WO2022069543A1

WO2022069543A1 - A sorting machine

Info

Publication number: WO2022069543A1
Application number: PCT/EP2021/076791
Authority: WO
Inventors: Preben Pedersen
Original assignee: Treco A/S
Priority date: 2020-10-01
Filing date: 2021-09-29
Publication date: 2022-04-07
Also published as: EP4221903A1

Abstract

A sorting machine for automatically sorting a plurality of postal items includes a plurality of sorting modules. Each sorting module includes an elevator assembly and an input conveyor. The sorting module has an elevator frame, an elevator cabin, a plurality of trays arranged inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down. Each tray is adapted to have a first position and a second position, the first position being inside the elevator cabin and the second position being outside the elevator cabin. Moreover, the sorting machine transfers the postal item from the input conveyor to the tray by first moving the tray outside the elevator cabin to the second position, and subsequently simultaneously moving input conveyor and the tray in the same direction to allow a fall of postal item from the input conveyor to the tray.

Description

A Sorting Machine

Technical Field of the invention

The present disclosure generally relates to a sorting machine. More specifically, the disclosure relates to a sorting machine for automatically sorting postal items.

Background of the invention

Automatic postal sorting machines are well known in the patent literature. Postal sorting machines load a number of postal items and then output the postal items in a delivery order so that the mailman/mailwoman has a stack of mail in the correct order for deliveries. This saves a lot of time during the delivery.

These machines can be very large, very complex and very expensive. For smaller post offices, such machines are a very large expense and such machines are typically not purchased. The post is therefore sorted by hand which is a tiring and slow operation.

Automatic postal sorting machines can typically be divided into two separate types. A first type of machine is a multiple pass sorting machine where the post is sorted in multiple passes similar to a linked list in a software program. This reguires a fast machine as it would otherwise take a long time to complete the sorting operation.

Another type of machine is known as a single pass machine. The machine reads in the postal items in a first operation and stores the individual post items in individual bins and remembers which bins have which postal items. Once all the postal items have been loaded into the individual bins, the machine ejects the postal items from the bins in the correct order. This type of machine reguires a number of bins which is egual to the number of unigue addresses on the postal items in the sorting operation. If there are 200 different postal addresses, 200 bins are needed. These types of machines are typically slower machines as the machine has to move the postal items into individual bins and then eject the post from the bins in a specific order. One example of such an automatic single pass postal sorting machine is described in W003095114.

Summary of the invention

A first aspect of the current invention is to provide an automatic postal sorting machine which is faster than the prior art machines.

A second aspect of the current invention is to provide an automatic postal sorting machine which is more robust than the prior art machines.

These aspects are provided at least in part by a sorting machine according to claim 1. According to claim 1 , the sorting machine automatically sorts a plurality of postal items and includes a plurality of sorting modules. Each sorting module includes an elevator assembly and an input conveyor. The elevator assembly has an elevator frame, an elevator cabin movably supported by the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame. Also, each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin in a horizontal direction. Further, the input conveyor is arranged at a fixed vertical position with respect to the elevator assembly. The elevator mechanism is arranged to selectively bring at least one tray into a vertical alignment with said input conveyor to facilitate a transport of a postal item disposed on the input conveyor to the tray which is in vertical alignment with the input conveyor. Moreover, the sorting machine is arranged to transfer a postal item from the input conveyor to the vertically aligned tray by first moving said tray outside the elevator cabin to the second position where the tray is disposed, at least partly, beneath an upper surface of the input conveyor, and subsequently simultaneously operating the input conveyor and displacing the tray in a direction of movement of the input conveyor to the first position such that a postal item leaves the input conveyor and is deposited on the tray while the postal item is travelling in the same direction as the tray.

In this way, a more secure transfer of the postal item to the tray is achieved. This allows the entire machine to operate faster while still having a stable delivery of the postal items.

In one embodiment, the sorting module includes a flap member disposed outside the elevator cabin and adapted to be displaced between an engaged position and a free position. In the engaged position, the flap member is adapted to be located behind a postal item disposed inside the tray, when the tray is arranged at the second position to facilitate a removal of the postal item from the tray. In the free position, the flap member is disposed away from the tray.

In one embodiment, to remove a postal item from the tray, the tray is moved to the second position, the flap member is displaced to the engaged position to arrange the flap member behind the postal item stored inside the tray, and the tray is pushed back to the first position. Further, an engagement of the flap member with the postal item facilitates the removal of the postal item from the tray when tray is pushed to the first position. In this way, the flap member itself does not have to be displaced in a large horizontal distance. This again optimizes the speed of the machine and reduces the need for many different actuators. In one embodiment, the flap member includes a plurality of flaps and the tray includes a rear wall comprising a plurality of openings to facilitate an insertion of the plurality of flaps inside the tray when the flap member is arranged in the engaged position.

According to one embodiment, the plurality of flaps engages with the postal item stored inside the tray when the tray is moved from the second position to the first position to remove the postal item from the tray.

Further, in one embodiment, each sorting module includes an output conveyor to receive a postal item removed from the tray. The output conveyor is adapted to hold a first postal item in a first buffer position and a second postal item in a second buffer position.

In one embodiment, the output conveyor includes a first portion and a second portion extending outwardly from the first portion and arranged at an inclination relative to the first portion. In the first buffer position, a postal item is disposed on the first portion, and in the second buffer position, a postal item is disposed on the second portion. In one embodiment, the angle between the first and second portions is greater than 5 degrees, greater than 10 degrees or greater than 15 degrees. By arranging the first and second portions at an angle to each other, the second portion can be arranged lower than the first portion. In this way, the second portion of the output conveyor of one sorting module can be located underneath a first portion of an output conveyor of an adjacent sorting module. In this way, the sorting modules can be arranged closer together thereby reducing the size of the complete sorting machine.

