U.S. patent application number 11/038032 was filed with the patent office on 2005-06-30 for flats sequencing system and method of use.
Invention is credited to McLaughlin, Jason G., Wisniewski, Michael A..
Application Number | 20050143856 11/038032 |
Document ID | / |
Family ID | 32849641 |
Filed Date | 2005-06-30 |
United States Patent
Application |
20050143856 |
Kind Code |
A1 |
McLaughlin, Jason G. ; et
al. |
June 30, 2005 |
Flats sequencing system and method of use
Abstract
A system and method sequencing objects in trays by assigning a
direction to tray locations, where each of the tray locations
provides space for trays. The objects are placed into the trays
corresponding to assigned directions of the objects. A
determination is made as to whether there are additional objects
that correspond to the direction and, if so, the direction is
assigned to unassigned tray locations based on pre-defined rules.
Once all of the objects are in the trays, the trays are moved to
the feeder system in a sequential order based on the directions. In
a second pass, the directions are reassigned to the tray locations
based on a number of trays required to hold the objects. The
objects are placed into the trays corresponding to the directions
of the objects. The trays are then transported to an unloading
stage in a sequential order corresponding to the reassigned
directions.
Inventors: |
McLaughlin, Jason G.;
(Owego, NY) ; Wisniewski, Michael A.; (Owego,
NY) |
Correspondence
Address: |
GREENBLUM & BERNSTEIN, P.L.C.
1950 ROLAND CLARKE PLACE
RESTON
VA
20191
US
|
Family ID: |
32849641 |
Appl. No.: |
11/038032 |
Filed: |
January 21, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11038032 |
Jan 21, 2005 |
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10365639 |
Feb 13, 2003 |
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6881916 |
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Current U.S.
Class: |
700/218 |
Current CPC
Class: |
Y10S 209/90 20130101;
B07C 3/00 20130101 |
Class at
Publication: |
700/218 |
International
Class: |
G06F 007/00; B65G
047/10; B65G 047/46; B07C 005/00; G06K 009/00 |
Claims
1-43. (canceled)
44. A method of sequencing objects in trays located at tray
locations of bin sections, comprising: moving filled trays with
objects through a feeder system in sequential order based on a
direction; reassigning the direction to tray locations based on a
number of trays required to hold the objects in the reassigned
direction; and placing the objects into the trays at the tray
locations associated with the reassigned directions.
45. The method of claim 44, further comprising: pre-assigning the
direction to the tray locations; providing an unassigned
designation to at least one tray location of the tray locations,
the tray locations providing space for the trays; placing the
objects into the trays of the tray locations with the direction
corresponding to assigned directions of the objects; and
determining whether there are additional objects requiring
placement which correspond to the direction and, if so, assigning
the direction to an unassigned tray location based on pre-defined
rules and placing the objects in the trays of the subsequently
assigned tray locations.
46. The method of claim 44, further comprising transporting the
trays with the objects to a loading area in a sequential order
corresponding to the reassigned direction.
47. The method of claim 44, wherein: the reassigned direction is a
set of sequenced delivery or storage points; and the tray locations
include at least one front tray location and at least one back tray
location; the tray locations are positioned in one or more
partitions; and at least one front tray location of each partition
includes an unassigned designation.
48. The method of claim 47, wherein the moving step comprises: (i)
determining whether a front tray in the front tray location is
filled with objects for a pre-assigned direction; (ii) determining
whether a transporting system is empty in front of the front tray;
(iii) determining whether a lower direction assigned tray will be
blocked by moving the front tray onto the transporting system; and
(iv) moving the front tray onto the transporting system when steps
(i) and (ii) are positive and step (iii) is negative.
49. The method of claim 47, further comprising waiting until the
first pass is complete when at least one of the step (ii) is
negative and step (iii) is positive.
50. The method of claim 47, further comprising moving a back tray
to the front tray location and, if required, placing an empty tray
at the back tray location.
51. The method of claim 44, wherein the reassigning step includes
assigning pre-assigned directions to the tray locations based on:
(i) recorded data used in a first pass; (ii) scanning away from a
sweep order; and (iii) assigning a direction to a first available
tray location in a direction away from the sweep order starting
with a lowest direction.
52. The method of claim 51, wherein the reassigning step further
comprises: determining whether there are more than two trays in a
same direction; and assigning the same direction to a next
available tray location, always filling a front tray location
first, when there are not more than two trays in the same
direction.
53. A system for sequencing objects in trays located at tray
locations of bin sections, comprising: means for moving trays with
objects through a transporting system in sequential order based on
predefined rules; means for reassigning a direction to tray
locations based on a number of trays required to hold the objects
in the reassigned direction; and means for transporting the trays,
once objects are placed in the trays having a corresponding
direction, to an unloading area based on a sequential order of the
reassigned directions.
