WO2001012348A1 - Automatic tray handling system for sorter - Google Patents
Automatic tray handling system for sorter Download PDFInfo
- Publication number
- WO2001012348A1 WO2001012348A1 PCT/EP2000/007347 EP0007347W WO0112348A1 WO 2001012348 A1 WO2001012348 A1 WO 2001012348A1 EP 0007347 W EP0007347 W EP 0007347W WO 0112348 A1 WO0112348 A1 WO 0112348A1
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- WO
- WIPO (PCT)
- Prior art keywords
- tray
- conveying surface
- trays
- handling system
- empty
- Prior art date
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B07—SEPARATING SOLIDS FROM SOLIDS; SORTING
- B07C—POSTAL SORTING; SORTING INDIVIDUAL ARTICLES, OR BULK MATERIAL FIT TO BE SORTED PIECE-MEAL, e.g. BY PICKING
- B07C3/00—Sorting according to destination
- B07C3/008—Means for collecting objects, e.g. containers for sorted mail items
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S209/00—Classifying, separating, and assorting solids
- Y10S209/90—Sorting flat-type mail
Definitions
- the present invention relates generally to tray handling equipment for removing filled or partially filled trays from a mail sorter and replenishing the mail sorter with empty trays
- the invention is particularly useful with flats mail sorters
- Flats mail sorters are known and are commercially available Flats mail sorters sort flat mail, such as magazines, large envelopes and the like, and discharge the sorted mail into trays Each of these trays may be devoted to a particular mail distribution center, carrier route, delivery point, zip code or the Itke
- a mail sortation system includes one or more rows of multiple sorter units
- Examples of flats mail sorters include models FSM100 and TOPS 2000, marketed in the United States by Rapistan Systems of Atecs Mannesmann AG As the mail is sorted, the filled or partially filled trays must be removed from the location at the particular sorter and replaced with an empty tray Occasionally, there is also a requirement that a sweep operation be performed, whereby all of the trays are removed from their respective locations, even if the trays are only partially filled Empty trays
- the present invention is intended to provide an automatic tray handling system for an article sortation system, such as a flats mail sortation system
- the tray handling system is operable to remove at least partially filled trays from multiple sorter units and provide empty trays to the sorter units for filling with articles, such as
- the article sorter includes a plurality of tray support areas for positioning a tray while the tray is being filled with sorted articles
- the conveying surface is operable to convey empty trays and/or at least partially filled trays generally adjacent to the tray support areas
- the tray moving devices are operable to move empty trays from the conveying surface to the tray support areas and to move at least partially filled trays from the tray support areas to the conveying surface
- the tray handling system is operable to convey empty trays in a generally continuous loop about the conveying surfaces until the empty trays are selected and filled at a sorter unit
- the article sorter system may include a pair of rows of sorter units
- the conveying surfaces include a first and second conveying surface along each side of the article sorter system Empty trays may be removed from the first conveying surface and, after filling at the sorter unit, may be inducted back onto the first conveying surface and conveyed to a labeling station at a discharge end of the tray handling system
- the first conveying surface is positioned above the second conveying surface
- a vertical tray moving device may be positioned at a downstream end of the first conveying surface to remove empty trays from the first conveying surface and move the trays down onto the second conveying surface so the empty trays may continue to cycle along the conveying surfaces
- a connecting conveyor may connect a downstream end of the second conveying surfaces to an upstream end of the first conveying surfaces to complete the loop
- the conveying surface compnses an empty tray conveyor and a filled tray conveyor Empty trays are removed from the empty tray conveyor and moved to the sorter unit for filling The filled trays or at least partially filled trays are then moved from the sorter unit to the filled tray conveyor for conveyance to a downstream operation, such as a labeling station at a discharge end of the tray handling system
- the filled or partially filled trays are electronically identified and tracked as they proceed along the conveying surface
- a labeling station may be positioned at a downstream end of the conveying surface and may be operable to create and affix a label to each filled tray as it ar ⁇ ves at the labeling station
- the labeling station may also include a scanner to ve ⁇ fy that the label affixed to each tray is approp ⁇ ate for the electronic identification of that particular tray
- a method for handling trays for use with an article sorter which includes a plurality of sorter units and a plurality of corresponding tray support areas for positioning a tray while the tray is being filled with sorted articles
- the method includes providing at least one conveying surface along the sorter units and conveying empty trays along the conveying surface
- the method further includes moving empty trays from the conveying surface to a tray support area and at least partially filling the empty tray at the tray support area
- the partially filled trays are then moved onto the conveying surface and may then be conveyed therealong to a downstream operation, such as a labeling station
- empty and filled trays are conveyed along a first conveying surface, while empty trays are conveyed along a second conveying surface
- the empty trays may be moved from a downstream end of the first conveying surface onto an upstream end of the second conveying surface
- the empty trays are than movable along the second tray conveying surface to return toward an upstream end of the first conveying surface
- the article sorter includes a pair of rows of sorter units along opposite sides of the article sorter
- the method provides for moving trays in a generally continuous loop around first and second conveying surfaces at both sides of the article sorter More particularly, the method may provide for moving empty trays at a downstream end of the second conveying surface at a first side of the article sorter onto an upstream end of the first conveying surface at the second side of the article sorter
- the empty trays are then conveyed along the first conveying surface along the second side and then moved from a downstream end thereof to an upstream end of the second conveying surface at the second side of the article sorter
- the empty trays are then conveyed along the second conveying surface at the second side to a downstream end thereof
- the empty trays are then moved from the downstream end of the second conveying surface at the second side to an upstream end of the first conveying surface at the first side of the article sorter
- the empty trays are then conveyed along the first conveying surface at the first side of the article sorter and moved from
- the first conveying surface is positioned generally above the second conveying surface
- the empty trays are moved from the downstream end of the first conveying surface to the upstream end of the second conveying surface via a vertical tray moving device
- the empty trays are moved from the downstream end of the second conveying surface to the upstream end of the first conveying surface via a return device, such as a connecting conveyor surface, such as an incline ramp belt conveyor
- the present invention provides an automatic tray handling system for an article sorter which is operable to remove at least partially filled trays from a sorter unit along the article sorter and replenish the sorter unit with an empty tray
- the present invention provides movement of empty trays in a generally continuous loop about the article sortation system until the empty trays are selected and filled by the sorter units Accordingly, the present invention substantially reduces the manual labor required to exchange filled trays with empty trays at an article sortation system, such as a flats mail sorter or the like
- FIG 1 is a perspective view of an input end of an automatic tray handling system according to the present invention
- FIG 2 is a perspective view of a discharge end of the automatic tray handling system of FIG 1
- FIG 3 is a top plan view of the automatic tray handling system of FIGS 1 and 2, with the upper conveying surfaces partially cut away to reveal additional details
- FIG 4 is an end elevation of the tray handling system of the present invention, taken at the input end of the tray handling system,
- FIG 5 is a partial sectional view of the tray handling system, taken along the
- FIG 6 is a partial sectional view of a vertical tray-moving device useful with the present invention, taken along the line VI-VI in FIG 3,
- FIG 7 is a side elevation of the vertical tray-moving device of FIG 6,
- FIG 8 is a top plan view of the vertical tray-moving device of FIGS 6 and 7
- FIG 9A is a perspective view of a section of the upper conveyor and a tray moving and support apparatus useful with the present invention, with a portion of the conveyor cut away,
- FIG 9B is an exploded perspective view of the tray moving apparatus of FIG 9A.