In one embodiment, each sorting module includes a linear actuator adapted to pull the tray out of the elevator cabin and push the tray back into the elevator cabin and thereby move the tray between the first position and the second position.

According to one embodiment, each tray includes an engagement structure defining a recess, and the linear actuator includes a hook member adapted to engage with the engagement structure to pull the tray out of the elevator cabin. The hook member and the recesses in the trays are arranged such that the hook member passes through the recesses of the trays as the trays are moved in the vertical direction. In this way, the hook member can be located at a stationary position while the trays move up and down. When a tray is stopped in the correct position, the hook member is already engaged with the recess and the hook member can then be pulled out by the linear actuator to pull the tray out. A separate “hook engaging” motion and actuator is not required.

According to one embodiment, the sorting machine further includes a transport conveyor having a plurality of transport belts, one transport belt associated with each sorting module. The plurality of transport belts are adapted to pivot between a horizontal position and a pivot position. The transport belts are arranged in-line when located at the horizontal position. Moreover, each of the transport belts is moveable to a pivot position to transport a postal item from the transport conveyor to a sorting module associated with the transport belt.

The claim set as filed provides claims directed to a first invention. However, this specification further discloses at least four additional inventions. These inventions could be made the subject of one or more divisional applications. It should also be noted, that for the sake of saving space, the different features of the first invention as specified in the current claim set, could be combined with the other inventions disclosed below as will be obvious to the person skilled in the art of claim drafting. According to an aspect of a second invention, a sorting machine for automatically sorting a plurality of postal items having a plurality of sorting modules is provided. Each sorting module includes an elevator assembly and an output conveyor. The elevator assembly has an elevator frame, an elevator cabin movably supported on the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin and adapted to store one or more of the postal items, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame. Moreover, each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin. The output conveyor is adapted to receive a postal item from the tray when the tray moves from the second position to the first position. Also, the output conveyor is adapted to be able to hold a postal item in a first buffer position and another postal item in a second buffer position.

According to an aspect of a third invention, a sorting machine for automatically sorting a plurality of postal items and having a plurality of sorting modules is provided. Each sorting module includes an elevator assembly and a flap member. The elevator assembly has an elevator frame, an elevator cabin movably supported on the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame. Each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin in a horizontal direction. Further, the flap member is disposed outside the elevator cabin and is adapted to be displaced between an engaged position and a free position. Also, the sorting machine removes a postal item from the tray by first moving the tray to the second position, then displacing the flap member to the engaged position to arrange the flap member behind the postal item stored inside the tray, and subsequently pushing the tray back to the first position. The postal item is removed due to an engagement of the flap member with the postal item when tray is pushed to the first position.

According to one aspect of a fourth invention, a sorting machine for automatically sorting a plurality of postal items and having a plurality of sorting modules is disclosed. Each sorting module includes an elevator assembly and a flap member. The elevator assembly has an elevator frame, an elevator cabin movably supported on the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame. Each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin in a horizontal direction. Further, the flap member is disposed outside the elevator cabin and is adapted to be displaced between an engaged position and a free position. Moreover, the flap member includes at least one flap and the tray includes a rear wall defining at least one opening to facilitate an insertion of the at least one flap into the tray. In the engaged position, the at least one flap is adapted to be located behind a postal item stored inside the tray, when the tray is arranged at the second position, and in the free position, the at least one flap is disposed away from the tray. In the engaged position, the at least one flap engages with the postal item stored inside the tray to remove the postal item from the tray when the tray is moved from the second position to the first position. In an aspect of a fifth invention, a sorting machine for automatically sorting a plurality of postal items having a plurality of sorting modules is provided. Each sorting module includes an elevator assembly and a linear actuator. The elevator assembly has an elevator frame, an elevator cabin movably supported on the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame. Each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin in a horizontal direction. Further, the linear actuator is adapted to pull the tray out of the elevator cabin and push the tray back into the elevator cabin and thereby moves the tray between the first position and the second position. Moreover, each tray includes an engagement structure defining a recess, and the linear actuator includes a hook member adapted to engage with the engagement structure to pull the tray out of the elevator cabin. The recesses of the trays arranged inside the elevator cabin are disposed in-line with each other such that the hook member passes through the recesses of the trays as the trays are moved up and down along the vertical direction.

Brief description of the drawings

In the following, the invention will be described in greater detail with reference to embodiments shown by the enclosed figures. It should be emphasized that the embodiments shown are used for example purposes only and should not be used to limit the scope of the invention.

Figure 1 shows a perspective view of one potential embodiment of a sorting machine according to an embodiment of the current invention.

Figure 2 shows a top view of the sorting machine of figure 1 . Figure 3 shows an enlarged view of a transport conveyor of the sorting machine of figure 1 depicting one transport belt of the transport conveyor in a pivot position according to an embodiment of the current invention.

Figure 4 shows a perspective view of a sorting module of the sorting machine according to an embodiment of the current invention. It should be noted that the sorting module of figures 4-11 has the output conveyor arranged mirrored with respect to the sorting modules of figures 1-3.

Figure 5 shows a rear perspective view of the sorting module of figure 4.

Figure 6 shows a top perspective view of the sorting module of figure 4 with some elements removed to illustrate details of the input conveyor.

Figure 7 shows an enlarged view of a portion of the sorting module of figure 4 depicting a tray arranged at the second position and a flap member disposed in an engaged position and located behind the tray.