54. A system for sequencing objects in trays located at tray
locations of bin sections, comprising: means for moving filled
trays with objects in sequential order based on a direction; means
for reassigning the direction to tray locations based on a number
of trays required to hold the objects in the reassigned direction;
and means for placing the objects into the trays at the tray
locations associated with the reassigned directions.
55. The system of claim 54, wherein the moving means is a
continuous looped carousal system.
56. The system of claim 54, further including a control system for
controlling the system of claim 54.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to a sequencing
system and method of use and, more particularly, to a sequencing
system and method of use for flats and other objects.
[0003] 2. Background Description
[0004] In view of increased demand on postal systems, worldwide, it
has become very important to automate the sorting and delivery
sequence of mail products such as magazines, newspapers, packages
and other articles or flats. These automated processes must be able
to sort the mail pieces in a delivery sequence so as to enable a
postal carrier the ability to deliver the mail pieces in the most
efficient route. This translates into less carriers needed to cover
the number of delivery points along each delivery route. This
ultimately reduces costs while increasing the productivity of the
carrier. Without the automated processes, it would be virtually
impossible for the postal system such as the United States Postal
Service (USPS) to efficiently delivery the flats in a time
sensitive and cost efficient manner.
[0005] Initially, the mail pieces are provided in random order to
the postal service prior to being sequenced. In the past, these
mail pieces were manually sequenced, but these manual processes
were labor intensive and quite inefficient. This has led to the
advent of automated systems, with much efficiency now being borne
into the system. In the automated processes, increased accuracy and
speed has become possible using bar code readers, feeding systems
and transport systems and the like. In one type of automated
system, for example, a multiple pass process is utilized which
requires a first pass for addresses to be read by an optical
character reader and thereafter the use of a multiple-pass sorting
process. In the first pass, the mail pieces are separated into bins
or holding trays and multiple further passes are used to reach a
delivery sequence order. The bar-code labeling process and
additional sorting steps required, however, involves additional
processing time and sorting machine overhead as well as additional
operator involvement to reach the result of delivery order
sequence.
[0006] By way of one example, an automated system using a two pass
algorithm is used to sort and sequence mail pieces. In this system,
bar code readers and transport systems are used, but many
shortcomings become apparent when using this type of system. For
instance, the bar-code labeling process and additional sorting
steps involves additional processing time, the need for sorting
holding bins and additional operator involvement. Also, it is known
that the sorting steps are prone to error thus leading to improper
sequencing of the mail pieces, as the final product.
[0007] By use of a specific example to illustrate these
shortcomings, a carousel-type system is able to handle
approximately 40,000 pieces of mail per hour, and uses different
holding trays for different set of delivery points. In using this
type of system, each holding tray is provided in a bin section
which is only capable of placement of a single holding tray. With
this system, due to the limits of the holding tray placement spots
and other shortcomings, the holding trays cannot be sequenced on
the carousel, itself, but must be taken from the carousel, stored
within a large storage area (flooring space), sorted, and returned
to the carousel for a second pass. In the sorting process, many
sorting errors result which reduces the efficiency of the system
and leads to improper sequencing of the mail pieces.
[0008] Referring again to the specific example utilizing a two pass
algorithm, directions are assigned to a set of delivery points, all
of which are assigned to each partition in the carousel. Taking
four directions with 16 delivery points, for example, a first
portion of the algorithm may assign the following directions to
each delivery point:
1 Direction #1 1 5 9 13 Direction #2 2 6 10 14 Direction #3 3 7 11
15 Direction #4 4 8 12 16
[0009] That is, in row #1 (direction 1) there are delivery points
for 1, 5, 9 and 13. In row #2, (direction 2) there are delivery
points for 2, 6, 10 and 14. In row # 3 (direction 3), there are
delivery points for 3, 7, 11 and 15. Lastly, in row #4 (direction
4), there are delivery points for 4, 8, 12 and 16.
[0010] However, these sets of delivery points are not in any
particular order. Also, due to the large volume of mail pieces
assigned to a particular direction, it is necessary to have several
holding trays for a particular number of mail pieces associated
with a delivery point. But, in such an assignment, when the holding
trays become filled, it is necessary to remove the holding trays
from the carousel, place an empty holding tray at the respective
bin section and continue filling the holding tray for that
direction. When the holding tray is removed, though, it must be
stored in a storage area until all of the holding trays are filled
or all of the mail pieces for the particular carousel run have been
placed in the respective holding trays. As can be imagined, this
takes an enormous amount of valuable floor space, and additionally,
requires the sorting of the holding trays into a proper order prior
to a second pass through the system. The sorting process is time
consuming and prone to sorting errors. In many instances, the
sorting of the holding trays also has to be performed manually,
which adds to time, cost and labor.