- FIG 10 is a side elevation of a portion of the tray handling system of the present invention
- FIG 1 1 is a perspective view of another embodiment of a tray handling system according to the present invention
- FIG 12 is an end elevation of the tray handling system of FIG 1 1 , with the tray handling system extending along both sides of a pair of rows of mail sorters
- FIG 13 is a side elevation of a portion of the tray handling system of FIGS 1 1 and 12
- FIG 14 is a top plan view of a portion of the tray handling system shown in FIG 13, and
- FIG 15 is a perspective view of a linear actuator useful with the present invention, as positioned at a lower portion of a vertical tray moving device
- an automatic tray handling system 10 is operable to provide empty trays 12a to a plurality of mail sorter units 14 of a sortation system 13, and to remove at least partially filled trays 12b from the sorter units 14 after the trays are filled (FIGS. 1 and 2).
- the invention is usable with a wide vanety of mail or article sortation systems, it is illustrated with a model ASM100 flats mail sorter marketed in the United States by Rapistan Systems of Atecs Mannesmann AG.
- Automatic tray handling system 10 includes a plurality of conveying surfaces 16, which are operable to move the trays 12 along one or both sides of the sorter units 14.
- a plurality of tray moving devices 20 are operable at respective sorter units 14 to pull empty trays 12a onto a tray support 72, which supports the empty tray while the sorter system discharges sorted mail into the tray. After the tray is at least partially filled by the sorter unit, the tray moving device 20 is then operable to move the at least partially filled tray back onto the conveying surface. Accordingly, the present invention provides a continuous supply of empty trays to the tray sorting units 14, and automatically discharges filled or at least partially filled trays from the sorter units onto the conveying surface 16, thereby substantially reducing the amount of manual labor processes required to replace filled trays with empty trays at each sorter unit.
- Sorter units 14 of sortation system 13 are generally known and are commercially available, such that a detailed desc ⁇ ption of these devices is not included herein. Suffice it to say that each sorter unit 14 includes a bucket 14a, a sorting device 14b and a chute 14c Unsorted mail or other articles are provided at the buckets 14a via a supply system (not shown), where the articles are then sorted by the sorting devices 14b and fall from the chute 14c into the bins or trays 12. As shown in FIG.
- an input end 11a of tray handling system 10 preferably provides one or more induct stations 38 and 40 for loading or inducting empty trays onto the tray handling system, while a discharge end 11b (FIG 2) of tray handling system 10 provides a downstream operation, such as a labeling station 22 which is operable to label the trays as they are discharged from tray handling system 10
- the sorter units 14 may be arranged in a pair of rows, and the conveying surfaces 16 of automatic tray handling system 10 may extend around both sides of the rows of sorter units 14
- the p ⁇ n ⁇ ples of the present invention are equally applicable to a single side of a mail sortation system which has one or more rows of sorter units Empty trays 12a are preferably movable in a continuous loop via conveying surfaces 16 and a pair of vertical tray moving or tray return devices 18 at one end of the tray handling system 10 (FIG 2) At least partially filled trays are conveyed from their respective sorter unit to labeling station 22 at discharge end 11 b of tray handling system 10
- conveying surface 16 includes a plurality of conveying surfaces More particularly, conveying surface 16 preferably includes a pair of opposite upper conveyors 24 and 26, a pair of opposite lower conveyors 28 and 30 and a pair of tray moving or return devices, such as incline or connecting surfaces or ramps 32 and 34, which are operable to move empty trays from lower conveyor 28 to upper conveyor 26 and from lower conveyor 30 to upper conveyor 24, respectively, at input end 11a
- a pop up belt transfer or 90 degree transfer 36 is positioned at each end of the incline ramps 32 and 34 to change the direction of travel of the trays 12 as they move from one of the lower conveyors to the respective incline ramp, and from the incline ramp to the respective upper conveyor
- transfer units are commercially available and known in the art, such that a detailed discussion will not be included herein B ⁇ efly, transfer units 36 are operable to convey a tray in a direction along the conveyor at which they are positioned, and may be operable to raise one or more belt conveyor st ⁇ ps
- incline ramps 32 and 34 also preferably include belt conveyors which are operable to move a continuous belt along the conveying path, as is know in the art
- Incline ramp 32 is connected between a pair of 90 degree transfer units 36a and 36b at a downstream end 28b of lower conveyor 28 and an upstream end 26a of upper conveyor 26, respectively
- incline ramp 34 is connected between a pair of 90 degree transfer units 36c and 36d at a downstream end 30b of lower conveyor 30 and an upstream end 24a of upper conveyor 24, respectively
- Upper conveyors 24 and 26 are preferably powered roller conveyors, which include a plurality of rollers 42 which are rotatably mounted along and between a pair of side walls of 44a and 44b of each conveying surface 24 and 26
- the plurality of rollers 42 further includes multiple powered rollers 43 (FIG 10), which are also connected to the sidewalls 44a and 44b and d ⁇ ven via an internal motor to cause rotation of the powered roller relative to the wall, as is known in the art of roller conveyors
- the powered rollers 43 are connected to a plurality of non-d ⁇ ven rollers 42, such as to a pair of non d ⁇ ven rollers at either side of the powered roller 43, via one or more bands or belts 45 (FIGS 8 and 10) to define individually d ⁇ ven zones, as is known in the art
- the powered rollers 43 are mounted to the side walls 44a and 44b by an axle mounting yoke 46 (FIG 10) of the typed disclosed in commonly assigned, co-pending U S Pat Application, Ser No 09/418,2
- trays 12 are conveyed along upper conveying surfaces 24 and 26 toward a downstream end 24b and 26b, respectively