Figure 8 shows an enlarged view of a portion of the sorting module of figure 4 depicting the flap member disposed in a free position.

Figure 9 shows an enlarged view of a portion of the sorting module of figure 4 depicting a hook member arranged in a recess of the tray.

Figure 10 shows an enlarged view of a portion of a stack of trays of the sorting module of figure 4.

Figure 11 shows a perspective view of the sorting module of figure 4 with different elements removed to illustrate an output conveyor having a first portion and a second portion. Detailed description of the embodiments

Referring to FIG. 1 , an exemplary sorting machine 100 suitable for automatically sorting a plurality of postal items 200 is shown. In this embodiment, the sorting machine 100 comprises six essentially identical sorting modules 102, but other embodiments could be provided with more or less sorting modules. The sorting machine 100 includes a plurality of sorting modules 102 arranged linearly in a row, a transport conveyor 104 extending substantially parallel and along the length of the row of sorting modules, a loading conveyor 106 for delivering the plurality of postal items 200 to the transport conveyor 104, and an input station 108 for loading the postal items 200 on the loading conveyor 106. In an embodiment, the input station 108 may include a robotic gripper (not shown) adapted to pick postal items 200 one by one from an input stack of postal items and position the postal items 200 one by one on the loading conveyor 106. Alternatively, an operator may manually placed the postal items 200, one by one, on the loading conveyor 106.

The sorting machine 100 may further include a scanner 110 to scan an upper surface of each postal item 200 disposed on the loading conveyor 106 to identify/determine an address to which the postal item 200 is to be delivered. In an embodiment, the scanner 110, such as, a camera, is adapted to take a photograph of the upper surface of the postal item 200 and then analyse the photograph to determine the correct address via a computer vision system. In an embodiment, the scanner 110 may use standard text recognition systems to extract correct address associated with the postal item 200. In some cases, the scanner 110 may not be able to recognize the address written on the postal item 200. In such a case, the postal item 200 continues into the machine and is stored in a bin as will be described later in this specification. The image taken by the camera is then shown to a human operator. The human operator can read the address and type in the correct address. The correct address is then assigned to the postal item 200 stored in the machine for proper sorting.

The loading conveyor 106 is adapted to move/convey each postal item 200 to the transport conveyor 104. The transport conveyor 104 extends along a width of all the sorting modules 102 of the sorting machine 100, and is adapted to deliver the postal items to any one of the sorting modules 102. To facilitate a delivery of postal items 200 to each of the sorting modules 102, the transport conveyor 104 may include a plurality of individual transport belts 112 arranged between a first longitudinal end 114 and a second longitudinal end 116 of the transport conveyor 104. Each transport belt 112 includes a frame 120 (best shown in FIGS. 3 and 4) and a belt 122 (best shown in FIGS. 3 and 4) supported by the frame 120 and adapted to move relative to the frame 120. It may be appreciated that each transport belt 112 is associated with a single sorting module 102 and facilitates the delivery of the postal items 200 to the associated sorting module 102. Moreover, each transport belt 112 is adapted to move/pivot between a horizontal position (shown in FIG. 3) and a pivot (i.e. inclined) position (shown in FIG. 3). In the horizontal position, the transport belts 112 facilitates a transfer/conveyance/transport of the postal items 200 to a next/adjacent/neighbouring transport belt 112, while in the pivot position the transport belts 112 enables a delivery of the postal items 200 to the associated sorting modules 102.

As shown in FIGS. 1 and 2, when the transport belts 112 are in the horizontal position, the transport belts 112 are aligned and coplanar with each other and extend substantially in a direction of movement of the transport conveyor 104, i.e., in a direction ‘A’. Further, each of the transport belts 112, when arranged/disposed in the pivot position, is located at an inclination relative to the direction of movement of the transport conveyor 104 and defines an opening 124 (shown in FIG. 3) through which the postal items 200 fall onto the associated sorting module 102. In an embodiment, a controller may control a movement of the transport belts 112 to the horizontal position and to the pivot position to enable a transport of the postal items 200 to the desired sorting modules 102 to facilitate a correct sorting of the postal items 200. As shown in FIG. 4 the transport belt 112 may be supported on the associated sorting module 102, and may be supported by a bracket 126 extending substantially perpendicularly from an elevator frame 128. The transport belt 112 may be pivotally coupled to the bracket 126 and may pivot about a pivot axis 130 to move between the horizontal position and the pivot position. In this embodiment, the pivot axis is located at the downstream side of the sorting module, so that when the transport belt is pivoted to the pivot position, the opening is arranged at the upstream side of the sorting module.

Referring to FIGS. 4 to 11 , a single sorting module 102 is shown. It should be noted that the sorting module 102 of figures 4 to 11 has an output conveyor 144 which is mirrored with respect to the sorting modules 102 shown in figures 1-3, but is otherwise identical in function. It may be appreciated that a construction, a structure, and a function of each of the sorting modules is identical, therefore the construction, the structure, and the function is explained with reference to a single sorting module 102. As shown in FIGS. 4 to 11 , the sorting module 102 includes an input conveyor 140 (best shown in FIG. 6) disposed beneath the associated transport belt 112 to receive the postal items 200 from the transport conveyor 104, an elevator assembly 142 adapted to receive the postal items 200 from the input conveyor 140, and an output conveyor 144 for receiving the postal items 200 from the elevator assembly 142.

