 feet. In one exemplary embodiment, the conveyor is about 10 feet long and about 2 feet wide and can hold five carriers at a given time. In some exemplary embodiments, the conveyor can operate at a speed of about 25 to 75 feet per minute (FPM), and in one example, it can operate at about 50 FPM. In some exemplary embodiments, the supply conveyor is divided into five zones, each two feet long, such as zones Z1 to Z5 shown in FIG.

  In some embodiments having multiple “zones” associated with the conveyor 10, as shown in FIG. 3, a detector or sensor 18, such as a light sensor or photoeye, is disposed thereon. For example, at the downstream end of each zone to detect the presence of the carrier. The detector 18 can output a signal that identifies the presence and / or absence of a carrier at a particular location, for example. In some embodiments, such as that shown in FIG. 3, a controller such as a computer, processor, etc. can be used to selectively activate the appropriate rollers via one or more roller drive mechanisms. In this manner, for example, a roller in a particular zone can automatically activate and carry the carrier. For example, full carriers are automatically advanced to an empty downstream zone where they are processed, for example.

  Preferably, a position detector or sensor 12, a pop-up stop 13 and an index push button 14 are located near the discharge end 10B of the supply conveyor. The pop-up stop 13 is preferably normally raised to prevent the carrier 60 from moving away from the end of the supply conveyor 10 when the platform 40 is not in an adjacent position. Preferably, when the fixed auxiliary platform 40 is moved to a position adjacent the discharge end of the supply conveyor, the coupling mechanism prevents the platform 40 from changing position. The position sensor 12 preferably verifies that the platform is in place and fixed. Preferably, during such verification, the pop-up stop 13 is automatically controlled to lower to allow the carrier 60 to be delivered away from the supply conveyor. This control can be performed in various ways, such as moving the pop-up stop using a solenoid and applying a starting current to the solenoid in response to detection by the sensor 12. In some embodiments, the control may utilize one or more controllers, such as the controller shown in FIG.

  Preferably, the index push button 14 moves the full carrier 60 from the downstream zone of the conveyor 10 to the platform 40. The push button 14 may include, for example, a button that is pushed by an operator (eg, by hand). In some embodiments, pressing button 14 retracts pop-up stop 13 and at least some rollers 11 of the conveyor move the carrier forward.

  Preferably, the operator is responsible for releasing the coupling mechanism between the platform 40 and the conveyor after the carrier has been safely reloaded. This latter function can help to ensure that the platform 40 does not leave the supply conveyor while a full carrier is being transferred to the platform 40. Once the auxiliary platform 40 and the supply conveyor 10 are separated, the pop-up stop 13 is preferably activated automatically and lifts to a fixed position.

Preferably, another index push button 15 and a fixed stop 16 are arranged at the inlet end 10 </ b> A of the supply conveyor 10. As described above, the preparation operator OpP fills the empty carrier 60 in the upstream loading zone. Preferably, the fixed stop 16 prevents the carrier from moving away from the entrance end of the conveyor. The operator OpP can preferably push the index push button 15 to advance a full carrier from the upstream loading zone Z1 via the conveyor 10. For example, the index push button 15 preferably rotates a roller 11 (eg, in zone Z1 in the example shown in FIG. 3) to move the carrier forward. Preferably, the emergency stop operating pull cord 17 runs substantially along the length of the supply conveyor, for example by manually activating (eg, pulling) the conveyor 10 to stop the conveyor 10 in some situations. Be able to stop manually.

  The supply conveyor includes motorized rollers in some exemplary embodiments, although one or more other conveyors may be used in various other embodiments. For example, one or more conveyor belts and / or other conveyors can be included. The term “conveyor” as used in this application is capable of moving a carrier, such as one or more rotating belts, one or more pushers, one or more moving platforms, and / or other suitable conveyors. Includes any mechanism. In a preferred embodiment, such a conveyor is configured to have different carrier movements between multiple zones along the conveyor.

Return conveyor Preferably, an empty carrier return conveyor 20 is provided. In the preferred embodiment, the return conveyor 20 is substantially similar to the supply conveyor 10 but can be used to return empty carriers. In one exemplary embodiment, the return conveyor 20 may be similar to the supply conveyor 10, for example, about 10 feet long and about 2 feet wide in the illustrated example. Similar to the supply conveyor 10, the dimensions of the return conveyor 20 can vary from situation to situation. Preferably, the return conveyor 20 is an electric roller or a low pressure integrated conveyor. Preferably, the conveyor 20 or a substantial portion of the conveyor 20 is located below the supply conveyor 10. In the preferred embodiment, the conveyor 20 is used to line up empty carriers and transport them to the preparation operator OpP.

