U.S. patent application number 10/844431 was filed with the patent office on 2004-12-09 for enhanced object-feeder pre-processing system.
Invention is credited to Hillerich, Thomas A. JR., Lauretano, Stephanie A., McConnell, William P., Mileaf, Daryl S., Ryan, Patrick J..
Application Number | 20040245714 10/844431 |
Document ID | / |
Family ID | 33452328 |
Filed Date | 2004-12-09 |
United States Patent
Application |
20040245714 |
Kind Code |
A1 |
Ryan, Patrick J. ; et
al. |
December 9, 2004 |
Enhanced object-feeder pre-processing system
Abstract
In some embodiments, a system and/or method includes
pre-processing objects (such as, e.g., mail or other thin-objects)
that are delivered to an object feeder. Various embodiments
disclosed herein can have various advantages, such as enhancing
processing, improving ergonomics and/or other advantages.
Inventors: |
Ryan, Patrick J.; (Wildwood,
MO) ; Mileaf, Daryl S.; (Hanover, MD) ;
Hillerich, Thomas A. JR.; (Shepherdsville, KY) ;
Lauretano, Stephanie A.; (Ellicott City, MD) ;
McConnell, William P.; (Woodstock, MD) |
Correspondence
Address: |
ROTHWELL, FIGG, ERNST & MANBECK, P.C.
1425 K STREET, N.W.
SUITE 800
WASHINGTON
DC
20005
US
|
Family ID: |
33452328 |
Appl. No.: |
10/844431 |
Filed: |
May 13, 2004 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60469828 |
May 13, 2003 |
|
|
|
Current U.S.
Class: |
271/264 |
Current CPC
Class: |
B07C 1/025 20130101 |
Class at
Publication: |
271/264 |
International
Class: |
B65H 005/00 |
Claims
What is claimed is:
1. A method for pre-processing mail delivered to at least one mail
feeder having a conveyor from which mail is fed to a downstream
system, comprising: a) having at least one preparation operator
place non-bundled mail on a carrier; b) delivering said carrier via
said delivery system to the feeder without requiring an operator to
lift said carrier; and c) transferring mail from said carrier to
the conveyer of the feeder.
2. The method of claim 1, wherein said transferring mail includes
having the feeder operator laterally move mail to the conveyor of
the feeder.
3. The method of claim 1, further including providing said mail as
mail flats.
4. The method of claim 1, further including delivering carriers
from a plurality of preparation operator locations to a common
supply, and delivering said carriers from said common supply to a
plurality of feed operator locations proximate respective mail
feeders.
5. The method of claim 1, wherein said delivering includes
delivering said carriers via said delivery system along a path that
includes a lateral component such that said carrier is moved, at
least in part, laterally.
6. The method of claim 1, wherein said delivering includes
delivering said carriers via said delivery system along a path that
includes a generally vertical component such that said carrier is
moved, at least in part, generally vertically.
7. The method of claim 1, wherein said delivery system includes a
conveyor.
8. The method of claim 1, wherein said delivery system includes a
movable platform.
9. The method of claim 1, wherein said delivery system includes a
conveyor and a movable platform.
10. The method of claim 9, wherein said movable platform is
supported upon a frame.
11. The method of claim 9, wherein said movable platform is raised
or lowered to the feeder.
12. The method of claim 9, wherein said movable platform is
laterally moved to the feeder.
13. The method of claim 9, wherein said movable platform is movable
between an end of said conveyor and adjacent said feeder.
14. The method of claim 1, further including sliding said mail off
of said carrier onto said feeder with a transfer slide having an
angled upper surface.
15. A method for pre-processing mail delivered to at least one mail
feeder having a conveyor from which mail is fed into a system,
comprising: a) de-bundling mail at at least one preparation
operator location; b) placing said de-bundled mail upon at least
one mail carrier; and c) delivering said at least one mail carrier
to at least one mail feeder via a delivery system that permits
egress of a feed operator around a periphery of each of the at
least one mail feeder.
16. The method of claim 15, further including delivering carriers
from a plurality of preparation operator locations to a common
supply, and delivering said carriers from said common supply to a
plurality of feed operator locations proximate respective mail
feeders.
17. The method of claim 15, wherein said delivering includes
delivering said carriers via said delivery system along a path that
includes a lateral component such that said carrier is moved, at
least in part, laterally to the feeder.
18. The method of claim 15, wherein said delivering includes
delivering said carriers via said delivery system along a path that
includes a generally vertical component such that said carrier is
moved, at least in part, generally vertically to the feeder.
19. The method of claim 15, wherein said delivery system includes a
conveyor.
20. The method of claim 15, wherein said delivery system includes a
movable platform.
21. The method of claim 15, wherein said delivery system includes a
conveyor and a movable platform.
22. The method of claim 21, wherein said movable platform is
movable between a position adjacent said conveyor and a position
adjacent said feeder.
23. The method of claim 15, further including sliding said mail off
of said carrier onto said feeder via an angled sliding surface.
24. A method for pre-processing and delivering objects to an
object-feeder, comprising: a) loading objects onto a plurality of
carriers; b) conveying said carriers with a supply conveyor towards
an object-feeder; c) transporting at least one of said carriers
from said conveyor toward said feeder upon a reciprocated
transporter; d) after transporting, transferring objects from said
at least one carrier to said feeder; e) after transferring, placing
said at least one carrier upon a return conveyor.
25. The method of claim 24, wherein said platform is reciprocated
at least partly in a generally vertical direction.
26. The method of claim 24, wherein said platform is reciprocated
at least partly in a generally horizontal direction.
27. The method of claim 24, wherein said objects includes mail.
28. A mail handling system, comprising: a) a feeder for feeding
mail; b) a plurality of mail carriers; c) a transporter upon which
at least one of said mail carriers can be placed; d) said
transporter including a platform that is movable along a path from
a location proximate said feeder to a location distal from said
feeder so as to permit egress of a feed operator around a periphery
of the feeder.
29. The mail handling system of claim 28, wherein said path
includes a lateral component such that said support is moved, at
least in part, laterally to the feeder.
30. The mail handling system of claim 28, wherein said path
includes a generally vertical component such that said support is
moved, at least in part, generally vertically to the feeder.