- Vertical tray moving devices 18 are positioned near or at the downstream ends 24b and 26b to remove empty trays 12a from the upper conveyors and move the empty trays onto an upstream end 28a and 30a of the lower conveyors 28 and 30, respectively, as discussed in detail below
- Labeling stations 22 are positioned at or near a discharge end 24c and 26c of upper conveyors 24 and 26, respectively, and are operable to label the filled trays as they are conveyed toward discharge end 11 b of automatic tray handling system 10
- one or both of the upper conveyors surfaces included a curved section 27, such that the discharge ends 24c and 26c of upper conveyors 24 and 26, respectively, are in close proximity, in order to reduce the manual labor of the system
- a scanner 46 is positioned at discharge ends 24c and 26c to ve ⁇ fy the information contained on the label applied to the trays
- a pair of reject conveyors 48 and 50 are
- lower conveyors 28 and 30 are preferably powered roller conveyors which include a plurality of d ⁇ ven rollers 43 and non-d ⁇ ven rollers 42 rotatably mounted to a pair of parallel walls or frames 44
- Lower conveyors 28 and 30 are preferably operable in a reverse direction from upper conveyors 24 and 26, to return the empty trays 12a back toward input end 11 a
- the 90 degree transfer units 36a and 36c are positioned at downstream ends 28a and 30a of conveyors 28 and 30, respectively, to move the empty trays onto the respective incline ramps 32 and 34 to transport the trays to the upper conveyors 24 and 26, respectively, at the other side of the sortation system 13
- vertical tray moving devices 18 are positioned at downstream ends 24b, 26b of upper conveyors 24, 26 and upstream ends 28a, 30a of lower conveyors 28, 30 As best shown in FIGS 3 and 5 - 8, each vertical tray moving device 18 is operable to move an empty tray from the respective upper conveyor 24,
- Lowe ⁇ ng device 62 of vertical tray moving device 18 preferably includes a pair of belts, chains or the like 63, each of which is reeved about a d ⁇ ven and non- d ⁇ ven wheel or roller 62a and 62b, respectively
- Each belt 63 includes at least one, and preferably three, support members 63a, which receive the empty tray 12a thereon and support tray 12a while lowe ⁇ ng the tray to the lower level
- the d ⁇ ven wheels or rollers 62a are operable to rotate in an opposite direction relative to the other, with respect to the view of FIG 7, such that support members 63a of each side of lowe ⁇ ng device 62 are correspondingly moved in a downward direction to support and lower the empty tray 12a
- lowe ⁇ ng device 62 includes the pair of belts and corresponding wheels/pulleys positioned at frame 66, such that there is a gap 67 between the support members 63a of each lowe ⁇ ng belt 63
- Lower moving device 64 is positioned in gap 67 between lowe ⁇ ng support members 63a and includes a continuous belt 65 which is movable about a d ⁇ ven and non-d ⁇ ven roller 64a and 64b respectively, such that at least one engaging member 65a contacts a side of empty tray 12a and pushes or otherwise moves tray 12a off of support members 63a of lowe ⁇ ng device 62 and onto the respective lower conveying surface 28, 30
- lower conveyor 28 includes one or more, and preferably a pair of, shorter rollers 42' which are mounted to inner wall 44a of lower conveyor 28, along with rollers 42 and 43 Shorter rollers 42' are mounted at an outer end to an outer bracket 44c which is laterally inset from outer wall 44b, in order to provide clearance for lower tray moving device 64, such that the empty tray may be moved out and fully onto the rollers 42 and 42' of lower conveyor 28 by lower tray moving device 64
- each tray moving device 60, 62 and 64 of vertical moving devices 18 is operable to move the corresponding belt and engaging members in one direction
- Each moving device preferably includes two or more engaging or support members along the respective belts, such that as one of the engaging or support members moves a tray via movement of the belts, another engaging or support member is correspondingly moved into position to engage or support the next empty tray
- Upper tray moving device 60 is operable to move belt 61 in response to an empty tray being detected at vertical tray moving device 18
- automatic tray handling system 10 is operable to identify and track filled or partially filled trays as they move along upper conveying surfaces 24 and 26, as discussed below The system is further operable to allow the tracked trays to pass by vertical tray moving devices 18 for labeling and discharge at discharge end 11 b, while stopping empty or non-tracked trays at the vertical tray moving devices 18
- vertical tray moving device 18 may include an optical sensor or scanner 70 to detect the tray and/or determine the status of the tray being conveyed along of the conveyors 28 and 30, or may otherwise determine when a tray approaching the vertical tray moving device is an empty or filled tray, without affecting the scope of the present invention
- vertical tray moving device 18 is first operable to raise or otherwise engage stop member 68 with the empty tray to prevent further movement along the upper conveyor, while engaging member 61a engages and pushes the tray off of the upper conveyor and onto the supports 63a of lowe ⁇ ng device 62 Lowe ⁇ ng device 62 is then operable to lower the tray in response to the tray being positioned on the support member 63
- vertical tray moving device may include one or more linear actuators 69 (FIG 15), which are operable to engage and move the empty tray from upper conveyer 24, 26 and/or onto lower conveyor 28, 30, without affecting the scope of the present invention
- Linear actuator 69 is preferably of the type disclosed in commonly assigned U S Provisional Pat Application, Ser No 60/166,079, filed Nov 17, 1999 for LINEAR ACTUATOR, by Schiesser et al , the disclosure of which is hereby incorporated herein by reference
- Linear actuator 69 includes
- linear motor 69c is positioned at carnage 69a, while a conductor plate or st ⁇ p 69d, which forms the secondary side of linear motor 69c, is secured along a surface 69e of guide member 69b
- linear motor 69c is a conventional linear motor such as a linear motor which is commercially available and manufactured by Mannesmann, Baldor/Normag and others
- Automatic tray handling system 10 is thus operable to move or convey empty trays throughout a continuous loop from one of the induct stations 38, 40.