  Similar to the supply conveyor 10, the return conveyor 20 can include any suitable conveyor, as will be understood based on this disclosure. Further, in some embodiments, the operation of the return conveyor can be controlled via a controller, such as, for example, the same controller shown in FIG.

Basket Preferably, a basket 30H is provided for accommodating thin mail items. In some embodiments, the basket 30H may include an open top container, for example, having a bottom and four side walls as shown in FIGS. In some exemplary non-limiting examples, a basket tilter 30 for operating the basket 30H is provided. In some exemplary embodiments, a Southworth Portable Postal Container Tilter (eg, PTU2DC type) may be used. These latter tilts have been used by the USPS for ergonomic processing of certain material handling equipment. In some examples, a tilting force is applied to allow the basket 30H to tilt to an ergonomic position. In some examples, the tilter may include a hydraulic transmission mechanism having, for example, a DC motor and a hydraulic pump. The container tilter can have a capacity in some embodiments greater than 1000 pounds (lbs), preferably at least about 2000 lbs. Preferably, it can rotate the plastic and / or canvas basket, wiretainer and / or Gaylord more than about 60 degrees, and preferably up to at least about 80 degrees to 90 degrees. . In one illustrative example, the tilter is supported by a roller (eg, 3 to 3.5 inches in diameter) on the front side and a pivoting caster (eg, about 6 inches in diameter) on the back side.

Conveyor (eg fixed auxiliary platform)
In a preferred embodiment, a transporter is provided for transporting the carrier to the feeder. Preferably, the transporter is configured to transport at least one full carrier from the conveyor to the feeder. The term transporter includes any device that transports or carries from one place to another. In a preferred embodiment, the transporter is movable to allow the supply operator to exit around the feeder. In various embodiments, any form of transporter can be used, such as a mobile platform, mobile drawer, trolley, wheel support, vehicle, conveyor and / or other suitable transport device. In some preferred embodiments, the transporter is reciprocable. In some preferred embodiments, the transporter may reciprocate along a generally constant path of travel (eg, along a track or the like), but in other embodiments, the reciprocating motion may be a specific path of travel. It may include a substantially anteroposterior movement between two positions that does not follow.

  In some embodiments, the delivery system for delivering the carrier to the feeder can include one or more transporters and / or one or more conveyors (eg, supply conveyor 10). The term delivery system includes any system that delivers objects and includes one or more such as a transporter, a conveyor, and the like.

  In some preferred embodiments, the transporter can include a platform such as a fixed auxiliary platform 40 that facilitates transport to the feeder 100. The term platform encompasses any structure that can support a carrier. In some examples, the platform can include a generally flat surface, while in other examples, the platform can include a variety of other configurations. Further, the platform can include a plurality of separate portions that together support one or more carriers. In the exemplary embodiment shown in FIG. 1, the platform 40 includes at least one generally upstanding support member 43 (shown in the exemplary embodiment shown in FIG. 1 two members 43) and at least one cross member. Is supported by a frame 41 having 42 (in the exemplary embodiment shown in FIG. 1, two members 42 are shown). In an alternative embodiment, platform 40 is supported by at least one suspension support member 44 (shown in the exemplary embodiment shown in FIG. 1 as two members 44). Preferably, each support member has a mounting mechanism 45 capable of linear movement (such as, for example, linear bearings, rollers, and / or other suitable laterally moving mechanisms as will be apparent based on this disclosure). And is movably attached to at least one transverse member 42. Preferably, a linear bearing or other moving mechanism is used to move the platform 40 along an axis substantially parallel to the axis along the supply conveyor (eg at its discharge end) to connect the supply conveyor 10 and the feeder 100. Configured to be able to. Furthermore, the direction of movement of the platform 40 is preferably parallel to the direction of movement of the conveying surface of the rollers of the supply conveyor 10.

  In some preferred embodiments, the platform 40 is manually positioned along the frame 41, such as by manually pushing it to slide it laterally over the frame 41. Thus, in some preferred embodiments, platform 40 is not powered by a power source. However, in various embodiments, motors and / or other movement mechanisms may be used to facilitate and / or provide movement of the platform 40 over the frame 41.