31. An thin-object handling system, comprising: a) a feeder for
feeding thin-objects; b) a plurality of carriers carrying a
plurality of said thin-objects; c) a conveyor for conveying said
carriers toward said feeder; d) a transporter arranged to transport
at least one of said carriers from said conveyor toward said
feeder, said transporter being movable to permit egress of a feed
operator around a periphery of the feeder.
32. The system of claim 31, wherein said thin objects include mail.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to, among, other
things, systems for handling mail (including, e.g., flats,
envelopes, letters, postcards and/or other mail) and/or other
objects, and certain preferred embodiments relate, more
particularly, to automated systems for pre-processing mail flats
handled by mail flats sorting systems.
[0003] 2. Background Discussion
[0004] Currently, a variety of systems are used for the handling of
objects, such as, e.g., thin objects like mail flats and/or other
mail. For example, the United States Postal Service (USPS) uses
various systems to facilitate and enhance the handling of mail
flats.
[0005] For example, some illustrative mail processing systems are
illustrated in U.S. Pat. No. 6,443,311 (the '311 patent), assigned
to Northrop Grumman Corporation, entitled Flats Bundle Collator,
the disclosure of which is incorporated herein by reference in its
entirety as though recited herein in full.
[0006] As another example, one illustrative mail processing system
is the AFSM100.TM. flats sorting system built by Northrop Grumman
Corporation and Rapistan Systems and used by the USPS. The AFSM100
flats sorting machine is a mail sorting system that can process,
e.g., large pieces of flat mail, such as for example magazines, in
large volumes. Each AFSM100 system has three mail-feeding
units.
[0007] In some of these existing mail processing systems, feeders
are used to deliver mail into the systems for processing. In some
illustrative and non-limiting examples, these feeders include a
delivery portion and a destacking (e.g., singulating) portion. In
such systems, mail is typically placed onto the delivery portion
and delivered to the destacking portion. In these example systems,
the mail pieces are usually delivered to a sorting section in
pieces (e.g., usually having a fixed gap and/or a fixed pitch).
[0008] In such systems, operators typically load (such as, e.g.,
manually from mail storage hampers) the mail to be processed onto
the delivery portion at the beginning of the operation. The
operators usually continue to load the mail while the system
processes the mail.
[0009] In modern-day mail processing environments, sorting and
other systems are running faster and longer than in the past. Among
other things, this can increase the burden upon the operators who
feed and/or operate the systems. In many instances, the performance
of mail processing equipment is increasingly dependant upon an
operator's capacity to support the system.
[0010] Therefore, a need exists for a pre-processing system that
can overcome, among other things, the above and/or other problems
with existing systems. SUMMARY OF THE PREFERRED EMBODIMENTS
[0011] Various embodiments of the present invention can
significantly improve upon existing systems and methods. In some
preferred embodiments of the present invention, one or more of the
above and/or other problems with existing systems can be
overcome.
[0012] According to some embodiments, a method for pre-processing
mail delivered to at least one mail feeder having a conveyor from
which mail is fed to a downstream system includes:
[0013] a) having at least one preparation operator place
non-bundled mail on a carrier; b) delivering the carrier via the
delivery system to the feeder without requiring an operator to lift
the carrier; and c) transferring mail from the carrier to the
conveyor of the feeder. Preferably, the transferring mail includes
having the feeder operator laterally move mail to the conveyor of
the feeder. In some embodiments, the method further includes
providing the mail as mail flats. In some embodiments, the method
further includes delivering carriers from a plurality of
preparation operator locations to a common supply, and delivering
the carriers from the common supply to a plurality of feed operator
locations proximate respective mail feeders. In some embodiments,
the delivering includes delivering the carriers via the delivery
system along a path that includes a lateral component such that the
carrier is moved, at least in part, laterally and/or delivering the
carriers via the delivery system along a path that includes a
generally vertical component such that the carrier is moved, at
least in part, generally vertically.
[0014] According to other embodiments, a method for pre-processing
mail delivered to at least one mail feeder having a conveyor from
which mail is fed into a system includes: a) de-bundling mail at at
least one preparation operator location; b) placing the de-bundled
mail upon at least one mail carrier; and c) delivering the at least
one mail carrier to at least one mail feeder via a delivery system
that permits egress of a feed operator around a periphery of each
of the at least one mail feeder. In some embodiments, the delivery
system includes a conveyor and a movable platform. In some
embodiments, the movable platform is movable between a position
adjacent the conveyor and a position adjacent the feeder.
[0015] According to other embodiments, a method for pre-processing
and delivering objects to an object-feeder, comprising: a) loading
objects onto a plurality of carriers; b) conveying the carriers
with a supply conveyor towards an object-feeder; c) transporting at
least one of the carriers from the conveyor toward the feeder upon
a reciprocated transporter; d) after transporting, transferring
objects from the at least one carrier to the feeder; e) after
transferring, placing the at least one carrier upon a return
conveyor.
[0016] According to other embodiments, a mail handling system
includes: a) a feeder for feeding mail; b) a plurality of mail
carriers; c) a transporter upon which at least one of the mail
carriers can be placed; d) the transporter including a platform
that is movable along a path from a location proximate the feeder
to a location distal from the feeder so as to permit egress of a
feed operator around a periphery of the feeder.
[0017] According to other embodiments, a thin-object handling
system includes: a) a feeder for feeding thin-objects; b) a
plurality of carriers carrying a plurality of the thin-objects; c)
a conveyor for conveying the carriers toward the feeder; d) a
transporter arranged to transport at least one of the carriers from
the conveyor toward the feeder, the transporter being movable to
permit egress of a feed operator around a periphery of the feeder.
In the preferred embodiments, the thin objects include mail.
[0018] The above and/or other aspects, features and/or advantages
of various embodiments will be further appreciated in view of the
following description in conjunction with the accompanying figures.