[0011] Once the holding trays are properly sorted, they are again
fed back through the system. In doing so, it is now possible to
reassign the directions in the following manner, for example,
2 Direction #1 1 2 3 4 Direction #2 5 6 7 8 Direction #3 9 10 11 12
Direction #4 13 14 15 16
[0012] Now, each direction is a provided in sequenced set of
delivery points. That is, direction 1 has delivery points for 1, 2,
3 and 4. Direction 2 has delivery points for 5, 6, 7, and 8.
Direction 3 has delivery points for 9, 10, 11 and 12. Lastly,
direction 4 has delivery points for 13, 14, 15 and 16.
[0013] But, it should be understood that the same problem exists.
That is, after each holding tray is filled, it must be removed from
the system, placed in a storage stage, and eventually sorted for
future delivery. In the sorting process, it is necessary to ensure
that the holding trays holding the mail pieces are provided in a
proper sequence so as to enable the carrier to easily traverse his
or her route in the most time and cost efficient manner. But,
sorting errors are abound resulting, in many instances, an improper
sequence order of the trays. This, of course, may lead to the
improper delivery of the mail pieces to an incorrect delivery
point.
[0014] Although this type of system is an improvement over manual
sorting and sequencing, and allows for less delivery errors, there
still remain many shortcomings. These shortcomings include sorting
errors, the need for increased flooring space for storage,
increased sorting and sequencing runs and the like. Also, if there
are sorting errors, the carrier may find it difficult to
efficiently traverse the assigned route, with many mail pieces
being improperly delivered or undelivered. Also, there may be
instances when manual intervention is needed, which increases labor
costs and lowers efficiencies throughout the entire system. Thus,
it is evident that much economy and improvement in delivery service
could be obtained by accurately ordering of the mail pieces without
the requirements for sorting of the holding trays and the like.
[0015] The present invention is directed to overcoming one or more
of the problems as set forth above.
SUMMARY OF THE INVENTION
[0016] In a first aspect of the present invention, a method is
provided for sequencing objects in trays located at tray locations
of bin sections. The method includes assigning a predetermined
direction to tray locations, where each of the tray locations
provides space for trays. The predetermined direction may include a
same direction or different directions for each tray location. The
steps of this first aspect of the invention further include
providing an unassigned designation to at least one tray location
which provides tray space for placement of objects such that the
placed objects remain in sequence. The objects are placed into the
trays which correspond to assigned directions of the objects. A
determination is made as to whether there are additional objects
requiring placement corresponding to the same predetermined
direction and, if so, the method assigns the predetermined
direction to unassigned tray locations based on pre-defined rules.
The objects are placed in the trays at the subsequently assigned
tray locations. The trays are moved to the feeder system in a
sequential order based on the predetermined direction.
[0017] In a second pass utilizing the first aspect of the present
invention, the method includes reassigning the predetermined
direction to the tray locations based on a number of trays required
to hold the objects. The reassigning step ensures that a lower
number reassigned direction is in front of a higher number
reassigned direction in an unloading direction. The objects are
placed into the trays of the tray locations corresponding to the
directions associated with the objects. The trays are then
transported to an unloading stage area in a sequential order
corresponding to the reassigned direction.
[0018] In a second aspect of the present invention, the method
includes providing a direction to front tray locations based on
first pass pre-assignment rules. The direction may be a same
direction or different directions dependent on an amount of routes
required. The method includes a commencement of a first pass and a
second pass. In the first pass:
[0019] (i) at least one front tray location is provided with an
unassigned designation. The at least one front tray location
provides tray space for placement of objects;
[0020] (ii) the objects are placed into trays corresponding to the
direction associated with the objects;
[0021] (iii) the filled trays are moved onto a transporting system
only if lower assigned trays remain unblocked. The moved trays will
provide an empty tray location;
[0022] (iv) the empty tray location may be now designated as
unassigned;
[0023] (v) a determination is then made as to whether there are
additional objects requiring placement which correspond to the
direction. If so, the direction will be assigned to the unassigned
tray locations for placement of the additional objects; and
[0024] (vi) the trays will be moved to a feeder system in
sequential order of the assigned direction.