- the empty trays are conveyed along the conveying surfaces 16 and moved by the vertical tray moving devices 18 until the empty tray is selected to be filled by one of the sorter units 14
- an empty tray may be placed on induct station 38 and moved across lower conveyor 28 via 90 degree transfer unit 36a, up incline ramp 32 and onto upper conveyor 26, via 90 degree transfer unit 36b.
- the empty trays conveyed along upper conveyor 26, if not selected and captured by one of the moving devices 20, as discussed below, are then vertically moved or returned down to lower conveyor 30 by one of the two vertical tray moving devices 18.
- automatic tray handling system 10 further includes a pair of buffer conveyors 52 and 54 positioned along each inward side of lower conveyors 28 and 30, respectively, and generally beneath the sorter units 14, as best seen in FIGS. 3 and 5.
- Buffer conveyors 52 and 54 provide temporary storage for additional empty trays 12a, which may be discharged from buffer trays 52, 54 onto upstream ends 28a, 30a of lower conveyors 28, 30, respectively, via a pair of 90 degrees transfer units 36g and 36h.
- empty trays 12a may be inducted onto buffer conveyors 52 and 54 as the automatic tray handling system 10 attains full capacity of trays moving therealong.
- the empty trays may be discharged from buffer conveyors 52 and 54 onto lower conveyors 28 and 30 in response to a reduced number of trays being conveyed along conveying surfaces 16, since additional trays may then be needed along tray handling system 10.
- Buffer conveyors 52, 54 preferably include index chain drive conveyors, which may move an incremental amount in one direction to load one or more trays onto buffer conveyors 52, 54, and then may move an incremental amount in the opposite direction to discharge one or more trays onto lower conveyors 28 and 30 as needed.
- Buffer conveyors 52, 54 are thus preferably operable in a last in, first out (LIFO) mode of operation, whereby the last tray to be inducted onto the buffer conveyors 52, 54 is the first tray to be discharged therefrom as additional trays are needed along conveyors 16 of automatic tray handling system 10.
- the buffer conveyors 52, 54 thus provide additional capacity of trays for the system, such that empty trays 12a need not be inducted at induct stations 38 and 40 as rapidly in order to facilitate full capacity operation of automatic tray handling system 10.
- the buffer conveyor may receive empty trays at one end, such as at upstream end 28a, 30a of lower conveyors 28, 30, and discharge the trays at an opposite end, such as at downstream end 28b, 30b of lower conveyor 28, 30.
- tray moving devices 20 are positioned at each sorter unit 14 and are operable to stop an empty tray as it moves along the upper conveyor 24 or 26 and pull the tray onto a tray support 72 for filling at the respective sorter 14. Each tray moving device 20 is further operable to move or push the filled or partially filled tray from the tray support 72 back onto the rollers 42 of the upper conveyor. Inner wall or bracket 44a for rollers 42 is secured along a frame or platform 74, which provides an outer rail for attachment of outer wall 44b for mounting the opposite end of rollers 42 thereto.
- Tray moving device 20 includes a tray push/pull member 76, a stop member 78 and tray support 72.
- tray stop member 78 includes a curved arm or bracket, which is pivotably mounted to a support bracket 80, such that an upper end 78a of tray stop 78 is raisable between a pair of adjacent rollers 42, 43 to engage and stop an empty tray from moving along the respective upper conveyor, while the tray push/pull member 76 engages and moves the tray off of the upper conveyor and onto the tray support 72
- Stop member 78 may be pivotable via any known means, such as by a rotary motor, a sp ⁇ ng biased system, or any other means to raise stop member 78, without affecting the scope of the present invention
- tray push/pull member 76 includes a pair of generally "U" shaped side frames 76a, 76b, which are interconnected at an upper end of each frame by a tray engaging or pulling member 76c at one end and a second tray engaging or pushing member 76d at the other end
- one side frame 76b of tray moving member 76 is slidably
- Tray moving member 76 is preferably movable relative to frame 74 via a stepper motor 86 or the like
- Stepper motor 86 includes a d ⁇ ve sprocket 86a
- frame 74 includes a cog sheave or spool 88, such that a timing belt 90 is routed and movable about d ⁇ ve sprocket 86a and spool 88 in response to actuation of stepper motor 86
- timing belt 90 includes an attachment plate 90a, which is secured to side frame 76b of tray moving member 76, such that movement of timing belt 90 results in a corresponding movement of tray moving member 76
- other means for moving a tray stop and/or engaging member may be implemented without affecting the scope of the present invention
- tray support 72 provides a support platform 72a for supporting a tray while the tray is being filled by a respective sorter unit 14 Because the filled trays are always supported by support 72 or conveyors 24 and 26, the trays for use with the present invention need not require ⁇ gid side walls to withstand clamping or grabbing of the trays when they are filled
- Tray support 72 is preferably formed such that a lower surface 72b is mountable to the platform of the upper conveyor while the sidewalls 72c and 72d are formed to provide dearance to stepper motor 86 and timing belt 90 and/or sideframes 76b and 76a of the tray moving member 76
- tray support 72 further includes a transition roller 92, which is rotatably mounted at tray support 72 and positioned between support platform 72a and rollers 42 43 of the upper conveying surface Transition roller 92 is o ⁇ ented generally normal to rollers 42, 43 and is preferably positioned such that an upper surface of transition roller 92 is at a same level as an upper surface of the rollers
- the present invention further includes a control system (not shown in detail), which is operable to actuate the d ⁇ ven rollers 43 of the conveying surfaces 16 and to actuate the tray moving devices 20 and the vertical tray moving devices 18 at approp ⁇ ate times
- the control system is interconnected with a control system of the sortation system
- the control system is operable to electronically identify a tray as it is being filled by a sorter unit and track the identified tray along upper conveying surfaces 24 and 26
- Tray handling system 10 is thus operable to allow the identified filled trays to move along the upper conveying surfaces past the vertical tray moving devices 18, while empty trays, which are not electronically identified and tracked by the control system, are stopped and lowered by the vertical tray moving devices 18
- the identification and tracking of the filled trays prevents the downstream tray moving devices 20 from stopping and filling an already filled tray, since such trays are identified and allowed to move along the conveying surface all the way to labeler 22 at discharge end 11 b of tray handling system 10
- empty trays are inducted onto the automatic tray handling system by manually placing the trays at one or both of the induction stations 38 and 40 at the upstream or induct end of the upper conveyors 24, 26.