Various embodiments can include and/or exclude different aspects,
features and/or advantages. In addition, various embodiments can
combine one or more aspect or feature from other embodiments. The
descriptions of aspects, features and/or advantages of particular
embodiments should not be construed as limiting other embodiments
or the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying figures are provided by way of example,
without limiting the broad scope of the invention or various other
embodiments. In the figures, like reference numerals designate like
or similar parts, wherein:
[0020] FIG. 1 is an elevational view of components of a system
according to some preferred embodiments of the invention;
[0021] FIG. 2 is an enlarged elevational view of, among other
things, preparation operation components of a system similar to
that shown in FIG. 1;
[0022] FIG. 3 is a schematic diagram depicting components that can
be employed to control the operation of a supply conveyor in some
illustrative embodiments of the invention;
[0023] FIG. 4 is an enlarged elevational view of, among other
things, feeder operation components of a system similar to that
shown in FIG. 1;
[0024] FIG. 5 is a schematic top elevational view of a plurality of
systems according to some illustrative embodiments of the
invention;
[0025] FIG. 6 is a schematic top view of a plurality of systems
according to some illustrative embodiments of the invention;
[0026] FIG. 7 is a schematic top view of a plurality of systems
according to some illustrative embodiments of the invention;
[0027] FIG. 8 is an elevational side view of two carriers that may
be employed in some illustrative embodiments of the invention;
[0028] FIG. 9 is an elevational view of a system according to some
preferred embodiments of the invention having common supply lines
between preparation operators and feeder operators; and
[0029] FIG. 10 is an elevational view of a system according to the
most preferred embodiments of the invention wherein carriers are
moved generally vertically to-and/or-from a feeder or other
system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] Various embodiments of the present invention can be employed
in a variety of systems and devices. In some non-limiting examples,
embodiments of the present invention can be employed within systems
similar to that shown in the '311 patent, such as, e.g., to enhance
processing at the feeder 10 shown in FIG. 1 of the '311 patent.
Additionally, various embodiments of the present invention can be
employed, in other non-limiting examples, for use with an
AFSM100.TM. flats sorting system.
[0031] While the preferred embodiments can be used to process mail
(including, for example, boxes, flats, envelopes, letters,
postcards and/or other mail), and the most preferred embodiments
can be used to process mail flats, various embodiments can also or
can alternatively be used to process other objects (such as, e.g.,
objects of any configuration). In the more preferred embodiments,
the objects comprise thin objects, such as, e.g., sheets, boards,
panels, magazines, paper goods and/or other thin objects. In some
preferred embodiments, mail flats are handled. In certain preferred
embodiments, a given system may handle a multitude of thin objects
(such as, e.g., mail flats) of different sizes and/or shapes at a
given time. However, the thin objects preferably fall within a
predetermined range of characteristics.
[0032] For example, in certain preferred embodiments, the system
can be adapted to handle mail flats having one or more of the
following characteristics. In some embodiments, each flat is
generally rectangular and: a) has a height of between about 12
inches and 5 inches; b) has a length of between about 15 inches and
6 inches long; and/or c) has a thickness of between about 0.75
inches and 0.009 inches. Moreover, in some embodiments, each flat
is also within one or more of the following weight limits: a) under
about 13 ounces (e.g., for first-class mail); b) under about 16
ounces (e.g., for standard mail); and/or c) under about 20 ounces
(e.g., for periodicals and bound printed matter). Moreover, in some
embodiments, each flat also meets various postal service (e.g.,
USPS) standards related to "turning ability" and/or "deflection."
While some preferred embodiments involve the handling of flats
having characteristics as discussed herein, numerous other
embodiments can be employed having various other flat
configurations or specifications, such as, e.g., that disclosed in
the '311 patent. The foregoing illustrative embodiments do not
limit the broad applicability of the invention to mail flats and/or
other objects or materials having other characteristics, which may
vary widely depending on the particular circumstances.
[0033] In some illustrative embodiments, a pre-processing system
can be provided so as to service one or more AFSM100.TM. system or
other system(s) and can include, for example, one or more,
preferably all, of the following: a full carrier supply conveyor
10; an empty carrier return conveyor 20; a movable container tilter
30; a fixed assist platform 40; a transfer slide 50; and/or a
plurality of mail carriers 60.
[0034] In illustrative embodiments, as shown in FIGS. 1 and 2,
bundled flat mail can be de-bundled and prepared directly from
hampers 30H into mail carriers 60 at the inlet end 10A of a supply
conveyor 10. The full carriers 60 can then be queued and
transported to a fixed assist platform 40 located between the
conveyor 10 and the feeder 100. The full carriers 60 can be moved
(e.g., using the fixed assist platform 40) onto a receiving region
110 at an inlet end of the feeder. The feeder operator OpF
preferably unloads the flats F into the feeder 100 and then places
the empty carrier 60 onto the empty carrier return conveyor 20.
[0035] While some embodiments can be used, e.g., with feeders that
feed mail, various other embodiments can be used with feeders that
feed other objects or materials. The terminology feeder includes,
as per Webster's II New Riverside Dictionary, "[a] device that
supplies . . . material" and is not limited to any particular form
of feeding or to any particular object fed.
[0036] Supply Conveyor:
[0037] In some illustrative embodiments, a full carrier supply
conveyor 10 can include a powered-roller, zone-accumulation
conveyor to queue and transport full carriers from a preparation
operator OpP loading zone (see, e.g., zone Z1 in FIG. 3 at the
inlet end 10A of the conveyor) to the fixed assist platform 40. The
conveyor 10 can include, e.g., a plurality of powered rollers 11.
In other embodiments, any other conveyor(s) can be employed, such
as, e.g., one or more rotary belt(s), one or more pusher(s), one or
more moving platform(s) and/or any other appropriate conveyor(s).
The downstream end of the supply conveyor can be located adjacent
to a location to which delivery is desired, such as adjacent a
feeder 100 (such as, e.g., an AFSM100 feeder). Preferably, there is
a distance Dl of at least about a few feet between the feeder or
the like and the discharge end of the conveyor (e.g., to enable an
operator to freely pass there-between). This distance D1 can be, in
some illustrative embodiments, between about 3 to 5 feet, and, in
one illustrative embodiment, about four feet, or, more preferably,
about 46 inches.
[0038] In some illustrative embodiments, the supply conveyor is
sufficiently long to handle a multitude of carriers at a given
time, such as, e.g., 2 or more carriers, or, more preferably, 3 or
more carriers, or, more preferably, 5 or more carriers. In some
illustrative examples, the conveyor can have a length DS of between
about 5 and 15 feet long. In some illustrative examples, the
conveyor can be between about 1 and 3 feet wide. In one
illustrative embodiment, the conveyor is about 10 feet long, about
2 feet wide and can store 5 carriers at a given time. In some
illustrative embodiments, the conveyor can run at a rate of between
about 25 and 75 feet per minute (FPM), and, in one illustrative
example, it can run at about 50 FPM. In some illustrative
embodiments, the supply conveyor is divided into five two-foot long
zones, such as, e.g., zones Z1-Z5 depicted in FIG. 3.