In the preferred embodiment, a fixed auxiliary platform 40 is used to transport a full carrier 60 from the discharge end of the supply conveyor 10 to the upstream end of the feeder 100. In the preferred embodiment, the fixed auxiliary platform 40 includes a plurality of non-powered conveyor rollers for facilitating movement of the carrier 60 to and from the auxiliary platform 40. In some exemplary embodiments, platform 40 is about 1 to 2 feet in length, more preferably about 16 inches in length, and about 1 to 3 feet in width, more preferably about 24 inches in width. A non-electric rotor carrying surface can be included. In some exemplary embodiments, the platform includes a first functional location 40P1 adjacent to the supply conveyor 10 and a second functional location 40P2 adjacent to the feeder 100, as shown in FIG. In between, about 3 to 5 feet, more preferably about 4 feet, in some exemplary embodiments, about 46 inches.

  In the preferred embodiment, these two functional positions of the platform are at the end of each of its effective movements. In the first position 40P1, the inlet end of the platform 40 is preferably located adjacent to the discharge end 10B of the supply conveyor 10. In the second position 40P2, the platform 40 is preferably located adjacent to the feeder 100, for example on the region 110, so that the full carrier on the platform carrying surface can be easily lowered into the feeder 100. To do.

  In some exemplary embodiments, the support frame structure and / or other support structures (such as the overhead type frame 41 shown in the exemplary embodiment, etc.) are at least one of the following two criteria described below: One, preferably configured to facilitate both.

  For the first preferred criteria, the exit path to and / or around the feeder 100 is preferably maintained sufficiently large (eg, the exit path is preferably an existing AFSM 100 system or other existing Substantially the same as that of the system). In some exemplary embodiments, such as shown in FIG. 5, a full carrier 60 may be moved from the discharge end 10B of the supply train of the supply conveyor 10 to a desired unloading position at the inlet of the feeder 100, such as in the feeder. It is possible to move without hindering the feeder operator exit 40E to the rear side. Preferably, the fixed auxiliary platform 40 is typically positioned at either the supply row position 40P1 or the feeder position 40P2 as shown in FIG. In the exemplary embodiment shown in FIG. 5, when the fixed auxiliary platform 40 is positioned at a position 40P1 adjacent to the discharge end of the supply conveyor, between the feeder 100A and the discharge end of the fixed auxiliary platform. There is a 30 inch passage D2. In the exemplary embodiment shown in FIG. 5, when the fixed auxiliary platform 40 is positioned at a position 40P2 adjacent to the feeder, a passage D1 of about 46 inches is provided between the feeder 100C and the discharge end of the supply conveyor. Exists. These dimensions are selected in some preferred embodiments, but the dimensions in other embodiments can vary depending on the situation. As just a few non-limiting examples, these dimensions are plus or minus 10% in some other embodiments, plus or minus 25% in some other embodiments, and some other In the embodiment, it can be changed by plus or minus 50%.

  With respect to the second preferred criteria, the feeder operator preferably has substantially complete access to the sides of the carrier, for example, without having to reach out in a non-ergonomic manner. For example, the feeder operator faces the side of the carrier with substantially no obstruction between operator OpF and the prepared mail piece (eg, as shown by operator position OpF / 40 in FIG. 5). It is preferable to be able to stand up. In particular, substantially complete access to the carrier 60 and / or the prepared mail piece helps to ensure ergonomic loading into the feeder 100.

  In some preferred embodiments, the fixed auxiliary system preferably includes one or more or preferably all of the following three control features.

The first control feature preferably includes the use of a non-powered roller that is mechanically limited to rotate in only one direction (preferably in substantially the same direction of travel as the supply conveyor 10). In particular, this can prevent full carriers from being carried back to the platform 40 while they are moved back toward the feeder 100. Preferably, the roller is wrapped with a high friction rubber sleeve (eg, to prevent movement of carrier 60 on the platform, such as sliding independent of platform roller rotation).

  The second control feature preferably provides a stop secured to the downstream end of the platform to prevent the full carrier from moving forward away from the downstream end of the platform. In particular, by combining a fixed platform stop with a mechanically limited roller rotation (eg according to the first control feature), for example, when a full carrier is moved to the platform, it is effectively Can be captured.