Referring to FIG. 6, the input conveyor 140 is adapted to receive the postal items 200 from the transport conveyor 104 and move in a direction ‘B’ that is substantially perpendicular to the movement of the transport conveyor 104. As shown, the input conveyor 140 is adapted to move the postal items 200 towards the elevator assembly 142. The input conveyor 140 includes a first longitudinal end 146 disposed distally from the elevator frame 128, a second longitudinal end 148 disposed proximally to the elevator frame 128, a first portion 150 and a second portion 152. The first portion 150 and the second portion 152 may be separated by a virtual line 154 such that the first portion 150 may extend from the first longitudinal end 146 to the second portion 152, while the second portion 152 may extend from the first portion 150 to the second longitudinal end 148. It may be appreciated that the first portion 150 is arranged/located directly below the associated transport belt 112, while the second portion 152 may be located at an offset from the transport belt 112. Further, the input conveyor 140 is supported on the bracket 126 and the second longitudinal end 148 is disposed at a distance from the elevator frame 128, such that a longitudinal gap 156 is defined between the input conveyor 140 and the elevator frame 128.

In an embodiment, the input conveyor 140 is adapted to hold a single postal item 200 in two buffer positions 200a, 200b. The postal item 200 drops from the transport conveyor 104 and rests on the input conveyor 140 in a first buffer position 200a. Accordingly, in the first buffer position 200a, the postal item 200 is disposed directly beneath the transport belt and on the first portion 150, while in a second buffer position 200b, the postal item 200 is arranged on the second portion 152 of the input conveyor 140. Accordingly, in the second buffer position 200b, the postal item 200 is located proximate to the elevator assembly 142 relative to the first buffer position 200a. In this manner, the input conveyor 140 is adapted to hold two postal items 200 simultaneously. For so doing, in an implementation, a length of the input conveyor 140 may be twice a width of the transport belt 112. From the second buffer position 200b, the postal item 200 moves/falls into a tray 164 of the elevator assembly 142 as described in more detail below. In one embodiment, instead of one long input conveyor 140, two separate conveyors may be provided in line with each other. To optimize the sorting speed of the machine, when a postal item is dropped onto the first portion, the input conveyor will activate and move the postal item to the second portion in order to make the first portion available for a new postal item.

As shown in FIGS. 4 to 11 , the elevator assembly 142 includes the elevator frame 128 extending upwardly from a ground surface, an elevator cabin 162 movably supported on the elevator frame 128 and adapted to move vertically up and down along a height of the elevator frame 128, a plurality of trays 164 arranged/arrayed/stacked vertically within the elevator cabin 162, and an elevator mechanism 166,168 (shown in FIG. 5) adapted to move the elevator cabin 162 up and down in the vertical direction relative to the elevator frame 128. The elevator mechanism may be a chain or belt 166 connected to the elevator cabin 162 and adapted to move the elevator cabin 162 in the vertical direction. In an embodiment, the elevator mechanism may include an electric motor 168 (shown in FIG. 5) to operate the chain or the belt 166.

Further, each tray 164 is adapted to have a first position (best shown in FIGS. 4 and 5) inside the elevator cabin 162 and a second position (best shown in FIG. 6 and FIG. 7) outside the elevator cabin 162. To move the tray 164 between the first position and the second position, the tray 164 is moved in a horizontal direction substantially parallel to the direction of movement of the input conveyor 140. Outside the elevator cabin 162 and in the second position, the tray 164 is arranged distally from the elevator cabin 162 and at least partly beneath the input conveyor 140.

Referring to FIGS. 6 to 9, to pull the tray 164 out of the elevator cabin 162 to the second position, and push the tray 164 inside the elevator cabin 162 to the first position, the sorting module 102 may include a tray displacing mechanism 170 extending substantially perpendicular to the elevator frame 128 and disposed outside the elevator cabin 162. In an embodiment, the tray displacing mechanism 170 is supported by the bracket 126 and may extend from the elevator cabin 162 to the input conveyor 140 such that a portion of the tray displacing mechanism 170 is located directly beneath/below the input conveyor 140. In an embodiment, the tray displacing mechanism 170 includes a pair of rails (best shown in FIG. 7), for example, a first rail 172 and a second rail 174 disposed spaced apart and substantially parallel to the first rail 172, defining a cavity 176 (shown in FIG. 9) therebetween. Outside the elevator cabin 162, the tray 164 is supported on the rails 172, 174, and slides relative to the rails 172, 174.

Further, as shown in FIGS. 8 and 9, the tray displacing mechanism 170 may include a linear actuator 177 to pull the tray 164 out of the elevator cabin 162 to the second position and push the tray 164 inside the elevator cabin 162 to the first position. In an embodiment, the linear actuator 177 may include a hook member 178 and a drive belt 179 connected to the hook member 178 and adapted to move the hook member 178 in a horizontal direction along a length of one of the rails, for example, the first rail 172. The hook member 178 is adapted to engage with the tray 164 when the tray is disposed in the first position and aligned with the rails 172, 174, and is adapted to pull the tray 164 outside the elevator cabin 162. The hook member 178 may include an L shape having a first member 180 connected/attached to the belt 179 and a second member 182 extending substantially perpendicular to the first member and adapted to engage with the tray 164 to pull the tray 164, disposed in the first position, outside the elevator cabin 162. Further, the second member 182 remains in engagement with the tray 164 when the tray 164 is moved between the first position and the second position.