[0039] In some embodiments that have a plurality of "zones"
associated with the conveyor 10, as shown in FIG. 3, detectors or
sensors 18, such as, e.g., photosensors or photoeyes, can be
located, for example, at a downstream edge of each zone to detect
the presence of carriers thereon. The detectors 18 can, e.g.,
output signals identifying the presence and/or absence of carriers
at particular locations. In some embodiments, as shown in FIG. 3, a
controller, such as e.g., a computer, a processor or the like can
be used to selectively activate appropriate rollers via one or more
roller drive mechanism(s). In this manner, for example, rollers
within a particular zone can be automatically activated to convey
carriers. For instance, full carriers can be automatically moved
forward into empty downstream zones, such as, e.g., as they are
processed.
[0040] Preferably, a position detector or sensor 12, a pop-up stop
13 and an index push button 14 are located proximate the discharge
end 10B of the supply conveyor. The pop-up stop 13 is preferably
normally raised so as to prevent carriers 60 from moving off the
end of the supply conveyor 10 when the platform 40 is not in a
position adjacent thereto. Preferably, when the fixed assist
platform 40 is moved into a position adjacent the discharge end of
the supply conveyor, a coupling mechanism prevents the platform 40
from shifting. The position sensor 12 preferably verifies that the
platform is in position and locked. Preferably, upon such
verification, the pop-up stop 13 is automatically controlled so as
to lower to allow carriers 60 to be delivered off of the supply
conveyor. The control can be effected in a variety of ways, such
as, e.g., using a solenoid to move the pop-up stop and providing an
actuating current to the solenoid in response to a detection by the
sensor 12. In some embodiments, the control can utilize one or more
controller, such as, e.g., the controller shown in FIG. 3.
[0041] Preferably, the index push button 14 causes a full carrier
60 to be moved from a downstream zone of the conveyor 10 onto the
platform 40. The index push button 14 can, e.g., include a button
that is depressed by an operator (e.g., manually or the like). In
some embodiments, pushing the button 14 will cause the pop up stop
13 to retract and will cause at least some rollers 11 of the
conveyor to move the carrier forward.
[0042] Preferably, the operator is responsible for releasing the
coupling mechanism between the platform 40 and the conveyor after
the carrier has been safely transferred. This latter feature can
help to ensure that the platform 40 does not separate from the
supply conveyor while a full carrier is being transferred to the
platform 40. Once the assist platform 40 and the supply conveyor 10
are decoupled, the pop-up stop 13 is preferably automatically
actuated to pop-up into a blocking position.
[0043] Preferably, another index push button 15 and a fixed stop 16
are located at the inlet end 10A of the supply conveyor 10. As
discussed above, the preparation operator OpP fills empty carriers
60 at an upstream loading zone. Preferably, the fixed stop 16
prevents the carriers from moving off the inlet end of the
conveyor. The operator OpP can preferably depress the index push
button 15 to move a full carrier from the upstream loading zone Z1
forward via the conveyor 10. For instance, the index push button 15
preferably causes certain rollers 11 (e.g., within zone Z1 in the
example shown in FIG. 3) to rotate and move a carrier forward.
Preferably, an emergency stop pull cord 17 runs substantially along
the length of the supply conveyor to enable the conveyor to be
manually stopped, such as, e.g., by being manually actuated (e.g.,
pulled) to stop the conveyor 10 during some circumstances.
[0044] While the supply conveyor includes powered rollers in some
illustrative embodiments, one or more other conveyor(s) could be
employed in various other embodiments. For example, one or more
conveyor belt(s) and/or other conveyor can be included. The
terminology "conveyor" used in this application includes any
mechanism by which carriers can be moved, such as, e.g., one or
more rotary belt(s), one or more pusher(s), one or more moving
platform(s) and/or any other appropriate conveyor(s). In preferred
embodiments, such conveyor(s) is configured to have differentiated
carrier movement between a plurality of zones along the
conveyors.
[0045] Return Conveyor:
[0046] Preferably, an empty carrier return conveyor 20 is provided.
In preferred embodiments, the return conveyor 20 can be
substantially similar to the supply conveyor 10, but usable to
return empty carriers. In one illustrative embodiment, the return
conveyor 20 can be similar to the supply conveyor 10, such as,
e.g., in one illustrative example, about 10 feet long and about 2
feet wide. As with the supply conveyor 10, the dimensions of the
return conveyor 20 can vary based on circumstances. Preferably, the
return conveyor 20 is a powered-roller, low-pressure accumulation
conveyor. Preferably, the conveyor 20 or a substantial portion of
the conveyor 20 is located below the supply conveyor 10. In
preferred embodiments, the conveyor 20 is used to queue and
transport empty carriers to the preparation operator OpP.
[0047] As with the supply conveyor 10, the return conveyor 20, as
would be understood based on this disclosure, can include any
appropriate conveyor(s). Moreover, in some embodiments, the
operation of the return conveyor could also be controlled via a
controller or the like, such as, e.g., via the same controller
depicted in FIG. 3.
[0048] Hamper:
[0049] Preferably, a hamper 30H is provided for containing mail
flats. In some embodiments, a hamper 30H can include an open-top
container having a bottom and four side walls as illustrated, e.g.,
in FIGS. 1 and 2. In some illustrative and non-limiting
embodiments, a hamper tilter 30 is provided for manipulating the
hamper 30H. In some illustrative embodiments, a SOUTHWORTH PORTABLE
POSTAL CONTAINER TILTER (such as, e.g., model PTU-2DC) can be used.
These latter tilters have been used by the USPS for ergonomic
processing of certain material transport equipment. In some
instances, a tilting force can be applied to enable tilting of the
hamper 30H to an ergonomic position. In some instances, the tilter
can include a hydraulic power train with, e.g., a DC motor and a
hydraulic pump. The container tilter, in some embodiments, can have
a capacity of over 1,000 pounds (lbs) and preferably at least about
2000 lbs. Preferably, it is capable of rotating plastic and/or
canvas hampers, wiretainers and/or Gaylords more than about 60
degrees, and, preferably, up to at least about 80-90 degrees. In
one illustrative example, the tilter is supported by rollers (e.g.,
about 3 to 31/2 inches in diameter) on a front side and swivel
casters (e.g., about 6 inches in diameter) on a rear side.