  The third control feature is preferably that when the platform moves to a platform loading position 40P1 adjacent to the discharge portion of the supply conveyor, it is automatically connected to, for example, the supply conveyor 10 and / or a fixed support adjacent thereto. Coupled (eg, fixed and / or latched). Any suitable coupling mechanism (e.g., a suitable locking and / or latching mechanism) can be used. By way of example only, a coupling mechanism 40C can be provided, as schematically shown in the dashed circle of FIG. 1, which includes a locking lever 40L that locks it. Having a cam surface 40S that can be rotated and / or moved in a generally vertical direction by a cam action on the locked locking block 40B (wherein the lever 40L and the block 40B are one or the other of the platform 40 and the conveyor 10, respectively) Fixed against).

  In a preferred embodiment, the transfer slide 50 can be provided at the upstream end of the feeder 100. Some preferred embodiments in which existing systems such as the AFSM100 system are extended may retrofit such feeder slides to existing feeders. In some preferred embodiments, the height and / or angle of the transfer slide is easily adjusted by the feeder operator OpF from the carrier to the feeder (eg, to the feeder conveyor belt), for example, a small number of thin mail items. It is set to be able to slide. In the preferred embodiment, it is not necessary to lift an object (eg, a thin piece of mail) to load it into the feeder. In particular, by sliding a thin piece of mail, an operator can handle a larger amount of objects (eg, a larger number of thin pieces of mail) and / or thereby reduce the number of operator loading cycles. In some exemplary and non-limiting examples, the length of the transfer slide is about 12 inches and the height is about 4 inches, and can be tilted at an angle of about 15 degrees.

Carrier In various embodiments, the object carrier 60 can have a variety of configurations (eg, depending on the characteristics of the object, such as a thin mail piece being carried). In some preferred embodiments, the carrier is made of a plastic material. In some preferred embodiments, the carrier is formed by a molding process such as, for example, injection molding. In some preferred embodiments, the size of the carrier is preferably selected such that a single carrier fits on the platform 40 (eg, leaving a small amount of extra space on the platform). In some preferred embodiments, the carrier is configured to weigh less than about 10 pounds, more preferably less than about 8 pounds, and even more preferably in some exemplary embodiments less than about 6 pounds. Is done. In some preferred embodiments, the carrier supports thin mail pieces and has more than 100 thin mail pieces, more preferably more than about 150 thin mail pieces, and in some exemplary embodiments, about Adapted to have a capacity to hold 170 thin mail pieces.

In some preferred embodiments, the side and bottom surfaces are more flexible (e.g., between about 5 degrees and 15 degrees, so as to effectively hold the prepared mail piece while it is transported on the supply conveyor. It is tilted at an angle α (preferably about 10 degrees). Preferably, two small upwardly projecting retaining edges 61 prevent mail pieces from sliding off the base support wall 62 of the carrier 60. Further, the base support wall 62 preferably generally intersects the side support wall 63 at an angle θ (preferably about 90 degrees, for example). In the preferred embodiment, the carrier is configured to include thin plastic walls, and preferably the walls 62 and 63 are reinforced by ribs 62R and 63R, respectively, as shown. In some exemplary embodiments, the carrier length L can be about 16 inches to 24 inches, more preferably about 20 inches. In some exemplary embodiments, the width W of the carrier can be about 10 inches to 20 inches, more preferably about 15 inches.

  As shown schematically in the dashed circle shown in FIG. 8, in some embodiments, the outer end 62E of the bottom support wall 62 can include an overhang portion 62L, which portion of the transfer slide 50. It is configured to extend beyond the entrance edge.

  Although several exemplary carrier designs have been shown and described, various embodiments can be adapted to various carrier designs. For example, various systems according to embodiments of the present invention may operate with various carrier types and designs.

Operation In some exemplary embodiments, the operation of such an embodiment may be as described below.

  With respect to preparation and queuing, the preparation operator OpP is preferably located near the inlet end 10A of the supply conveyor 10. A basket 30H of bundled objects (eg, bundled thin mail) is preferably positioned adjacent to the inlet of the supply conveyor. Preferably, the basket is placed within a few feet of the conveyor 10, most preferably within reach of the arm of the preparation operator OpP. The preparation operator preferably uses the basket tilter 30 to operate the basket 30H to an ergonomic position. During operation, the preparation operator OpP preferably removes the empty carrier from the outlet of the empty carrier return line 20. The preparation operator preferably places the empty carrier in an upstream zone (eg, zone Z1 shown in FIG. 3) at the entrance of the supply conveyor 10.