Referring again to FIG. 10, each tray 164 includes a base 184, front end 186, a rear end 188, a rear wall 190 arranged at the rear end 188, and two side walls 192, 194. The rear wall 190 and the sidewalls 192, 194 extend substantially perpendicular to the base 184 and together define a tray chamber 196 to receive and store one or more postal items 200. In an embodiment, the tray 164 includes a front opening 198 through which the postal item 200 from the tray 164 is discharged. Moreover, the rear wall 190 defines a plurality of openings 202 (herein after referred to as rear openings 202) extending along an entire height of the rear wall 190 from the base 184 of the tray 164. The rear openings 202 facilitate an insertion or extension of a flap member 210 (shown in FIGS. 6 to 9) inside the tray 164 to cause a removal of the postal item 200 from the tray chamber 196 through the front opening 198 when the tray 164 is pushed back into the elevator cabin 162. Further, the tray 164 may include a plurality of ridges 212 or protrusions extending upwardly from the base 184. Owing to the ridges 212, the postal item 200 stored inside the tray chamber 196 remains lifted off the base 184 of tray 164, enabling an easy removal of the postal item 200 from the tray 164 since a contact area between the tray 164 and the postal item 200 will be smaller. Also, the tray 164 may include an engagement structure 214 connected to the sidewall 192 and extending outwardly, in width-wise direction, of the tray 164. The engagement structure 214 may be disposed outside the elevator cabin 162 when the tray 164 is at the first position, and may be arranged proximate to the front end 186 of the tray 164.

As best shown in FIG. 9, the engagement structure 214 may be a horizontally disposed II shaped structure and may define a recess 216 to receive the second member 182 of the hook member 178. The second member 182 of the hook member 178 is adapted to engage with the engagement structure 214 to pull the tray 164 out of the elevator cabin 162. Further, the recesses 216 of the trays 164 arranged inside the elevator cabin 162 are vertically inline with each other. Accordingly, the second member 182 (i.e. the hook member 178) remains disengaged from the trays 164 and passes through the recesses in the trays 164 as the elevator cabin 162 moves up and down. In this manner, the hook member 178 remains stationary while the trays 164 move up and down. Also, as the second member 182 remains inside the recess 216 of the tray 164 arranged in the first position and in alignment with the tray displacing mechanism 170, the tray 164 can be quickly moved out of the elevator cabin 162 by actuating the drive belt 179. Upon actuation of the drive belt 179, the second member 182 of the hook member 178 engages with the engagement structure 214 and pulls the tray 164 outside the elevator cabin 162. Further, the second member 178 of the hook member 178 remains in engagement with the engagement structure 214 when the tray 164 is disposed at the second position, and pushes the tray 164 to the first position when the drive belt 179 is moved towards the elevator assembly 128.

Further, as shown in FIG. 9, the sorting module may include an alignment block 218 disposed proximate to an upper end of the elevator frame 128 and above the tray displacing mechanism 170. The alignment block includes a curved surface 219 facing front ends 186 of the trays 164 arranged inside the elevator cabin 162. The alignment block 218 is arranged such that as the trays 164 move up and down with the elevator cabin 162, front edges of the trays 164 may come into contact with the curved surface 219 of alignment block 218 and are pushed into the elevator cabin 162 into the proper position. In this way, it is ensured that the trays 164 while moving up and down will be in the correct position so that the engagement structure 214 of the tray 164 does not come into conflict with the hook member 178.

Referring back to FIGS. 6 to 9, the sorting module 102 includes the flap member 210 that is arranged outside the elevator cabin 162 and adjacent to the front end 186 of the tray 164 when the tray 164 located at the first position. The flap member 210 is adapted to displace, for example, rotate between an engaged position (shown in FIGS. 6 and 7) and a free position (shown in FIG. 8 and FIG. 9). In the engaged position, the flap member 210 extends vertically downwardly and may be disposed substantially parallel to front edges of the trays 164, while in the free position, the flap member 210 may be disposed at an inclination relative to the horizontal and vertical direction. In an embodiment, in the engaged position, the flap member 210 is adapted to contact/engage with the postal item 200 stored inside the tray chamber 196 when the tray 164 is pushed back inside the elevator cabin 162, while in the free position, the flap member 210 is disposed away from the tray 164 such that the tray 164 can be pushed into the elevator cabin 162 without having the flap member 210 come into contact with a postal item 200 stored in the tray 164. Also, in the engaged position, the flap member 210 is adapted to be located behind a postal item 200 disposed inside the tray 164, when the tray 164 is arranged at the second position to facilitate a removal of the postal item 200 from the tray 164.

In an embodiment, the flap member 210 may include a plurality of flaps 220 (best shown in FIG. 7 and FIG. 8) arrayed linearly and disposed spaced apart from each other. In the engaged position of the flap member 210, the flaps 220 extend vertically downwardly and may extend substantially parallel to the rear wall 190 of the tray 164, while in the free position, the flaps 220 may extend at an inclination relative to the vertical and are disposed away from the tray 164. Further, in the engaged position of the flap member 210, the plurality of flaps 220 may be aligned with the plurality of rear openings 202 (as shown in FIG. 6 and 7) to facilitate an insertion of the flaps 220 inside the tray chamber 196 though the rear openings 202. In some embodiments, in the engaged position of the flap member 210, the flaps 220 are arranged behind the rear wall 190 of the tray 164 so that the flaps 220 enter the tray chamber 196 through the rear openings 202 and push the postal item 200 out of the tray 164 when the tray 164 is moved back inside the elevator cabin 162. The postal item 200 that is removed from the tray falls onto the output conveyor 144. Further, in the engaged position, the flaps 220 may be arranged such that bottom edges 222 of the flaps 220 are located above an inner bottom surface 224 of the tray 164 located in the second position, but below upper surfaces 226 of the ridges 212 of the tray arranged at the second position.