[0025] In the second pass of the second aspect of the
invention,
[0026] (i) the direction will be reassigned to the tray locations
based on a number of trays required to hold the objects in the
reassigned direction and, in aspects, whether there are more than
two trays having a same assigned direction;
[0027] (ii) the objects will be placed into the trays at the tray
locations associated with the reassigned directions. Each placed
object is related to one of the reassigned directions of the tray
locations in which the objects are placed; and
[0028] (iii) the trays will be transported to an unloading area
based on a sequential order of the reassigned directions.
[0029] In still another aspect of the present invention, a method
of sequencing objects in trays located at tray locations of bin
sections is provided. In the steps of this aspect, directions to
tray locations are pre-assigned. Objects are placed in a tray in
one of the tray locations such that each placed object is related
to one of the directions of the tray locations in which the objects
are place. The filled trays are moved in sequential order based on
the directions. The tray locations are reassigned the direction and
the objects are placed into the trays at the tray locations
associated with the reassigned directions. The trays are
transported to an unloading area based on a sequential order of the
reassigned directions.
[0030] In yet another aspect of the present invention, a system for
sequencing objects in trays located at tray locations of bin
sections is provided. In this system a module is provided which
assigns a predetermined direction to tray locations. The
predetermined direction includes a same direction or different
directions and each of the tray locations provides space for trays.
A first pass module controls the assignment designation to at least
one tray location of the tray locations. This module also controls
placement of the objects into the trays of the tray locations
corresponding to assigned directions of the objects. The first pass
module also determines whether there are additional objects
requiring placement which correspond to the predetermined direction
and, if so, assigns the predetermined direction to unassigned tray
locations based on pre-defined rules. Thereafter, the first pass
module controls the movement of the trays to a feeder system in
sequential order based on the predetermined direction.
[0031] The second pass module of this aspect of the invention
controls the reassignment of the predetermined direction to the
tray locations based on a number of trays required to hold the
objects. The reassignment ensures that a lower number reassigned
direction is in front of a higher number reassigned direction in an
unloading direction. The second pass module then controls placement
of the objects into the trays and transportation of the trays to a
loading area in a sequential order corresponding to the reassigned
direction.
[0032] In another aspect of the present invention, a system is
provided for sequencing objects in trays located at tray locations
of bin sections. The system includes a mechanism for pre-assigning
a direction to tray locations adapted for placing trays and a
mechanism for placing an object in a tray corresponding to the
direction. Additionally, a mechanism is provided for moving trays
with the objects through a transporting system of the feeder system
in sequential order based on predefined rules. A mechanism is
provided for reassigning the direction to the tray locations based
on a number of trays required to hold the objects in the reassigned
direction. A mechanism is also provided for transporting the trays
once objects are placed in the trays having a corresponding
direction to an unloading area based on a sequential order of the
reassigned directions.
[0033] In another aspect of the present invention a sequencing
system includes at least one feeder having a reading device and a
moving mechanism provided to hold a plurality of holding devices.
The system further includes at least one bin positioned adjacent to
the moving mechanism, each bin being designated with at least one
front tray location and at least one rear tray location capable of
being assigned to a direction. A transporting system is adjacent
the front tray location. The transporting system either transports
objects to the at least one feeder and to a delivery point in
sequential order.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] The foregoing and other objects, aspects and advantages will
be better understood from the following detailed description of a
preferred embodiment of the invention with reference to the
drawings, in which:
[0035] FIG. 1 shows an embodiment of the tray sequencing system of
the present invention;
[0036] FIG. 2 shows an example of a first pass pre-assignment rule
in accordance with an embodiment of the present invention;
[0037] FIG. 3 shows a flow diagram for sequencing flats during a
first pass using an embodiment of the tray sequencing system of
FIG. 1;
[0038] FIG. 4 shows a flow diagram for sequencing flats during a
first pass using an embodiment of the tray sequencing system;
[0039] FIG. 5 is an illustrative example using the flow steps of
FIGS. 3 and 4;
[0040] FIG. 6 shows a flow diagram for sequencing flats in a
delivery order after completion of the first pass; and
[0041] FIG. 7 is an illustrative example using the flow steps of
FIG. 6.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
[0042] The present invention is directed to a system and method for
sequencing flats and other objects. These flats and objects,
hereinafter referred to as flats, may be mail pieces, magazines,
catalogs, bundles or other defined objects having certain
predefined dimensions. The system and method of the present
invention may be used to sequence flats for delivery by a postal
system such as the United States Postal Service, or is also well
adapted to sequencing flats for warehousing or storage. By using
the method and system of the present invention, sorting and
excessive movement of holding trays may be eliminated thus reducing
the need for additional flooring space, as well as eliminating
potential sorting errors due to excess sorting steps. The use of
the present invention also reduces the steps needed to sequence the
flats and thus reduces associated costs and the like.