[0050] Transporter (e.g., Fixed Assist Platform):
[0051] In preferred embodiments, a transporter is provided that
transports carriers to the feeder. Preferably, the transporter is
configured to transport at least one full carrier from the conveyor
to the feeder. The terminology transporter includes any device that
transports or conveys from one place to another. In preferred
embodiments, the transporter is movable to permit egress of a feed
operator around a periphery of the feeder. In various embodiments,
any form of transporter can be employed, such as, e.g., movable
platform(s), movable drawer(s), trolley(s), wheeled support(s),
vehicle(s), conveyor(s) and/or other appropriate transporter
device(s). In some preferred embodiments, the transporter is
reciprocatable. In some preferred embodiments, the transporter can
be reciprocated along a generally constant path of travel (e.g.,
along a track or the like), while in other embodiments the
reciprocation can involve a generally back-and-forth movement
between two locations that does not follow a particular path of
travel.
[0052] In some embodiments, a delivery system that delivers
carriers to a feeder can include one or more transporter and/or one
or more conveyor (such as, e.g., supply conveyor 10). The
terminology delivery system includes any system that delivers
objects and encompasses one or more, e.g., transporter(s),
conveyor(s) and/or the like.
[0053] In some preferred embodiments, the transporter can include a
platform, such as, e.g., fixed assist platform 40, that facilitates
transport to the feeder 100. The terminology platform encompasses
any structure that can support a carrier. In some embodiments, the
platform can include a generally flat surface, while in other
embodiments the platform can include a variety of other
configurations. In addition, a platform can include a plurality of
separate portions that together support one or more carrier. In the
illustrative embodiment shown in FIG. 1, the platform 40 is
supported via a frame 41 having at least one generally upright
support member 43 (two members 43 are shown in the illustrative
embodiment shown in FIG. 1) and at least one transverse member 42
(two members 42 are shown in the illustrative embodiment shown in
FIG. 1). In an illustrative embodiment, the platform 40 is
supported via at least one hanging support member 44 (two members
44 are shown in the illustrative embodiment shown in FIG. 1).
Preferably, each support member(s) is movably attached to at least
one transverse member 42 via a linearly movable attachment
mechanism 45 (such as, e.g., via linear bearings, rollers and/or
other suitable lateral moving mechanisms as would be apparent based
on this disclosure). Preferably, the linear bearings or other
moving mechanisms are configured to allow the platform 40 to be
moved along an axis that is substantially parallel to an axis along
the supply conveyor (e.g., at a discharge end thereof) and
connecting the supply conveyor 10 and the feeder 100. Moreover, the
direction of travel of the platform 40 is preferably parallel to
the direction of travel of the roller conveying surface of the
supply conveyor 10.
[0054] In some preferred embodiments, the platform 40 is manually
positioned along the frame 41, such as by manually pushing the
platform so as to slide it laterally across the frame 41. Thus, in
some preferred embodiments, the platform 40 is not moved via a
power source. However, in various embodiments, a motor and/or other
moving mechanism can be used to facilitate and/or to effect
movement of the platform 40 across the frame 41.
[0055] In preferred embodiments, the fixed assist platform 40 is
used to transport full carriers 60 from a discharge end of the
supply conveyor 10 to an upstream end of the feeder 100. In
preferred embodiments, the fixed assist platform 40 includes a
plurality of non-powered conveyor rollers for facilitating movement
of the carriers 60 to and from the assist platform 40. In some
illustrative embodiments, the platform 40 can include a non-powered
roller conveying surface that is between about 1-2 feet long, and,
more preferably, about 16 inches long, and about 1-3 feet wide,
and, more preferably, about 24 inches wide. In some illustrative
embodiments, the platform is moved between about 3-5 feet, and,
more preferably, about 4 feet, and, in some illustrative
embodiments, about 46 inches between a first functional position
40P1 adjacent the supply conveyor 10 and a second functional
position 40P2 adjacent the feeder 100, such as shown in FIG. 5.
[0056] In preferred embodiments, these two functional positions of
the platform are at each end of its effective travel. In the first
position 40P1, an inlet end of the platform 40 is preferably
located adjacent a discharge end 10B of the supply conveyor 10. In
the second position 40P2, the platform 40 is preferably located
adjacent to the feeder 100, such as, e.g., upon a region 110, such
that a full carrier located on the conveying surface of the
platform can be easily unloaded into the feeder 100.
[0057] In some illustrative embodiments, a supporting frame
structure and/or other supporting structure (such as, e.g., the
overhead type frame 41 shown in the illustrative embodiment) is
configured to facilitate at least one, preferably both, of the
following two criteria discussed below.
[0058] For the first preferred criteria, egresses to and/or around
a feeder 100 or the like are preferably maintained so as to be
sufficiently large (such as, e.g., egresses are preferably
substantially the same as that with an existing system, such as in
an existing AFSM100 system). In some illustrative embodiments, such
as shown in FIG. 5, full carriers 60 can be moved from a discharge
end 10B of the supply queue of the supply conveyor 10 to a
desirable unload position at the inlet of the feeder 100 without
blocking feeder operator egress 40E to, e.g., a backside of the
feeder. Preferably, the fixed assist platform 40 is usually
positioned either at a supply queue position 40P1 or at a feeder
position 40P2, such as depicted in FIG. 5. In the illustrative
embodiment shown in FIG. 5, when the fixed assist platform 40 is
positioned at location 40P1 adjacent the discharge end of the
supply conveyor, there is about a 30 inch aisle D2 between the
feeder 100A and a discharge end of fixed assist platform. In the
illustrative embodiment shown in FIG. 5, when the fixed assist
platform 40 is positioned at a location 40P2 adjacent the feeder,
there is about a 46 inch aisle D1 between the feeder 100C and the
discharge end of the supply conveyor. While these dimensions are
selected in some preferred embodiments, dimensions in other
embodiments can vary depending on circumstances. As merely some
non-limiting examples, these dimensions can be changed
plus-or-minus 10% in some embodiments, or plus-or-minus 25% in some
other embodiments, or plus-or-minus 50% in some other
embodiments.