Referring back to FIG. 4, 5, and 6, the output conveyor 144 extends below the tray displacing mechanism 170 and is adapted to receive a postal item 200 discharged from the tray 164. Further, the output conveyor 144 is attached or coupled to the bracket 126. The output conveyor 144 is adapted to convey/transport the postal items 200 in a direction substantially perpendicular to the direction of movement of the input conveyor 140. In an embodiment, the output conveyor 144 is adapted to move the postal items 200 along the width wise direction of the sorting module 102. As shown in FIG. 11 , the output conveyor 144 includes a first portion 230 arranged beneath the tray displacing mechanism 170 and is adapted to receive the postal item 200 falling from the tray 164 through the cavity 176, and a second portion 240 connected to the first portion 230 and extending outwardly and downwardly from the first portion 230. As shown, the second portion 240 may extend at an inclination relative to the first portion 230 and may extend outwardly of the bracket 126 to facilitate a positioning of the second portion 240 beneath/below a first portion 230 of an output conveyor 144 of an adjacent/neighbouring sorting module 102. In some embodiments, the first portion 230 and the second portion 240 may be substantially parallel and inline to each other, and/or may include two separate belts, instead of a single belt as in the current embodiment.

Further, the first portion 230 may include a first belt 232 to transport the postal items 200 to the second portion 240, and the second portion 240 may include a second belt 242 to transport the postal items 200 received from the first belt 232 to an output belt 250 (shown in FIG. 1 and FIG. 2) of the sorting machine 100. Accordingly, the output conveyor 144 is adapted to hold a single postal item 200 in two positions, for example, a first buffer position and a second buffer position. In the first buffer position, the postal item 200 is disposed on the first portion 230, while the postal item 200 is stored/disposed on the second portion 240 in the second buffer position. In this manner, the output conveyor 144 is adapted to hold two postal items 200 simultaneously. Further, the output conveyor 144 may include a gate 244 movable between a closed position and an open position and arranged at a distal end of the output conveyor 144. In the closed position, the gate 244 prevents a transportation of the postal item 200 from the second portion 240 to the output belt 250, while in the open position, the gate 244 allows a transport of the postal item 200 from the second portion 240 to the output belt 250. It may be appreciated that an opening and a closing of the gate 244 and movement of the second belt 242 may be controlled by a controller of the postal sorting machine 102 to facilitate an ejection of the postal items 200 from the sorting machine 100 in correct and desired order. In one embodiment (not shown), a single belt is arranged at an inclination and is provided with two separately operatable gates, one gate at the end of the second portion 240 and one gate between the first portion 230 and the second portion 240.

As shown in FIG. 1 , the output belt 250 of the sorting machine 100 is adapted to receive the postal items 200 from each of the sorting modules 102, and extend along a width of each of the sorting modules 102. It may be envisioned that the output belt 250 is arranged/mounted beneath the second portions 240 of the output conveyors 144 of each of the sorting modules 102 to enable a receipt of the postal items 200 from each of the sorting modules 102. Further, the sorting machine 100 includes an output station 260 to receive the postal items 200 from the output belt 250 in a correct and desired order.

A working of the sorting machine 100 is now described. At first, a stack of unsorted postal items 200 is brought to the sorting machine 100, and is positioned proximate to the input station 108. Thereafter, the postal items 200 are placed on the loading conveyor 106 one by one. In an embodiment, a robotic gripper may lift the unsorted postal items 200 and put the postal items 200 on the loading conveyor 106 one by one. In some other implementations, a person may add the postal items 200, one at a time, to the loading conveyor 106. It may be appreciated that postal items 200 are placed on the loading conveyor 106 with the address facing up. Subsequently, each postal item 200 passes through the scanner 110 where the address marked on each postal item 200 is photographed and then analysed to determine the correct address of delivery. In an embodiment, the address is determined using text recognition techniques known in the art. In some cases, the address written on one or more of the postal items 200 may not be determined accurately by the controller. Such postal items 200 are still stored in the sorting machine 100 and a human operator can later on read the address via a photograph of the postal item and type in the correct address. As the location of the postal item is known to the controller (as described below), the correct address can then be associated with the postal item for proper sorting.

The loading conveyor 106 transports the postal items 200 to the transport conveyor 104 that transfers the postal items 200 to various sorting modules 102. To facilitate the transfer of the postal items 200 to the sorting modules 102, the individual transport belts 112 are hinged/pivoted to the pivot position to cause a drop of the postal items 200 onto the associated sorting modules 102. It may be appreciated that only a single postal item 200 is dropped/transferred to one sorting module 102 at a time. Also, when the transport belt 112 swings/pivots up to the pivot position, the postal item 200 falls down onto the input conveyor 140 running perpendicular to the transport belt 112. In this manner, the postal items are received by various input conveyors 140 of the various sorting modules 102.

As described earlier, the input conveyor 140 can hold two postal items 200 simultaneously, one on the first portion 150 and one on the second portion 152. Any postal item 200 from the transport conveyor 104 first falls on to the first portion 150, i.e., in the first buffer position 200a. After receiving the postal item 200, the input conveyor 140 is rotated/moved in the direction ‘B’ to move the postal item 200 to the second portion 152, i.e. the second buffer position 200b. Thereafter, the input conveyor 140 is stopped, and a second postal item 200 is allowed to fall on the input conveyor 140 from the transport conveyor 104. In this manner, the input conveyor 140 can store up to two postal items 200 at a time.