Embodiments of Flats Sequencing and Method of Use of the Present
Invention
[0043] FIG. 1 shows an embodiment of the tray sequencing system of
the present invention. The tray sequencing system of the present
invention is generally depicted as reference numeral 10 and
includes a plurality of flat feeders 12a-12d, each having a bar
code scanner 14a-14d, respectively, or other optical reading
device. Those of ordinary skill in the art, though, should
recognize that any number of feeders and respective optical reading
devices may be used with the present invention and that the use of
four flat feeders and respective optical reading devices is
provided for illustrative purposes only. Thus, the present
invention is not limited to any number of flat feeders and
respective reading devices.
[0044] Still referring to FIG. 1, a carousel 16 is provided to hold
a plurality of carriers 18. The carousel 16, in one embodiment, is
a two tiered continuous looped transport system in which each
carrier 18 is designed to include four pockets, each assigned to a
respective flat feeder 12a-12d. In use, the feeders 12a-12d are
designed to deposit flats into the respective carriers 18 for
transport to holding trays 20 positioned at a respective bin 22.
The holding trays may be designed to hold any number of flats,
depending on the application of the present invention. Information
from the flats are read by the bar code scanners or other optical
devices and stored for future use by the system of the present
invention. A control system "C" controls the system and processes
of the present invention. The deposited flats may be transported
from the feeders to the carriers and then into the trays by any
well-known or conventional system. For example, the system may use
known robotics, mail handling systems and like to effectuate the
handling of the flats throughout the entire system.
[0045] At each bin 22, is a front tray location 22a and rear or
back tray location 22b each capable of being assigned to a
direction (i.e., a logical assignment of a set of delivery points
selected for sequencing the flats). In embodiments, the front tray
location 22a is located closest to a conveying system 24 and the
back tray location 22b is located farthest from the conveying
system 24. In embodiments, for example, the front tray location 22a
may be on a first side of the carousel 16 closest to the conveying
system 24 and the back tray location 22b may be on the other side
of the carousel 16, farther away from the conveying system 24. Of
course, there may be other configurations following this ordering
scheme, and additionally there may be three or more tray locations
for each bin section, depending on the application of the present
invention. The trays 20 are transported to the tray locations via a
tray conveying system 26. The conveying system may carry the trays
(i) back to the feeders for a second pass or (ii) in a sequential
delivery order to an unloading area for future delivery or storage
after the second pass is complete.
[0046] FIG. 2 shows an example of a first pass pre-assignment rule
in accordance with an embodiment of the present invention. In this
illustration, the pre-assignment rule is associated with the use of
the tray sequencing system 10 of FIG. 1. That is, the first pass
pre-assignment rule of FIG. 2 is used with a system having four
feeders and includes four partitions. In addition, the example of
FIG. 2 uses 360 bin sections numbered 1 through 360, each bin
section having a front tray location and a back tray location. In
the example of FIG. 2, each partition thus has 90 bin sections
(i.e., 360 bins/4 partitions). Also, in the example of FIG. 2, 85
directions are assigned to each of the four partitions thus
providing for 340 directions. The directions, in this example, are
merely illustrative of an amount of routes the present invention
will sequence for future delivery. The directions may be assigned
in the following manner: 650 delivery points per carrier (any
arbitrarily assigned number) are multiplied by 11 carriers for each
partition. This equals 7150, of which the square root equals
approximately 85 directions.
[0047] In the pre-assignment rule, directions are assigned to a
respective tray location, with the exception of at least one front
tray location being unassigned. In this example, all back tray
locations are unassigned. The use of the unassigned tray
location(s) will become apparent in view of the flow diagrams and
further examples discussed below.
[0048] In the example of FIG. 2, the first pass pre-assignment rule
assigns 85 directions to each partition. In the 1.sup.st partition,
directions 1-85 are pre-assigned to front tray locations of bin
sections 6-90, leaving bin sections 1-5 unassigned. In the 2.sup.nd
partition, directions 86-170 are pre-assigned to front tray
locations of bin sections 91-175, leaving bin sections 176-180
unassigned. In the 3.sup.rd partition, directions 171-255 are
pre-assigned to front tray locations of bin sections 186-270,
leaving bin sections 181-185 unassigned. In the 4.sup.th partition,
directions 259-340 are pre-assigned to front tray locations of bin
sections 270-355, leaving bin sections 356-360 unassigned. It
should be recognized that due to the configuration of the looped
carousel, the bin sections of the 1.sup.st and 3.sup.rd partitions
will be numbered in increasing sequential order leading away from
the feeders. In contrast, the bin sections of the 2.sup.nd and
4.sup.th partitions will be numbered in increasing sequential order
as they are located closer to the feeders.