- empty trays may be inducted onto the upstream ends 28a and 30a of the lower conveying surfaces 28 and 30 via an induction station 19 at each vertical tray moving device 18.
- empty trays may be manually placed along the conveying surfaces 16, such as along the lower conveying surfaces 28 and 30.
- empty trays are lowered by the vertical tray moving devices 18 onto the lower conveying surface, or input directly at indudion stations 19 of moving devices 18, and transferred across the lower conveying surfaces and into the buffer conveyors 52 and 54 via transfer units 36g and 36h at upstream ends 28a and 30a of lower conveyors 28 and 30, respectively.
- the trays will be moved onto the buffer conveyors one tray position at a time until the buffer conveyors are approximately filled with trays.
- empty trays are continued to be loaded at the induction stations 38 and 40 and conveyed about the conveying surfaces 16 of the tray handling system 10.
- empty trays will be loaded into the tray handling system until the lower conveying surfaces 28 and 30 are both approximately 90 percent full.
- empty trays may be manually loaded directly onto the lower conveying surfaces 28 and 30 along their entire length or within 90 percent of their capacity.
- the normal operation of automatic tray handling system 10 may begin.
- empty trays may be loaded onto the induct stations 38 and 40 or directly onto the lower conveying surfaces 28 or 30.
- the present invention is operable to release empty trays from the lower conveying surfaces 28 and 30 such that there is approximately a 10-foot gap between each adjacent pair of empty trays along upper conveying surfaces 24 and 26.
- This provides a sufficient time delay between trays to allow time for the tray to be stopped and moved off of the conveying surface by the tray moving devices 20 or vertical tray moving devices 18, and to allow sufficient space between consecutive empty trays for filled trays to be inducted onto the conveying surface from one of the sorter units. Based on a total machine normal output of five trays per minute, this gap ensures that nearly twice the required number of trays are made available during each minute of operation.
- the empty trays then are moved up the incline belts and onto the upper conveyor surfaces for selection and capture by the tray moving devices 20 at each sorter unit.
- the empty trays will automatically and continuously be conveyed toward the discharge end of the upper conveying surfaces until they are required to replace a discharged full tray at a sorter unit 14. If the empty tray is not required or selected to replace a full tray, the empty tray will continue the loop via the vertical tray moving devices 18, whereby they will accumulate on the lower conveying surface and cycle through the system again.
- tray moving device 20 When a full tray is ready to be discharged from the sorter unit 14, the control will wait until an empty tray passes the corresponding sorter unit and then will activate tray moving device 20 to push the full tray out onto the respective upper conveying surface 24 or 26.
- the tray moving device 20 is operable to lower the stop arm 78 out of the way at the end of its push cycle to allow the full tray to convey toward the discharge end of the upper conveying surface 24 or 26.
- the stop member 78 is again operable to raise and capture the next oncoming and/or available empty tray, such that the tray moving device may pull the empty tray onto the tray support 72 for filling by the corresponding sorter unit.
- the filled trays are then conveyed along the upper conveying surfaces 24, 26 and are labeled and discharged at discharge end 11b of tray handling system 10
- the control selects and reserves the next available empty tray inducted onto the conveying surfaces 16 for that particular sorter unit.
- the sorter unit may not capture the next empty tray that passes thereby, since this tray may already be selected and reserved for another sorter unit which discharged its filled tray p ⁇ or to the other sorter unit.