Upon positioning the postal item 200 on the second portion 152 (i.e. in the second buffer position 200b, an empty tray 164 is moved out of the elevator cabin 162. For so doing, the elevator mechanism may move the elevator cabin 162 up and down to bring one of the empty tray 164 in the first position such that the empty tray is horizontally aligned with the tray displacing mechanism 170. In the first position, the empty tray 164 is also vertically aligned with the input conveyor 140. Accordingly, the second member 182 of the hook member 178 is arranged inside the recess 216 of the empty tray 164. As soon as the empty tray 164 is in alignment with the tray displacing mechanism 170, and hence arranged in the first position, the tray displacing mechanism 170 (i.e. drive belt 179) is moved, causing the engagement of hook member 178 with the engagement structure 214, and enabling a pulling of the empty tray 164 outside the elevator cabin 162. The drive belt 179 is operated/moved until the empty tray 164 reaches the second position. In the second position, at least a portion of the tray 164 is arranged directly below/beneath an upper surface of the second portion 152 of the input conveyor 140. After the empty tray 164 is arranged at the second position, the sorting machine 100 simultaneously starts and moves the input conveyor 140 and the empty tray 164 in the direction ‘B’ towards the elevator cabin. Movements or speeds of the input conveyor 140 and the drive belt 179, and hence the empty tray 164, is controlled such that the postal item 200 located on the input conveyor 140 leaves the input conveyor and is deposited inside the tray 164. In such a case, the postal item 200 travels in the direction of travel of the empty tray 164. In an embodiment, the input conveyor 140 and the empty tray 164 are moved at the same speeds so the postal item 200 stored in the second buffer position falls properly inside the moving empty tray 164. In some embodiments, the speed of the empty tray 164 is less than 25% slower or less than 25% faster than the speed of the input conveyor 140.

It should be noted that in certain cases, if two or more postal items have the same address, then the two or more postal items can be stored in the same tray. When adding a second postal item on top of a first postal item, the above described method of adding the postal item to the tray, will ensure that the second postal item is laid nicely on top of the first item, without any risk of the postal items getting into conflict with each other.

Upon receiving the postal item 200 inside the tray 164, the tray 164 is pushed fully back inside the elevator cabin 162 by continuing to move the tray 164 in the direction ‘B’, while the input conveyor 140 is stopped after the discharge of the postal item 200 from the second portion 152. Once the tray 164 having the postal item 200 is pushed back inside the elevator cabin 162, the elevator 166 moves the elevator cabin 162 up or down to position a new empty tray 164 aligned with the input conveyor.

In this manner, all the postal items 200 are stored in various trays 164 of the various sorting modules 102. It may be appreciated that the controller of the sorting machine 100 records the locations of the storage of all the postal items 200. After loading the postal items 200 in the trays 164 is complete, the controller can then find the best delivery route and starts to eject the postal items 200 from the trays 164 according to the optimal delivery order. To eject a postal item 200 from a tray 164 disposed inside the elevator cabin 162, the tray 164 is vertically moved by the elevator mechanism such that the tray 164 is in alignment with the tray displacing mechanism 170. The tray 164 is now in the first position and aligned with tray sliding mechanism 170 such that the second member 182 of the hook member 178 is disposed in the recess 214 of the engagement structure 214. Thereafter, the drive belt 179, and hence the linear actuator 177, is moved in a direction towards the input conveyor 140 to facilitate a pulling of the tray 164 having the postal item 200 out of the elevator cabin 162 by the hook member 178. Once the tray 164 is pulled completely out of the elevator cabin 162 and arranged at the second position, the flap member 210 is rotated to the engaged position from the free position. Accordingly, the flap member 210, and hence the flaps 220, are positioned in a vertically downward direction behind the rear wall 190 of the tray 164. Also, in the engaged position, the flaps 220 are inline or aligned with the rear openings 202. In some implementations, the flap member 210, and hence the flaps 220, enters the tray 164 through the rear openings 202 upon rotation/displacement of the flap member 210 to the engaged position. In such a case, the flap member 210 is positioned proximate to the rear wall 190 and behind the postal item 200 stored inside the tray 164. Subsequently, the drive belt 179 is started and moved towards the elevator cabin 162 in the direction ‘B’ to push the tray 164 inside the elevator cabin 162. As the tray 164 moves towards the elevator cabin 162, the postal item 200 contacts the flap member 210, restricting the movement of postal item 200 in the direction ‘B’ along with the tray 164, causing the postal item 200 to be pushed out of tray 164 through the front opening 198 and fall down from the tray 164. In this manner, the postal item 200 is discharged from the tray 164 and falls on the output conveyor 144 through the cavity 176.

Accordingly, the first portion 230 of the output conveyor 144 receives the postal item 200 falling from the tray 164. The postal item 200 is then transferred to the second portion 240 of the output conveyor 144 by moving the first belt 232 of the first portion 230. Accordingly, the output conveyor 144 can hold/store a postal item 200 in two positions, the first buffer position on the first portion 230 and the second buffer position on the second portion 240. Due to the movement of the postal item 200 to the second portion 240, the first portion 230 is ready to receive another postal item 200 from the elevator cabin 162. Accordingly, the sorting machine 100 may keep operating the elevator cabin 162, the trays 164, the tray displacing mechanism 170, and the flap member 210 to discharge/deliver another postal item 200 to first portion 230 of the output conveyor 144, while one postal item 200 is waiting to be ejected from the second portion 240 of the output conveyor 14. Thereby, the sorting machine 100 facilitates a faster sorting and discharge of the postal items 200.

The postal item 200 stored on the second portion 240, i.e., in the second buffer position, of the output conveyor 144 is moved to the output belt 250 by opening the gate 244 and moving the second belt 242. It may be envisioned that the postal item 200 is stored on the second portion 240, i.e. in the second buffer position, to deliver the postal item 200 in the correct order on the output belt 250. Accordingly, the controller may keep a record of all the postal items 200 being delivered to the output belt 250 by all the sorting modules 102, and starts the second belts 242 of the sorting modules 102 such that the postal items 200 are arranged on the output belt 250 in a desired sequence/order. The output belt 250 transports the postal items 200 in the correct sequence to the output station 260. At the output station 260, the postal items 200 are bundled into a stack by a worker and transferred to a delivery station.