[0049] Those of ordinary skill in the art should recognize that
more or less than four partitions might be used with more or less
than 360 bin sections. Additionally, the numbering of the bin
sections may also vary depending on the configuration of the looped
carousal, the number of delivery points, etc. By way of example,
two partitions each having 50 bin sections and 45 directions may be
implemented using the first pre-assignment rule of the present
invention. In this scenario,
[0050] (i) directions 1-45 may be pre-assigned to the front tray
locations of bin sections 6-50, with front tray locations of bin
sections 1-5 being unassigned, and
[0051] (ii) directions 46-90 may be pre-assigned to front tray
locations of bin sections 56-100, with front tray locations of bin
sections 51-55 being unassigned.
[0052] As another example, 48 directions may be assigned to the 50
bin sections of each partition. In this example,
[0053] (i) directions 1-48 may be pre-assigned to front tray
locations of bin sections 3-50, with bins 1 and 2 being unassigned,
and
[0054] (ii) directions 49-98 may be pre-assigned to front tray
locations of bin sections 58-100 with bin sections 51 and 52 being
unassigned.
[0055] Again, in these examples, all back tray locations are
unassigned.
[0056] FIG. 3 shows a flow diagram for sequencing flats during a
first pass using an embodiment of the tray sequencing system of
FIG. 1. In this flow, two trays are assigned to each bin section,
and the initial bin allocation using the pre-assignment rule of
FIG. 2 is provided. It should be noted that the flow diagram of
FIG. 3 (and FIGS. 4 and 6) may represent a high-level block diagram
of the present invention. A computer software program or hardwired
circuit can be used to implement the steps of the present
invention. In the case of software, the program can be stored on
media such as, for example, magnetic media (e.g., diskette, tape,
or fixed disc) or optical media such as a CD-ROM. Additionally, the
software can be supplied via the Internet or some other type of
network. A workstation or personal computer that typically runs the
software includes a plurality of input/output devices and a system
unit that includes both hardware and software necessary to provide
the tools to execute the steps of the present invention.
[0057] Referring now more specifically to FIG. 3, in step 300, the
process begins. At step 302, a determination is made as to whether
a front tray associated with a pre-assigned direction is filled. If
not, at step 304 the system will continue to fill the tray for that
direction. If the front tray is filled, the process continues to
step 306, at which time a determination is made as to whether the
conveying system is empty in front of the filled tray. If filled
(not empty), at step 308, the process waits until the first pass
sequence ends. If the conveying system is empty in front of the
filled tray, a determination is made at step 310 as to whether a
lower direction tray will be blocked by moving the tray onto the
conveying system. If not, the tray is moved onto the conveying
system at step 312. If there is a blockage, the process returns to
step 308. At step 314, the back tray is moved to the front tray
location at an earliest convenience in order to ensure that an
upcoming flat for that direction may still be loaded into the tray
prior to such movement. In embodiments, this would be considered a
"wait" time. And, at step 316 an empty tray is placed at the back
tray location. At step 318, the tray is moved as far forward as
possible on the conveying system without blocking a lower direction
or pre-assignment.
[0058] Now, FIG. 4 shows further steps for assigning tray locations
when a tray is filled for a particular direction and overflow flats
having the same direction must be dropped at a tray location. At
step 400, the process starts to scan in a sweep direction starting
with the pre-assigned location (i.e., the location of the filled
tray for that direction). At step 402, a determination is made as
to whether the pre-assigned tray location is empty. If the tray
location is empty, the process then assigns that tray location the
same direction at step 404. If not, at step 406 the process begins
to scan in the sweep direction starting from the filled tray
location for that direction. At step 408, a determination is made
as to whether the front tray location is free and all trays on the
conveying system toward the sweep direction have a lower or equal
direction. If yes, then the process assigns the direction to that
front tray location at step 410. If not, then a determination is
made as to whether the back tray location is free and the front
tray location has a lower or equal direction (step 412). If yes, at
step 414 the process assigns the direction to that back tray
location.
[0059] FIG. 5 shows an example implementing the steps of FIGS. 3
and 4. In FIG. 5, an example of two flats per tray is illustrated
with the use of four feeders and one partition. In FIG. 5, the
example also includes directions 1-20 with the use of 23 bin
sections. Initially, front tray locations of bin sections 3-23 are
assigned directions 1-20 (direction 19 is assigned to bin sections
21 and 22), with the remaining tray locations being unassigned. The
unassigned bin sections include, amongst others, front tray
locations of bin sections 1 and 2. It is well understood that the
example of FIG. 5 is merely one illustrative example implementing
the flow steps of FIGS. 3 and 4, and thus the present invention
should not be limited in any manner to this specific example.