[0059] With respect to the second preferred criteria, the feeder
operator is preferably allowed substantially full access to a side
of the carrier without, e.g., a need for reaching in a
non-ergonomic manner. For instance, the feeder operator is
preferably able to stand facing a side of the carrier substantially
without obstructions between the operator OpF and the prepared mail
(such as, e.g. shown at operator position OpF/40 in FIG. 5). Among
other things, substantially complete access to the carrier 60
and/or the prepared mail can help to ensure an ergonomic loading of
the feeder 100.
[0060] In some preferred embodiments, the fixed assist system
preferably includes one or more, preferably all, of the following
three control features.
[0061] A first control feature preferably includes the use of
non-powered rollers that are mechanically limited so as rotate in
only one direction (preferably, in substantially the same direction
of travel as the supply conveyor 10). Among other things, this can
enable the full carriers to be conveyed onto the platform 40, while
inhibiting them from backing off the platform when moved toward the
feeder 100. Preferably, the rollers are also lagged with a high
friction rubber sleeve (such as, e.g., to inhibit movement, such as
sliding, of the carriers 60 upon the platform independent of the
rotation of the platform rollers).
[0062] A second control feature preferably includes providing a
fixed stop at the downstream end of the platform so that full
carriers are inhibited from moving forward off the downstream end
of the platform. Among other things, combining a fixed platform
stop with a mechanically limited roller rotation (such as, e.g.,
according to the first control feature) can effectively trap a full
carrier, such as, e.g., when it is moved onto the platform.
[0063] A third control feature preferably includes that the
platform automatically couples (e.g., locks and/or latches) to,
e.g., the supply conveyor 10 and/or to a fixed support proximate
thereto when it is moved into the platform loading position 40P1
adjacent the discharge of the supply conveyor. Any appropriate
coupling mechanism (e.g., any appropriate lock and/or latch
mechanism) can be used. As merely one example, as shown
schematically within the dashed circle in FIG. 1, a coupling
mechanism 40C can be provided that includes a locking lever 40L
having a camming surface 40S that can cause the lever 40L to rotate
and/or move in a generally vertical direction by a camming action
over a fixed locking block 40B (wherein, the lever 40L and the
block 40B are fixed relative to a respective one or the other of
the platform 40 and the conveyor 10).
[0064] In preferred embodiments, a transfer slide 50 is also
provided on an upstream end of the feeder 100. In some preferred
embodiments, wherein an existing system, such as an AFSM100 system,
is being upgraded, an existing feeder may be retrofitted with such
a transfer slide. In some preferred embodiments, the elevation
and/or the angle of the transfer slide is set to allow the feeder
operator OpF to easily slide objects, such as, e.g., handfuls of
mail flats, from a carrier onto the feeder (e.g., onto a conveyor
belt of the feeder). In preferred embodiments, the objects (e.g.,
mail flats) do not have to be lifted to be loaded into the feeder.
Among other things, sliding the flats can allow the operator to
handle larger amounts of objects (e.g., larger handfuls of mail
flats) and/or can reduce the number of operator loading cycles. In
some illustrative and non-limiting embodiments, the transfer slide
can have a length of about 12 inches, a height of about 4 inches,
and be inclined at an angle of about 15 degrees.
[0065] Carriers:
[0066] In various embodiments, the object carriers 60 can have a
variety of constructions (e.g., depending on the characteristics of
the objects, such as, e.g., mail flats, to be carried). In some
preferred embodiments, the carriers are made with plastics
material. In some preferred embodiments, the carriers are formed by
a molding process, such as, e.g., by injection molding. In some
preferred embodiments, the carrier size is preferably selected so
as to fit a single carrier upon the platform 40 (such as, e.g.,
with a limited amount of extra space on the platform). In some
preferred embodiments, the carriers are constructed so as to weigh
less than about 10 pounds, and, more preferably, less than about 8
pounds, and, more preferably, approximately 6 pounds in some
illustrative embodiments. In some preferred embodiments, the
carriers are adapted to support mail flats and have a capacity of
holding more than one hundred mail flats, and, more preferably,
more than about 150 mail flats, and, in some illustrative
embodiments, approximately 170 mail flats.
[0067] In some preferred embodiments, side and bottom surfaces are
canted at an angle .alpha. (such as, e.g., between about 5 and 15
degrees, and, more preferably, approximately 10 degrees) to
effectively retain the prepared mail while it is transported on the
supply conveyor. Preferably, two small upwardly protruding
retaining edges 61 prevent the mail from sliding off the base
support wall 62 of the carrier 60. In addition, the base support
wall 62 is preferably generally transverse to a side support wall
63 at an angle .theta. (preferably, e.g., approximately 90
degrees). In preferred embodiments, the carriers are constructed so
as to include thin plastic walls and, preferably, the walls 62 and
63 are reinforced with ribs 62R and 63R, respectively, as shown. In
some illustrative embodiments, the carriers can have a length L of
about 16 to 24 inches, and, more preferably, about 20 inches. In
some illustrative embodiments, the carriers can have a width W of
about 10 to 20 inches, and, more preferably, about 15 inches.
[0068] As shown schematically in the dashed line circle shown in
FIG. 8, in some embodiments, an outer end 62E of the bottom support
wall 62 can include an overhanging section 62L, which is configured
to extend over an input edge of a transfer slide 50.
[0069] While some illustrative carrier designs have been depicted
and described, various embodiments can accommodate various carrier
designs. For example, various systems according to embodiments of
the present invention may operate with a variety of carrier types
and designs.
[0070] Operation:
[0071] In some illustrative embodiments, the operation of such
embodiments may be as set forth below.
[0072] With respect to preparation and queuing, a preparation
operator OpP is preferably stationed proximate an inlet end 10A of
the supply conveyor 10. A hamper 30H of bundled objects (e.g.,
bundled mail flats) is preferably positioned adjacent to the inlet
of the supply conveyor. Preferably, the hamper is located within a
few feet of the conveyor 10, and, most preferably, within arms
reach of the preparation operator OpP. The preparation operator
preferably uses a hamper tilter 30 to manipulate the hamper 30H
into an ergonomic position. During operation, the preparation
operator OpP preferably retrieves empty carriers from a discharge
of an empty carrier return line 20. The preparation operator
preferably places the empty carriers upon the upstream zone (such
as, e.g., zone Z1 shown in FIG. 3) at an inlet of the supply
conveyor 10.