Preferably, the preparation operator removes the bundle of thin mail pieces from the basket 30H and removes the binding that holds the thin mail pieces in the bundle state. In some preferred embodiments, a hanging band cutter 30C (eg, as shown in FIG. 9) may be provided to facilitate cutting of the binding. A thin piece of mail that has been broken up with the binding removed is preferably placed on the carrier 60. In some preferred embodiments, the thin mail piece is placed on the carrier 60 with any bound edges below. The position of the basket 30H relative to the carrier, the use of basket tilter, and the height of the carrier 60 (in the loading zone of the supply conveyor 10) are preferably arranged to minimize operator movement and maximize operator ergonomics. Is done. In the embodiment shown in FIG. 6, the basket 30H is placed substantially next to the supply conveyor 10 and the operator OpP faces the basket and the supply conveyor simultaneously. In the embodiment shown in FIG. 7, the basket 30H is placed at an angle (eg, generally perpendicular) to the supply conveyor 10 so that the operator OpP can easily move between positions as shown. Can be stretched. In some preferred embodiments, the operator OpP does not need to walk significantly and / or bend the body (eg, torso) significantly. In some preferred embodiments, the operator does not need to bend the body significantly, for example in some embodiments having a low-position return conveyor, and the operator does not need to bend each time the carrier is loaded (eg to remove an empty carrier). ) You only need to bend your body once.

  Preferably, the preparation operator OpP presses the index button 15 when the carrier 60 in the loading zone of the conveyor 10 is full. Preferably, the supply conveyor 10 is then automatically activated to advance a full carrier to the next zone. Using various forms of automatic control, such as a computer control system, processor and / or other controls that cause the desired movement to occur upon activation of button 15 (eg, using a controller such as shown in FIG. Can do. The prepared carrier 60 is preferably transported to an auxiliary platform supplied and fixed by the conveyor 10. If the carriers cannot be transported immediately onto a fixed auxiliary platform, the carriers are preferably queued on the supply conveyor 10.

  As shown in FIGS. 6 and 7, in some embodiments, one or more supply operators OpF may have a backup basket 30HB so that the supply operator can prepare for backup. Acting as an operator, the object can be prepared when there is no full carrier to the supply operator. This helps to maximize personnel and resource usage, among other things.

  With regard to feeder operation, in a preferred embodiment, the feeder operator manually moves an empty fixed auxiliary platform 40 to a position 40P1 at the discharge end of the supply conveyor. As described above, the coupling mechanism preferably automatically connects the fixed auxiliary platform and the supply conveyor. Preferably, the feeder operator OpF then presses the index button 14 and waits until the full carrier has been completely transported to the fixed auxiliary platform 40. In some embodiments, in some or all examples, to provide a manual force (e.g., a small or moderate manual force) to help move the carrier, e.g., to a non-powered roller of platform 40, You may rely on the operator.

  Preferably, after the carrier 60 is securely positioned on the fixed auxiliary platform, the feeder operator OpF manually disconnects the fixed auxiliary platform from the supply conveyor. In the preferred embodiment, operator OpF manually moves the platform to carrier unloading position 40P2 in feeder 100. The feeder operator OpF preferably removes the mail piece from the carrier and places it in the feeder. When all the mail has been removed from the carrier, the supply operator OpF can, for example, place an empty carrier into the carrier return line.

  As noted above, the thin mail piece preferably does not significantly lift the thin mail piece, does not carry the thin mail piece significantly, does not stretch the body significantly, and / or does not bend the body significantly. , Removed from the carrier and placed in the feeder. Further, in the preferred embodiment, the need for the supply operator to walk and / or bend the body can be greatly reduced.

Other Embodiments In other embodiments, various aspects, features and / or embodiments of the above-described embodiments can be modified.

  In some embodiments, for example, the fixed auxiliary platform 40 may have a powered carrying surface. For example, an electric motor (not shown) can be supported by the support member 44. This motor may move sideways with the platform, for example. Further, the motor may be coupled, for example, to rotate a roller on the platform.

  In other embodiments, for example, a non-manual (e.g., automatic) moving mechanism may be provided so that a fixed auxiliary platform (e.g., between positions 40P1 and 40P2, etc.) may be moved manually or manually. In addition to moving, it may move and / or facilitate its movement.