Instead, the present invention contemplates many scenarios using
the steps discussed herein such as the use of more or less
sequences, more or less bin sections or the like.
[0060] Referring to sequence 1, front trays of directions 7 and 10
are filled (i.e., sequence 1 on the left side of the illustration
shows two flats for direction 7 and 10) and moved onto the
conveying system. The front tray locations for directions 7 and 10
are associated with bin sections 9 and 12, respectively. This is
possible because the following holds true:
[0061] 1. a front tray associated with a pre-assigned direction is
filled (step 302);
[0062] 2. the conveying system is empty in front of the tray (step
306); and
[0063] 3. moving the tray onto the conveying system (step 312) will
not block a lower direction tray (step 310).
[0064] Still referring specifically to direction 10, in sequence 2,
the front tray of bin section 12 for direction 10 is filled.
Referring to FIG. 4, this tray is filled, after scanning in the
sweep direction (step 400), because it was determined that:
[0065] 1. the pre-assigned tray location 10 was empty;
[0066] 2. a new tray was moved in its place; and
[0067] 3. the new tray was ready to be filled by flats having a
direction of 10 (step 402).
[0068] In sequence 3, there are no further 10 directions. In this
sequence, a discussion of the 11 and 12 directions will be
illustrated using the steps of FIGS. 3 and 4. In this scenario,
front trays assigned to direction 11 and direction 12 are both
placed on the conveying system in accordance with the steps of FIG.
3. Also the front tray locations for directions 11 and 12 are
filled in accordance with steps 400 and 402. (See, sequence 1 and
2.) Now, for direction 12, once the pre-assigned front tray of bin
section 14 is filled, then the back tray of bin sections 14 and 13,
in order, will be filled in accordance with steps 412 and 414.
Similarly, for direction 11, once the pre-assigned front tray of
bin section 13 is filled, and the back tray of bin 13 is partially
filled with flats for direction 12, then the back tray of bin
section 12 will be filled with flats for direction 11.
[0069] In sequence 4, the need for unassigned tray locations
becomes apparent. Specifically, as the process moves through the
steps of FIGS. 3 and 4, the lower directions may be assigned to the
unassigned tray locations. This happens due to higher directions
being assigned to tray locations in lower numbered bin sections,
for example, with reference to direction 11. To illustrate this
subtlety, direction 1, in sequence 4, is assigned to all tray
locations and the conveying system position of bin section 3 and
the front tray location of bin section 2, a previously unassigned
location. This is due to direction 2 being assigned to bin section
4 and the requirement that four trays are needed for direction 1.
Thus, the unassigned bin sections may become important, in certain
embodiments, of the present invention.
[0070] It is also seen in this example, that previously assigned
tray locations may become unassigned locations after filled trays
are moved onto he transporting system (i.e., sequence 3, front tray
locations of bin sections 9-11). In this specific situation, the
previously assigned directions for 7, 8 and 9, in sequence 3 are
turned into unassigned locations when the trays for the directions
are moved onto the conveying system. Thereafter, using the steps of
the present invention, these unassigned tray locations of bin
sections are then reassigned directions 12, 13, 11, respectively,
for sequence 4. In this manner, all lower directions remain
unblocked by a higher direction.
[0071] Once all of the flats are properly loaded into the assigned
trays, the trays are moved in sequential order to the feeder. That
is, starting with the lowest to the highest assigned directions,
all of the trays are placed on the conveying system and transported
to the feeder for a second pass. By way of example, all of the
trays assigned with a 1.sup.st direction are placed on the
conveying system prior all of the trays assigned with a 2.sup.nd
direction. This procedure is followed until all of the trays are
placed on the conveyor, i.e., the trays assigned with directions
1-20. In this manner, the sequentially ordered trays will now reach
the feeders in an order according to a set of delivery points, for
a second and final pass.
[0072] FIG. 6 shows a flow diagram for sequencing flats in a
delivery order using a second pass. In this example, two trays are
allocated to each bin section and the bin output can selectively
output to one of the two trays. Additionally, the front tray is
physically in front of the back tray such that the back tray cannot
move to the conveying system through the front tray. Additionally,
the pre-assigned tray locations are based on recorded data used in
the first pass.
[0073] At step 600, the process starts scanning the first available
tray location in a bin section. In this step, the scanning is
performed away from the sweep order (away from the unloading area).