- control is preferably operable in a "first come, first served" mode of operation, which precludes a sorter unit at a downstream end of one of the upper conveying surfaces 24 and 26 from waiting a prolonged penod of time until an empty tray is not captured at any of the upstream sorter units Any empty trays not captured and filled by any of the sorter units du ⁇ ng the pass in front of the sorter units will be transferred onto the lower conveyor units 28 and 30 via the vertical tray moving devices 18 located at the downstream end of the upper conveyors 24 and 26
- the empty trays are repeatedly conveyed about the continuous loop of conveying surfaces 16 until the empty tray is captured and filled at one of the sorter units 14 of sortation system 13
- the present invention is also operable in a sweep process, whereby the tray handling system is purged of filled and/or partially filled trays and each sorter unit is provided with a new empty tray Du ⁇ ng the sweep process, the mail delivery or supply system will deliver all of the inducted mail to the sorters or into a reject bin As the mail is delivered du
- tray handling system 10 may be replaced by an empty tray raising device, without affeding the scope of the present invention
- the empty tray raising devices are then operable to remove empty trays from the downstream end of lower conveying surfaces, raise the trays upward, and induct or return the empty trays onto the upstream end of the upper conveying surfaces, in a similar manner that the trays are lowered by the vertical tray moving devices 18
- the empty trays would then be movable about a separate continuous loop along each side of sortation machine or system
- an automatic tray handling system 100 is operable to move empty trays 112a from an empty tray conveyor 128 to an approp ⁇ ate mail sorter 114 for filling, and then to move the at least partially filled trays 112b from the mail sorter onto a full tray takeaway conveyor 124
- empty tray conveyor 128 is positioned along and below full tray conveyor 124, such that the empty trays are moved upwardly from a lower level to an upper level at the sorter units 114 by a tray moving device 120 positioned at each sorter unit 114
- the empty tray conveyor may be positioned above the full tray take away conveyor, without affecting the scope of the present invention
- automatic tray handling system 100 is applicable to a sortation system 113, which indudes one or more rows of sorter units 114, similar to sortation system 13, discussed above and as known in the art An upper, full tray conveyor 124 and a lower, empty tray conveyor 128 are then positioned along each row of sorter units at each side of sortation system
- Both of the empty tray conveyor 128 and full tray conveyor 124 preferably compnse powered roller conveyors, similar to upper and lower conveying surfaces 24, 26, 28 and 30, discussed above
- several of the rollers 142 of the upper, full tray conveyor 124 are angled or skewed along the conveyor path to assist the tray handling system in moving the full tray out from the sorter unit and onto the upper conveyor 124
- Automatic tray handling system 100 preferably includes at least one induction station (not shown) positioned at an induct end or upstream end of empty tray conveyor 128, while a labeling and discharge area (also not shown) are positioned at a downstream or discharge end of each upper full tray conveyor 124
- the induct stations, labelers and discharge stations are substantially similar to indud stations 38, 40, labelers 22, and discharge end 1 1 b of automatic tray handling system 10, discussed above, such that a detailed desc ⁇ ption will not be repeated herein
- the operators may orient the trays such that a label holder is properly positioned to receive the label onto the tray at the labeling station at the discharge end of the tray handling system.
- Tray moving devices 120 are positioned at each sorter unit 114 along the conveying surfaces 124 and 128. Each tray moving device 120 is operable to stop an empty tray moving along empty tray conveyor 128, pull the empty tray onto a tray support or tray lifter 163a and raise the empty tray upward to position the empty tray under the corresponding sorter unit for filling of the empty tray. After the tray is filled, the tray moving device is again operable to push or otherwise move the filled tray onto the upper full tray take away conveyor 124, whereby the full tray is conveyed along the conveyor to the labeler at the discharge end of the conveyor. As best shown in FIGS. 12 and 13, each tray-moving device 120 includes a lower tray- pulling device 160, a vertical tray moving device 162 and an upper tray-pushing device 164.
- Each tray moving device 120 further includes a stop member 178, which is operable to raise between a pair of adjacent rollers along empty tray conveyor 128 to stop an empty tray, while lower tray pulling device 160 engages and pulls the empty tray onto the tray support 163a.
- Tray stop 178 may include a pivotable arm similar to stop member 78 discussed above, or may be any other means for stopping a tray along the conveyor, without affecting the scope of the present invention. It is further envisioned that the trays may be otherwise stopped at each targeted location along empty tray conveyor 128 via actuation and deactuation of individual powered roller zones which convey the tray along conveyor 128 and thus may be individually operable to stop the tray at a selected zone, without affecting the scope of the present invention.
- lower tray pulling device 160 includes an engaging arm 161 , which is extendable to engage an opposite side of the empty tray from the tray moving device 120 and is retractable or otherwise movable toward the tray moving device 120, thereby engaging the opposite side of the empty tray and pulling the empty tray toward the moving device 120.
- Lower tray pulling device 160 may be movable via any know means, such as via a driven belt, similar to tray moving device 60 discussed above, or via a linear actuator 169 (FIG. 13), similar to linear aduator 69 discussed above and shown in FIG. 15.
- Lower tray moving or pulling device 160 may be mounted at the tray moving device 120, or may otherwise be movably mounted along and between a pair of adjacent rollers at the empty tray conveyor 128 As best shown in FIG 14, each tray moving device 120 further indudes a guide member 194, which fundions to guide the empty tray into position on the supports 163a, such that the empty tray is properly o ⁇ ented for receiving the sorted mail from the sorter unit 114
- vertical tray raising device 162 is operable to raise the supports 163a and thus the empty tray upward into position immediately beneath the chute 1 14c of the associated sorter unit 114
- vertical tray raising device 162 includes a vertical ball/screw actuator 163, which is operable to rotate a threaded shaft 162b to raise tray support 163a via engagement with a threaded connector 163c at tray supports 163a
- Tray supports 163a are preferably a pair of L-shaped metal support arms which support the trays at a lower arm 163d of support arm 163a, while an upper arm 163e is mounted to the vertical tray moving device 162
- Vertical tray moving device 162 is thus operable to raise the tray upwardly and to support the empty tray as the empty tray is filled by the corresponding sorter unit 114 Accordingly, the tray supports 163a must have sufficient strength to support the weight of a filled tray
- upper tray moving or pushing device 164 is operable to push or otherwise move the filled tray from the support 163a onto the upper, full tray take away conveyor 124
- Upper tray moving device 164 preferably indudes an integral motor operated pusher 165 and is mounted at support 163a, as shown in FIG 13
- the pusher or tray engaging member 165 may be movable along a chain, belt or linkage 165a via a pair of d ⁇ ven and guide wheels 165b, similar to tray moving device 64, discussed above
- the engaging member 165 engages a lower portion of the trays, as shown in FIG 12, to prevent tipping of the filled tray as it is moved onto upper conveyor 124
- tray moving device 164 is operable to reverse the direction of movement of the engaging member 165 to return the engaging member to an initial position at an inward side of the tray support 163a Because upper tray moving device 164 is operable to move a filled tray onto the upper conveying surface
- Automatic tray handling system 100 includes an integrated software and control system which is designed to track filled trays from each of the sorter units to the labeling system at a discharge end of the tray handling system, in order to ensure that the corred label is applied to the approp ⁇ ate tray
- a scanner (not shown) is provided to scan the applied label and confirm that the correct label was applied to the approp ⁇ ate tray If the label is not correct, the tray is diverted to a reject area, where a signal may be provided to notify an operator that the tray was mislabeled.