  In other embodiments, for example, the platform 40 can be raised and / or lowered to align with an empty carrier line 20 and / or with a supply line and / or with other processing equipment. Or you may. In some embodiments, this raising and / or lowering action can be provided manually. In some embodiments, this raising and / or lowering action may be performed via a non-manual mechanism such as an elevator mechanism driven by a motor. In one exemplary embodiment, platform 40 can be movably supported on support member 44 via a drive chain driven by a motor.

  In other embodiments, for example, the platform 40 can have a frame and / or support structure that is supported from below rather than from above. Further, in other embodiments, for example, platform 40 may be supported by a frame and / or other structure suspended from the ceiling and / or from another structure.

  In other embodiments, for example, the feed conveyor system, the empty conveyor system, and / or the fixed auxiliary platform system can be configured to be movable. For example, one or more or all of these systems may be equipped with wheels or casters to allow the system to move within the facility or the like.

  In another embodiment, for example, as shown in FIG. 9, one main trunk line 10 </ b> M may supply a plurality of supply lines 10. In the exemplary embodiment shown in FIG. 9, the main trunk line 10M can supply the supply line 10 via a lateral (eg, right angle) transfer mechanism. Similarly, as shown in FIG. 9, in some embodiments, a similar empty carrier return line 20M can be positioned proximate (eg, below) the supply line. In some embodiments, the main trunk line 10M can be fed from multiple preparatory workstations PW, such as via a lateral (eg, right angle) transfer mechanism 10L (three workstations are illustrated). Although other embodiments may include any desired number of workstations). Similarly, an empty carrier return or recirculation line can be positioned proximate (eg, below) the workstation's lateral transfer mechanism as shown. FIG. 9 further illustrates an optional thin mail container supply line 10FT that may be provided in some other embodiments. For example, a thin mail container supply line can be used to supply thin mail containers from, for example, a Postal Service Tray Management System (TMS), or other source.

Other Most Preferred Embodiments FIG. 10 illustrates some aspects and features according to some most preferred embodiments of the present invention. In the embodiment shown in FIG. 10, a generally vertical elevator 200 is provided. In a preferred embodiment, the elevator 200 includes a conveyor system for moving the carrier up and down between the supply conveyor 10M and the return conveyor 20M (such as the illustrated rollers or other conveyor mechanisms described above). In some preferred embodiments, the elevator conveyor system includes two platforms, an upper platform 40E for carrying an empty carrier 60E and a lower platform 40F for carrying a full carrier 60F. In some exemplary embodiments, platforms 40E and 40F may be mounted together to maintain a constant distance relative to each other (eg, a distance substantially equal to the distance between conveyors 10M and 20M). Good. In FIG. 10, the leftmost elevator indicates that an empty carrier 60E and a full carrier 60F are conveyed together. However, in some cases, platform 40E may not have another carrier while transporting full carrier 60F to feeder 100. In that case, the empty carrier can be placed on the platform 40E when the object is transferred to the feeder. The elevator can then raise the platform such that empty carriers 60E are ejected laterally to the conveyor 20M and full carriers are moved laterally to the platform 40F. The elevator can then lower the new full carrier and continue the process. In other embodiments, platforms 40E and 40F may be controlled to move independently of each other. In other embodiments, the platforms are positioned adjacent to each other (eg, using a modified elevator 20 having multiple elevator shafts) so that upward and / or downward movement occurs independently of each other. Also good. However, by mounting both platforms to move along a path having a common axis, more space can be saved and more easily retracted around the feeder 100.

  In the exemplary embodiment shown in FIG. 10, the elevator 200 includes a support frame 41. Preferably, the elevator has transparent and / or translucent walls or windows (made for example of glass, plexiglass, plastic etc.) so that the interior is visible during operation. Preferably, conveyors 10M and 20M include lateral guide rails (as shown), support edges, etc. to help hold the carrier. Preferably, carriers 60E and / or 60F are delivered between conveyors 10M and / or 20M via a lateral transfer mechanism as described above. Further, in some preferred embodiments, sensors or detectors as described above can be used to facilitate system control based on carrier positioning. For example, the lateral transfer mechanism may be controlled based on the presence of a carrier in the elevator 200 or the like in some embodiments.