[0073] Preferably, the preparation operator acquires bundles of
mail flats from the hamper 30H and removes the bindings that
maintain the mail flats in such bundles. In some preferred
embodiments, a hanging band cutter 30C (such as, e.g., shown in
FIG. 9) can be provided to facilitate cutting of the bindings.
After a binding is removed, the loose mail flats are preferably
placed onto a carrier 60. In some preferred embodiments, the mail
flats are placed with any bound edges down upon the carrier 60. The
position of the hamper 30H relative to the carrier, the use of the
hamper tilter, and the elevation of the carrier 60 (at a loading
zone of the supply conveyor 10) are preferably arranged so as to
minimize operator movement and to maximize operator ergonomics. In
the embodiment shown in FIG. 6, the hamper 30H is located
substantially next to the supply conveyor 10, wherein an operator
OpP faces the hamper and the supply conveyor at the same time. In
the embodiment shown in FIG. 7, the hamper 30H is located at an
angle (e.g., generally perpendicular) to the supply conveyor 10,
wherein an operator OpP can readily reach between such positions as
shown. In some preferred embodiments, the operator OpP is not
required to significantly walk and/or to significantly turn their
body (e.g., their torso). In some preferred embodiments, the
operator is not required to bend significantly, such as, e.g., in
some embodiments with a lower position return conveyor, an operator
merely bends once per carrier load (e.g., to retrieve an empty
carrier).
[0074] Preferably, once a carrier 60 upon the loading zone of the
conveyor 10 is full, the preparation operator OpP presses the index
button 15. Preferably, the supply conveyor 10 is then automatically
activated to move the full carrier forward into the next zone.
Various forms of automatic control can be used, such as, e.g.,
computer control systems, processors and/or any other control to
effect desired movement upon activation of the button 15 (such as,
e.g., using a controller as shown in FIG. 3). The prepared carriers
60 are preferably supplied via the conveyor 10 for transportation
to the fixed assist platform. If a carrier cannot be immediately
transported on the fixed assist platform, it is preferably queued
on the supply conveyor 10.
[0075] As shown in FIGS. 6 and 7, in some embodiments, one or more
feed operators OpF can be provided with backup hampers 30HB,
whereby feed operators can function as backup preparation operators
and prepare objects in the event that a full carrier is not present
for the feed operator. Among other things, this can help to
maximize use of personnel and resources.
[0076] With respect to feeder operation, in preferred embodiments,
the feeder operator manually moves the empty fixed assist platform
40 into position 40P1 at the discharge end of the supply conveyor.
As discussed above, a coupling mechanism preferably automatically
couples the fixed assist platform and the supply conveyor.
Preferably, the feeder operator OpF then presses the indexing
button 14 and waits until a full carrier is completely transported
onto the fixed assist platform 40. In some embodiments, the
operator can be relied upon to, in some or all instances, apply a
manual force (e.g., a small or moderate manual force) to help move
the carrier onto, e.g., non-powered rollers of the platform 40.
[0077] Preferably, once the carrier 60 is securely located on the
fixed assist platform, the feeder operator OpF manually decouples
the fixed assist platform from the supply conveyor. In preferred
embodiments, the operator OpF also manually moves the platform to
the carrier unload position 40P2 at the feeder 100. The feeder
operator OpF preferably removes the mail from the carrier and
places it into the feeder. Once all the mail has been emptied from
the carrier, the feed operator OpF can, e.g., place the empty
carrier onto the carrier return line.
[0078] As discussed above, the mail flats are preferably removed
from the carrier and placed onto the feeder without the need for
the operator to significantly lift the flats, to significantly
carry the flats, to significantly reach his or her body and/or to
significantly bend his or her body. Additionally, in preferred
embodiments, the feed operator's need to walk and/or to turn can be
significantly reduced.
[0079] Other Embodiments
[0080] In other embodiments, the various aspects, features and/or
embodiments described above can be modified.
[0081] In some embodiments, for example, the fixed assist platform
40 can have a powered conveying surface. For instance, an electric
motor (not shown) could also be supported via the support members
44. The motor could be, e.g., laterally moved along with the
platform. Moreover, the motor could be, e.g., coupled to effect
rotation of the rollers on the platform.
[0082] In other embodiments, for example, a non-manual (e.g.,
automatic) moving mechanism could be provided to effect and/or to
facilitate movement of the fixed assist platform (such as, e.g.,
between positions 40P1 and 40P2), rather than, or in addition to,
manually moving the platform there-between.
[0083] In other embodiments, for example, the platform 40 can be
raised and/or lowered to interface with the empty carrier line 20,
and/or to interface with the supply line and/or to interface with
other processing equipment. In some embodiments, this raising
and/or lowering action could be imparted manually. In some
embodiments, this raising and/or lowering action could be imparted
via a non-manual mechanism, such as via a motor-driven elevator
mechanism. In some illustrative examples, the platform 40 could be
movably supported upon the support member(s) 44 via a motor driven
drive chain.
[0084] In other embodiments, for example, the platform 40 can have
a frame and/or support structure that is supported from below,
rather than from above. Furthermore, in other embodiments, for
example, the platform 40 could be supported upon a frame and/or
other structure that is suspended from a ceiling and/or from
another structure.
[0085] In other embodiments, for example, the supply conveyor
system, the empty conveyor system and/or the fixed assist platform
system could be constructed so as to be movable. For instance, one
or more, or all, of these systems could be fitted with wheels or
casters to allow the system to be moved within a facility or the
like.
[0086] In other embodiments, as shown for example in FIG. 9, a
plurality of supply lines 10 could be fed by a main trunk line 10M.
In the illustrative embodiment shown in FIG. 9, the main trunk line
10M can feed to the supply lines 10 via lateral (e.g., right-angle)
transfer mechanisms. As also illustrated in FIG. 9, in some
embodiments, a similar empty carrier return line 20M can be
positioned proximate (e.g., underneath) the supply line. In some
embodiments, the main trunk line 10M could be fed from a plurality
of preparation workstations PW (while three workstations are shown
in the illustrated embodiment, other embodiments can include any
desired number of workstations), such as via lateral (e.g.,
right-angle) transfer mechanisms 10L. Similarly, empty carrier
return or recirculation lines can be positioned proximate (e.g.,
underneath) the workstation lateral transfer mechanisms as shown.
FIG. 9 also shows an optional flats tub supply line 10FT that can
be provided in some other embodiments. For instance, a flats tub
supply line could be used to supply tubs of flats from other
sources, such as, for example, from postal service tray management
systems (TMS), or from other sources.