It is to be noted, that depending on the speed of the sorting machine 100 and how many postal items 200 there are in a postal route, it is possible to start loading the postal items 200 from a second route into the sorting machine 100, while the postal items 200 from a first route are being ejected from the sorting machine 100. In this way, the sorting machine 100 can be working on two postal routes at the same time.

It is to be noted that the figures and the above description have shown the example embodiments in a simple and schematic manner. Many of the specific mechanical details have not been shown since the person skilled in the art should be familiar with these details and they would just unnecessarily complicate this description.

List of Elements

100 sorting machine

102 sorting module

104 transport conveyor

106 loading conveyor

108 input station

110 scanner

112 transport belt

120 frame

122 belt

124 opening

126 bracket

128 elevator frame

130 pivot axis

140 Input conveyor

142 elevator assembly

144 output conveyor

146 first longitudinal end

148 second longitudinal end

150 first portion

152 second portion

154 virtual line

156 longitudinal gap

162 elevator cabin

164 tray

166 belt

168 electric motor

170 tray displacing mechanism

172 first rail

174 second rail 176 cavity

177 linear actuator

178 hook member

179 drive belt

180 first member

182 second member

184 base

186 front end

188 rear end

190 rear wall

192 sidewalll

194 sidewall

196 tray chamber

198 front opening

200 postal item

202 rear opening

210 flap member

212 ridge

214 engagement structure

216 recess

218 alignment block

219 curved surface

220 flap

222 bottom edge

224 inner bottom surface

226 upper surface

230 first portion

232 first belt

240 second portion

242 second belt

244 gate 250 output belt

260 output station

Claims

Claims A sorting machine for automatically sorting a plurality of postal items, the sorting machine comprising: a plurality of sorting modules, each sorting module including: an elevator assembly having an elevator frame, an elevator cabin movably supported by the elevator frame, a plurality of trays arranged as a vertical stack of trays inside the elevator cabin, and an elevator mechanism arranged to move the elevator cabin up and down in a vertical direction relative to the elevator frame, wherein each tray is adapted to be displaced with respect to the elevator cabin between a first position and a second position, the first position being inside the elevator cabin and the second position being at least partially outside the elevator cabin in a horizontal direction; and an input conveyor arranged at a fixed vertical position with respect to the elevator assembly, said elevator mechanism being arranged to move the vertical stack of trays up and down to selectively bring at least one tray into vertical alignment with said input conveyor to facilitate a transport of a postal item disposed on the input conveyor to the tray which is in vertical alignment with the input conveyor, characterized in that: the sorting machine is arranged to transfer a postal item from the input conveyor to the vertically aligned tray by first moving said tray outside the elevator cabin to the second position where the tray is disposed, at least partly, beneath an upper surface of the input conveyor and subsequently simultaneously operating the input conveyor and displacing the tray in a direction of movement of the input conveyor to the first position such that a postal item leaves the input conveyor and is deposited on the tray while the postal item is travelling in the same direction as the tray.

2. The sorting machine of claim 1 , wherein the sorting module includes a flap member disposed outside the elevator cabin and adapted to be displaced between an engaged position and a free position, wherein in the engaged position, the flap member is adapted to be located behind a postal item stored inside the tray, when the tray is arranged at the second position to facilitate a removal of the postal item from the tray, and in the free position, the flap member is disposed away from the tray.

3. The sorting machine of claim 2, wherein the sorting machine is arranged to remove a postal item from the tray by performing the following steps: the tray is moved to the second position, the flap member is displaced to the engaged position to arrange the flap member behind the postal item stored inside the tray, and the tray is pushed back to the first position, wherein an engagement of the flap member with the postal item facilitates the removal of the postal item from the tray when tray is pushed to the first position.

4. The sorting machine of claim 2 or claim 3, wherein the flap member includes at least one flap and the tray includes a rear wall comprising at least one opening to facilitate an insertion of the at least one flap inside the tray when the flap member is arranged at the engaged position. The sorting machine of claim 4, wherein the at least one flap engages with the postal item stored inside the tray when the tray is moved from the second position to the first position to remove the postal item from the tray. The sorting machine of any preceding claim, wherein each sorting module includes an output conveyor to receive a postal item removed from the tray, the output conveyor being adapted to hold a first postal item in a first buffer position and a second postal item in a second buffer position. The sorting machine of claim 6, wherein the output conveyor includes a first portion and a second portion extending outwardly from the first portion and arranged at an inclination relative to the first portion, wherein in the first buffer position, a postal item is disposed on the first portion, and in the second buffer position, a postal item is disposed on the second portion. The sorting machine of any preceding claim, wherein each sorting module includes a linear actuator adapted to pull the tray out of the elevator cabin and push the tray back into the elevator cabin and thereby move the tray between the first position and the second position. The sorting machine of claim 8, wherein each tray includes an engagement structure defining a recess, and the linear actuator includes a hook member adapted to engage with the engagement structure to pull the tray out of the elevator cabin, wherein the recesses are arranged in line such that the hook member passes through the recesses of the trays as the trays are moved in the vertical direction. The sorting machine of any preceding claim further including a transport conveyor having a plurality of transport belts adapted to pivot between a horizontal position and a pivot position, wherein the transport belts are arranged in-line when located at the horizontal position, each of the transport belts being moved to the pivot position to transport a postal item from the transport conveyor to an associated sorting module.