  In some exemplary embodiments, platforms 40E and 40F may include a mechanism for facilitating transport to and / or from the platform. For example, in some embodiments, the platform may include electric rollers or electric casters to facilitate movement along one or two axes (eg, parallel to the platform). This allows the carrier to be easily transferred to and / or from the platform (eg, at an upper position proximate to conveyors 10M and 20M and / or a lower position proximate to feeder operator OpF). In some preferred embodiments, the front of the elevator 200 that is in front of the operator OpF includes openings, doors, gates, etc. to allow the operator OpF to reach the carrier on the platforms 40E and / or 40F. In some preferred embodiments, fixed and / or pop-up stops may be used to limit carrier movement from the elevator until the operator OpF desires.

In some preferred embodiments, the conveyors 10M and 20M shown in FIG. 10 may extend to another elevator (not shown) similar to the elevator 200. This latter elevator can then assist in the transfer of the carrier to and / or from one or more preparatory operator positions. For example, the elevator may then include additional conveyors and structures similar to those shown on the right side of dashed line BB in FIG. 2, similar to those shown on the left side of dashed line AA in FIG. Or other suitable conveyors and / or structures as will be understood based on this disclosure. In some preferred embodiments, when the supply conveyor reaches the preparation operator OpP, rather than maintaining it in the down position as shown in FIG. 10, the conveyor (e.g., conveyor 10 and / or At a height similar to that shown in FIGS. 2 and 9 (for example, by tilting 20 upward and / or downward) to a desired level, eg, a position similar to that shown in FIGS. It is adapted so that the preparation operator OpP can place the carrier on the supply conveyor 10.

  Various aspects of the embodiment described above with reference to FIGS. 1-9 can be used in the embodiment shown in FIG.

  In some exemplary embodiments, the feeder 100 may include a conveyor belt 120 and a pusher 130 that extend along most of its upper surface. The pusher 130 (see FIG. 10) acts as a kind of “book end” for a thin object, such as a thin mail piece, placed at a narrow end in a manner aligned with the right side of the pusher 130 (see FIG. 10). , And can be controlled to follow the conveyor belt 120. Conveyor belt 120 and pusher 130 can be moved laterally to a feeder for delivery of thin mail items F to mail processing system 300. In some embodiments, the pusher 130 can grip the handle 130H by hand and lift it up back to the left side of the conveyor belt 120 to support additional thin mail items, if desired. Installed. Preferably, pusher 130 is disengaged from its associated drive mechanism when lifted, and reengaged with its associated drive mechanism when lowered toward conveyor belt 120.

  While exemplary embodiments of the present invention have been described, the present invention is not limited to the various preferred embodiments described herein, as those skilled in the art will recognize based on this disclosure (eg, various embodiments). Including any and all examples having modifications, omissions, combinations, adaptations and / or changes (in various aspects). Limitations in the claims should be construed broadly based on the language used in the claims, and are not limited to the examples described herein or in the course of filing the application, as these examples are non-exclusive Should be interpreted. For example, in this disclosure, the term “preferably” is non-exclusive and means “preferably but not limited to”. Means plus function or step plus function limitations are only used for a particular claim limitation if all of the following conditions exist in that limitation: The conditions are: a) "means for" or "steps to do" are specified, b) the corresponding function is specified, and c) the structure or step is supported. The structure, material or operation to be performed is not specified.

1 is an elevation view of components of a system according to some preferred embodiments of the present invention. FIG. FIG. 2 is an enlarged elevation view of a system similar to that shown in FIG. FIG. 3 is a schematic diagram illustrating components that can be used to control the operation of a supply conveyor in some exemplary embodiments of the present invention. FIG. 2 is an enlarged elevation view of a system similar to that shown in FIG. 1, particularly the components of feeder operation. 1 is a schematic top elevation view of multiple systems according to some exemplary embodiments of the present invention. FIG. 1 is a schematic top view of a plurality of systems in accordance with some exemplary embodiments of the present invention. FIG. 1 is a schematic top view of a plurality of systems in accordance with some exemplary embodiments of the present invention. FIG. FIG. 3 is a side elevation view of two carriers that may be used in some exemplary embodiments of the present invention. 1 is an elevational view of a system according to some preferred embodiments of the present invention having a common supply line between a preparation operator and a feeder operator. FIG. 1 is an elevational view of a system according to the most preferred embodiment of the present invention in which a carrier is moved to and / or from a feeder or other system in a generally vertical direction.