- automatic tray handling system 100 is operable to move empty trays along the empty tray conveyor 128 positioned at one or both sides of the sortation system 113.
- empty mail trays are inducted onto the empty tray conveyors and staged at every third bin or sorter unit such that they are positioned to provide optimum clearance and gapping for proper tray transferring, and to avoid potential interference between trays.
- the tray stop members which are operable to retain an empty tray at a upstream position along the empty tray conveyor 128, will release the empty tray and allow the tray to advance to the desired position.
- tray stop member 178 of tray moving device 120 will stop the empty tray at the appropriate sorter unit and lower tray moving device 160 will move the empty tray onto the tray supports 163a for raising the tray to the sorter unit. After the empty tray is raised into position under chute 114c, the empty tray is then filled by the sorter unit until the control system indicates that the tray has been filled. Once the tray is filled, the upper tray moving device 164 is operable to move the filled tray onto the full tray take away conveyor, provided there is no full tray present in the transfer path. After the upper tray moving device 164 returns to its initial position, the vertical tray moving device 162 will lower the supports 163a and prepare to accept another empty tray from the empty tray conveyor 128 and lower tray moving device 160.
- the control system of the automatic tray handling system are operable to prevent any interference between oncoming trays on the upper conveyor 124 and full trays ready to be discharged from the tray supports and sorter units.
- the flat sorter unit When a tray becomes filled by the particular sorter at which it is positioned, the flat sorter unit will communicate to the automatic tray handling system controller that the tray must be removed.
- the upstream trays When a tray is destined to exit the sorter unit, and an open position is available on the filled tray conveyor 124, the upstream trays will be held in position along the conveyor 124 until the tray leaving the particular sorter unit is moved onto the conveyor 124 Once the tray is in position on the conveyor, all of the trays may continue to move toward the label p ⁇ nter If a tray is ready to leave the sorter and an open position is not available on the take away conveyor 124, such as because another tray is moving into position, the full tray will be held at the sorter unit until the position is cleared
- the control system identifies and acknowledges discharged full trays along the full tray conveyor 124, and is operable to track the full trays along the length of the full tray conveyor 124 to the automatic labeling system located at the discharge end of the conveyor
- each sorter unit is positioned at an individual zone or section of the powered roller conveyor 124 which consists of its own powered zone and sensor assembly, thereby facilitating individual zone-to-zone tracking of trays by the control
- the tray tracking system of the present invention is operable to ensure that the filled tray has the proper label attached to rt at the label p ⁇ nters Accordingly, the trays must be tracked from their sort location to the labeler
- Each filled tray is electronically identified with approp ⁇ ate destination data by the sorter machine software before the tray leaves the respective sorter unit After the sort schedule is determined, the software will communicate to the automatic tray handling system controller which output bin destinations are dedicated to each sort location on the sortation system The data can then be tracked with the tray when it is discharged from the sorter unit
- each tracking zone is associated with a particular sorter unit and is independently controlled
- Each zone also may utilize a photo eye or sensor to identify the tray position along the conveyor Whenever a full tray is discharged from a sorter unit onto the full conveyor 124, the output bin destination data is electronically moved with the tray, as the tray is conveyed toward the automatic label p ⁇ nter The tray will be conveyed into the next zone or zones if those zones are not occupied by another tray The tray continues to be conveyed along the full tray conveyor 124 as long as the next downstream zone is clear or vacant
- the control of the automatic tray handling system 100 is operable to communicate to the label printer which label data must be printed for that particular tray. The correct label will then be printed and affixed to the tray.
- a scanner (not shown) may be provided to scan a bar code on the printed label once it has been printed and applied, in order to verify that the label is corred for that particular tray.
- the system is operable to detect a jam in the conveyor. When a jam has been detected, the system is operable to hold all of the upstream trays until the jam has been cleared and the system reset. Preferably, the system is also operable to detect a missing tray if a tray is removed, to deted a tray that does not belong in that particular zone, or to detect an extra tray that has been placed on the filled tray conveyor 124. The extra tray will be sent to the reject area until the tray's data can be accounted for. Automatic tray handling system 100 is also operable to perform a sweep process to clear the full trays from the system.
- the empty trays staged at every third position along the empty tray conveyor 128 are advanced to close gaps, while any required additional trays may be fed into the conveyor at the induct stations.
- any remaining mail in the mail supply and/or sortation system must be sorted to the appropriate bins before any full trays can be swept. Once the message is received that the sort is complete and all remaining mail has been discharged from the sorting system buckets, the full tray sweep process can begin.
- the upper tray moving devices 164 are operable to substantially simultaneously push or extend the full trays 112b onto full tray conveyor 124.
- the vertical tray moving devices 162 are operable to lower the supports 163a to position the supports at a lower level to accept empty trays from the empty tray conveyor 128.
- the first half of the filled trays are then advanced toward the automatic labeler, while empty trays along the empty tray conveyor 128 are simultaneously transferred onto the respective supports 163a.