[0087] Other Most Preferred Embodiments
[0088] FIG. 10 illustrates some aspects and features according to
some most preferred embodiments of the invention. In the
embodiments shown in FIG. 10, a generally vertical elevator 200 is
provided. In preferred embodiments, the elevator 200 includes a
conveyor system for moving carriers up-and-down between a supply
conveyor 10M (such as, e.g., having rollers, as shown, or other
conveyor mechanisms as described above) and a return conveyor 20M.
In some preferred embodiments, the elevator conveyor system
includes two platforms, including an upper platform 40E for
conveying empty carriers 60E and a lower platform 40F for conveying
full carriers 60F. In some illustrative embodiments, the platforms
40E and 40F can be mounted together so as to remain a fixed
distance from one another (e.g., a distance substantially equal to
the distance between the conveyors 10M and 20M). In FIG. 10, the
leftmost elevator shows an empty carrier 60E and a full carrier 60F
in transport together. In some instances, however, the platform 40E
may be without another carrier during transport of a full carrier
60F to the feeder 100. Then, upon transfer of the objects to the
feeder, the emptied carrier can be placed upon the platform 40E.
The elevator can then raise the platforms such that the empty
carrier 60E is laterally discharged to the conveyor 20M, and, such
that a full carrier is laterally moved to the platform 40F. Then,
the elevator can lower the new full carrier to continue the
process. In other embodiments, the platforms 40E and 40F can be
controlled so as to move independently from one another. In other
embodiments, the platforms could be located adjacent one another
(e.g., with a modified elevator 200 having, e.g., plural elevator
shafts) so that upward and/or downward movement may occur
independently of one another. However, mounting both platforms to
move along a path having a common axis can enhance space saving
characteristics and improve egress around the feeder 100.
[0089] In the illustrative embodiment shown in FIG. 10, the
elevator 200 includes a support frame 41. Preferably, the elevator
has transparent and/or translucent walls or windows (such as, e.g.,
made of glass, plexiglass, plastic or the like) to enable the
interior to be viewed during operation. Preferably, the conveyors
10M and 20M include lateral guide rails (shown), support edges or
the like to help retain the carriers thereon. Preferably, carriers
60E and/or 60F are delivered between the conveyors 10M and/or 20M
via lateral transfer mechanisms, such as discussed above.
Additionally, in some preferred embodiments, sensors or detectors,
such as discussed above, can be used to facilitate control of the
system based on carrier positioning. For instance, the lateral
transfer mechanisms can be controlled based on carrier presence
within the elevators 200 and the like in some embodiments.
[0090] In some illustrative embodiments, the platforms 40E and 40F
can include mechanisms to facilitate transfer to and/or from the
platform. For instance, in some embodiments, the platforms can
include powered rollers or powered casters to facilitate movement
along one or two axes (e.g., parallel to the platform). In this
manner, the carriers can easily be transferred to and/or from the
platforms (such as, e.g., at their upper positions proximate the
conveyors 10M and 20M and/or at their lower positions proximate the
feeder operator OpF). In some preferred embodiments, the front of
the elevators 200 in front of the operator OpF will include
openings, doors, gates or the like to enable access to the carriers
on the platforms 40E and/or 40F by the operator OpF. In some
preferred embodiments, fixed and/or pop-up stops can be used to
limit movement of the carriers from the elevator until desired by
the operator OpF.
[0091] In some preferred embodiments, the conveyors 10M and 20M
shown in FIG. 10 can extend to another elevator (not shown) similar
to the elevators 200. This latter elevator can then assist in the
transfer of the carriers to-and/or-from one or more preparation
operator location. For example, this elevator can then transfer the
carriers to additional conveyors and structure similar to that
shown to the left side of the dashed line A-A in FIG. 9, similar to
that shown to the right side of the dashed line B-B in FIG. 2, or
to other appropriate conveyors and/or structures as would be
understood based on this disclosure. In some preferred embodiments,
rather than maintaining the supply conveyor in a lower position as
shown in FIG. 10 when it reaches the preparation operator OpP, the
conveyors would be adapted to allow the preparation operator OpP to
place carriers on a supply conveyor 10 at an elevation similar to
that shown in FIGS. 2 and 9 (such as, e.g., by ramping the
conveyors 10 and/or 20 upward and/or downward to a desired level,
such as, e.g., to positions similar to that shown in FIGS. 2 and
9).
[0092] Various aspects of the embodiments described above with
reference to FIGS. 1-9 can be employed in the embodiments depicted
in FIG. 10.
[0093] In some illustrative embodiments, the feeder 100 can include
a conveyor belt 120 extending along a substantial portion of a top
surface thereof and a pusher 130. The pusher 130 can be controlled
so as to follow the conveyor belt 120 so as to act as a kind of
"book end" for thin objects, such as, e.g., mail flats, placed on
their narrow ends in a side-by-side manner at a right side of the
pusher 130 (with reference to FIG. 10). The conveyor belt 120 and
the pusher 130 can move flats F laterally into the feeder for
delivery into the mail processing system 300. In some embodiments,
the pusher 130 is mounted such that, when desired it can be
manually grasped at handle 130H and raised upward and moved back to
a left side of the conveyor belt 120 to support additional flats.
Preferably, the pusher 130 is disengaged from its associated drive
mechanism upon being lifted and is re-engaged with its associated
drive mechanism upon being lowered back toward the conveyor belt
120.
[0094] While illustrative embodiments of the invention have been
described herein, the present invention is not limited to the
various preferred embodiments described herein, but includes any
and all embodiments having modifications, omissions, combinations
(e.g., of aspects across various embodiments), adaptations and/or
alterations as would be appreciated by those in the art based on
the present disclosure. The limitations in the claims are to be
interpreted broadly based the language employed in the claims and
not limited to examples described in the present specification or
during the prosecution of the application, which examples are to be
construed as non-exclusive. For example, in the present disclosure,
the term "preferably" is non-exclusive and means "preferably, but
not limited to." Means-plus-function or step-plus-function
limitations will only be employed where for a specific claim
limitation all of the following conditions are present in that
limitation: a) "means for" or "step for" is expressly recited; b) a
corresponding function is expressly recited; and c) structure,
material or acts that support that structure or step are not
recited.
* * * * *