At step 602, a determination is made as to whether there are one or
two trays in the same direction. If yes, then the process proceeds
to step 604. At step 604, the direction will be assigned to the
next available tray location, always filling the front tray
location first. If there are more than two trays for a direction,
at step 606, the bin section is preset to the next bin section
where all tray locations are free. At step 608, a direction is
assigned to the bin section. In this step, the process assigns a
direction to all conveying system positions between and including
the preset bin location and the preset bin location--(number of
trays per direction--X) and assigns all tray locations to the
preset bin location--(number of trays per direction--X). In the
case that the preset bin location--(number of trays per
direction--X)<0, at step 610, all left over directions are
assigned to any back tray location available in that partition. It
should be understood that X could be any number that equals the
number of tray locations and conveying system location for each bin
section. For example, using the embodiment of FIG. 1, X=3.
[0074] FIG. 7 is an example implementing the flow steps of FIG. 6.
The example of FIG. 7 is merely one illustrative example
implementing the flow steps of FIG. 6, and thus the present
invention should not be limited in any manner to this specific
example. Instead, the present invention contemplates many scenarios
using the steps discussed herein such as more or less sequences and
more or less bin sections. In FIG. 7, two sequences are provided,
with 20 directions. In this example, much like that discussed in
the example of FIG. 5, each tray is capable of holding two flats.
In this example, 22 bin sections are used and each bin section has
two tray locations and one conveying system location (X=3).
[0075] Implementing the steps of FIG. 6, the following is
illustrative of the use of several different directions. First, the
pre-assigned tray locations are based on the recorded data used in
the first pass. Then, it is determined that there are eight flats
for direction 1, translating into four trays. For this example, a
simplifying assumption is made that two flats equal a full tray,
but in practice, many flats may make a full tray. Using the steps
of FIG. 6, it is determined that there are more than two trays in
direction 1 (step 602). Using step 606, bin section 22 is preset
since this bin section has both tray locations free. Then, a
direction is assigned to the conveying system and tray location
(corresponding to a bin section) using the following calculations
of step 608:
[0076] 1. The conveying system location is assigned a direction
based on all conveyor positions between and including the preset
bin section and the preset bin section--(number of trays per
direction--3). In this example, the preset bin section is 22 and
the preset bin section--(number of trays per direction--3) is 21.
Thus, the system of the present invention will assign a direction
to all conveying system locations associated with bin sections 21
and 22. Two trays will then be loaded and transported onto the
conveying system at bin sections 21 and 22.
[0077] 2. The tray locations will be assigned based on the preset
bin location--(number of trays per direction--3). In this example,
the tray locations associated with bin sections 22 will be assigned
direction 1 (i.e., preset bin location of 22--(4 trays--3)). Two
trays will then be loaded for the front and back tray locations at
bin section 21.
[0078] By way of further example, direction 2 has four flats, which
translates into the need for two trays. Using the steps of FIG. 6,
it is first determined that there are two trays in direction 2
(step 602). Implementing step 604, it is determined that there are
two free trays in bin section 22. Then, a direction 2 is assigned
to the two free trays in the front tray location and the back tray
location of bin section 22. This same process may be used for
directions 3 through 8, 10, 15 and 17-20.
[0079] In an example using direction 9, there are seven flats
requiring four trays. Using step 602, it is determined that there
are more than two trays needed for direction 9. Thus, implementing
step 606, bin section 15 is preset since this bin section has both
tray locations free, noting that directions 1-8 occupy, partially
or fully, bin sections 16-22. Then, using the formula of step 608,
a direction is assigned to the conveying system and tray location
(corresponding to a bin section) using the following
calculations:
[0080] 1. The conveying system location is assigned based on all
conveyor positions between and including the preset bin section and
the preset bin section--(number of trays per direction--3). In this
example, the preset bin section is 15 and the preset bin
section--(number of trays per direction--3) is 14. Thus, the system
of the present invention will assign direction 9 to all conveying
system locations associated with bin sections 14 and 15. Two trays
will then be loaded and transported onto the conveying system at
bin sections 14 and 15.
[0081] 2. The tray locations will be assigned based on the preset
bin location--(number of trays per direction--3). In this example,
the tray locations associated with bin section 14 will be assigned
direction 9 (i.e., preset bin location of 15--(4 trays--3)).
[0082] This same procedure will be used for the remaining
directions requiring three or more trays (i.e., directions 11-14
and 16).
[0083] Once all of the trays are properly filled, they will be
incrementally and sequentially placed on the conveying system (as
discussed with reference to FIG. 5), but now transported to the
unloading area for delivery or storage. In this manner, there is no
need for sorting of the trays, thus requiring less floor space and
less time and expense.
[0084] While the invention has been described in terms of preferred
embodiments, those skilled in the art will recognize that the
invention can be practiced with modification within the spirit and
scope of the appended claims.
* * * * *