- the second group of filled trays from the other sorter units are discharged onto the full tray conveyor 124. Similar to the first set, as soon as the tray moving devices 164 return, the empty tray replenishment process is repeated for the second group of sorter units While the second group of trays are being pushed out, the empty trays are staged simultaneously, such that the empty trays are positioned to be pulled onto the supports 163a for the second group of sorter units
- the present invention provides an automatic tray handling system that is especially useful with automated article sorting machines, such as flats mail sorting machines
- the invention could be used with other sorters such as letter mail sorters and the like, without affecting the scope of the present invention
- the present invention is thus operable to deliver empty trays to any and all of the sorter units of the sortation system and further is operable to automatically convey full trays to the labeling stations
- the tray handling system of the present invention is operable to deliver empty trays to individual sorter units and remove filled trays from the sorter units, whereby the filled trays are conveyed to downstream operations, such as a labeling station, at a discharge end of the tray handling system
- the only manual intervention that may be required is to manually induct multiple empty trays into the system, whereby the tray handling system conveys and stages the trays for filling at the approp ⁇ ate sorter units
- the present invention is designed to be adapted for implementation with conventional or known sorting machines, such that the present invention may be retrofitted to existing units with minimal changes
- the automatic tray handling system of the present invention provides a safe working environment for operators and maintenance personnel, while at the same time maintaining ready access to the sorter units of the sorting machine
- the automatic tray handling system is also configured to minimize space taken up around the sorter machines
- the control system of the present invention further facilitates electronic tracking of trays along the conveyors between the sorter units and the labeling stations After a label is applied to the tray, the label may be scanned to ve ⁇ fy that the label was p ⁇ nted properly for that particular tray
- the present invention is preferably tied into the controls of the sortation system, such that the sortation system can communicate to the tray handling system when a particular tray has been filled and when an empty tray is needed at each of the sorter units of the sortation system
- An automatic tray handling system for use with an article sorter having a plurality of sorter units and a plurality of tray support areas for positioning a tray while the tray is being filled with sorted articles, said automatic tray handling system compnsing at least one conveying surface which is operable to convey at least one of empty trays and at least partially filled trays generally adjacent to the tray support areas, and a plurality of tray moving devices which are operable to move empty trays from said at least one conveying surface to the tray support areas and to move at least partially filled trays from the tray support areas to said at least one conveying surface
- the automatic tray handling system of claim 4 wherein said first conveying surface is operable to convey both empty trays and at least partially filled trays therealong 7
- the automatic tray handling system of claim 4 further including at least one tray return device which is operable to move empty trays between said first and second conveying surfaces
- each of said plurality of tray moving devices is operable to stop an empty tray which is moving along said at least one conveying surface and pull the empty tray in a direction generally transverse to said at least one conveying surface and toward a corresponding tray support area
- each of said plurality of tray moving devices is movable to move empty trays to the support areas in an order in which the support areas become available
Abstract
Description
Claims
Priority Applications (9)
Application Number | Priority Date | Filing Date | Title |
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DK00949422T DK1242197T3 (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for sorting device |
DE60006420T DE60006420T2 (en) | 1999-08-13 | 2000-07-31 | AUTOMATIC CONTAINER TREATMENT SYSTEM FOR A SORTER |
AT00949422T ATE253414T1 (en) | 1999-08-13 | 2000-07-31 | AUTOMATIC CONTAINER HANDLING SYSTEM FOR A SORTER |
AU62784/00A AU771900B2 (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for sorter |
MXPA02001554A MXPA02001554A (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for sorter. |
BR0013241-1A BR0013241A (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for classifier |
JP2001516682A JP2003507171A (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling equipment for sorting equipment |
EP00949422A EP1242197B1 (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for sorter |
CA002381485A CA2381485A1 (en) | 1999-08-13 | 2000-07-31 | Automatic tray handling system for sorter |
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FR3077743A1 (en) * | 2018-02-13 | 2019-08-16 | Solystic | COURIER SORTING SYSTEM WITH CONTAINER OF BINS AND ROBOT SHUTTLE MANIPULATOR OF BINS |
FR3077744A1 (en) * | 2018-02-13 | 2019-08-16 | Solystic | COURIER SORTING SYSTEM WITH ROBOT BOWL INJECTION SHUTTER ON CONVEYOR |
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WO2019158829A1 (en) | 2018-02-13 | 2019-08-22 | Solystic | Mail sorting facility with a shuttle robot for injecting trays onto a conveyor |
US11219924B2 (en) | 2018-02-13 | 2022-01-11 | Solystic | Mail sorting installation with a tray conveyor and a tray-manipulating shuttle robot |
US11278936B2 (en) | 2018-02-13 | 2022-03-22 | Solystic | Mail sorting installation with a shuttle robot for injecting trays onto a conveyor |
FR3079760A1 (en) * | 2018-04-10 | 2019-10-11 | Solystic | COURIER SORTING SYSTEM WITH RETRACTABLE BANK CONVEYOR AND ROBOT SHUTTLE MANIPULATOR |
EP3552720A1 (en) * | 2018-04-10 | 2019-10-16 | Solystic | Mail sorting installation with a tray conveyor with retractable edge and shuttle robot for handling trays |
US10906068B2 (en) | 2018-04-10 | 2021-02-02 | Solystic | Mail sorting installation with a tray conveyor having a retractable edge and its tray-manipulating shuttle robot |
Also Published As
Publication number | Publication date |
---|---|
US6561339B1 (en) | 2003-05-13 |
US20050230222A1 (en) | 2005-10-20 |
DK1242197T3 (en) | 2003-12-15 |
DE60006420D1 (en) | 2003-12-11 |
MXPA02001554A (en) | 2003-07-21 |
EP1242197A1 (en) | 2002-09-25 |
AU6278400A (en) | 2001-03-13 |
EP1242197B1 (en) | 2003-11-05 |
AU771900B2 (en) | 2004-04-08 |
US20040016623A1 (en) | 2004-01-29 |
US7156220B2 (en) | 2007-01-02 |
JP2003507171A (en) | 2003-02-25 |
CA2381485A1 (en) | 2001-02-22 |
US6907982B2 (en) | 2005-06-21 |
BR0013241A (en) | 2002-04-23 |
ATE253414T1 (en) | 2003-11-15 |
DE60006420T2 (en) | 2004-09-09 |
ES2209933T3 (en) | 2004-07-01 |
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