Claims (32)

A method for pre-processing mail sent to at least one mail feeder having a conveyor for delivering mail to a downstream system comprising:
a) causing at least one preparation operator to place unbundled mail pieces on the carrier;
b) delivering the carrier to the feeder via the delivery system without causing the operator to lift the carrier;
c) transshipment of mail items from the carrier to a feeder conveyor.   The method of claim 1, wherein the step of transshipping the mail piece comprises causing a feeder operator to move the mail piece laterally to a feeder conveyor.   The method of claim 1, further comprising providing the mail piece as a thin mail piece.   Delivering the carrier from a plurality of preparatory operator positions to a common supply; and delivering the carrier from the common supply to a plurality of supply operator positions proximate each mail feeder. Item 2. The method according to Item 1.   The delivering step of claim 1, wherein delivering comprises delivering the carrier through the delivery system along a path that includes lateral components such that the carrier is moved at least partially laterally. The method described.   The delivering step comprises delivering the carrier through the delivery system along a path that includes a generally vertical component such that the carrier is moved at least partially in a generally vertical direction. The method according to 1.   The method of claim 1, wherein the delivery system comprises a conveyor.   The method of claim 1, wherein the delivery system includes a movable platform.   The method of claim 1, wherein the delivery system includes a conveyor and a movable platform.   The method of claim 9, wherein the movable platform is supported on a frame.   The method of claim 9, wherein the movable platform is raised or lowered to a feeder.   The method of claim 9, wherein the movable platform is moved laterally to a feeder.   The method of claim 9, wherein the movable platform is movable between an end of the conveyor and the vicinity of the feeder.   The method of claim 1, further comprising the step of sliding the mail piece from the carrier to the feeder having a transfer slide having an angled top surface. A method for pre-processing mail sent to at least one mail feeder having a conveyor for supplying mail to the system comprising:
a) unpacking the mail piece at at least one preparatory operator position;
b) placing the unbundled mail piece on at least one mail piece carrier;
c) delivering the at least one mail carrier to the at least one mail feeder via a delivery system that allows a supply operator to exit around each of the at least one mail feeder; Including.   Delivering the carrier from a plurality of preparatory operator positions to a common supply; and delivering the carrier from the common supply to a plurality of supply operator positions proximate each mail feeder. Item 16. The method according to Item 15.   The step of delivering includes delivering the carrier through the delivery system along a path that includes lateral components such that the carrier is moved at least partially laterally relative to the feeder. The method of claim 15.   The step of delivering includes delivering the carrier along a path that includes generally vertical components such that the carrier is moved at least partially generally perpendicular to the feeder through the delivery system. The method of claim 15.   The method of claim 15, wherein the delivery system comprises a conveyor.   The method of claim 15, wherein the delivery system includes a movable platform.   The method of claim 15, wherein the delivery system includes a conveyor and a movable platform.   The method of claim 21, wherein the movable platform is movable between a position adjacent to the conveyor and a position adjacent to the feeder.   16. The method of claim 15, further comprising the step of sliding the mail piece from the carrier to the feeder via an angled sliding surface. A method for pre-processing an object and sending it to an object feeder,
a) loading an object on a plurality of carriers;
b) conveying the carrier to an object feeder on a supply conveyor;
c) transporting at least one of the carriers from the conveyor to the feeder with a reciprocating transporter;
d) after loading, transferring the object from the at least one carrier to the feeder;
e) placing the at least one carrier on a return conveyor after transshipment.   25. The method of claim 24, wherein the platform is reciprocated at least partially in a generally vertical direction.   25. The method of claim 24, wherein the platform is reciprocated at least partially generally laterally.   The method of claim 24, wherein the object comprises a mail piece. a) a feeder for supplying mail;
b) a plurality of mail carriers;
c) a transporter capable of placing at least one of said mail carrier,
d) a postal item including a platform that is movable along a path from a position proximate to the feeder to a position away from the feeder to allow the supply operator to leave in the vicinity of the feeder; Handling system.   29. A mail handling system according to claim 28, wherein the path includes a lateral component such that the support is at least partially moved laterally relative to the feeder.   29. A mail handling system according to claim 28, wherein the path includes a generally vertical component such that the support is moved at least partially in a generally vertical direction relative to the feeder. a) a feeder for feeding thin objects;
b) a plurality of carriers carrying a plurality of said thin objects;
c) a conveyor for carrying the carrier toward the feeder;
d) a transport configured to transport at least one of the carriers from the conveyor to the feeder, the transport being configured to allow a supply operator to leave the periphery of the feeder A thin object handling system that is movable. 32. The system of claim 31, wherein the thin object comprises a mail piece.

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