1. Field of the Invention
The present invention relates generally to machines utilized to sort documents, i.e., mail pieces such as letters, and more particularly, to a sorting machine having dual magazines located at one end for increasing sorting capacity.
2. Description of Related Art
Automated sorting machines are well known in the art for sorting large volumes of documents (e.g. letters, postcards, checks, flats, and the like) into groups having a common identifying criteria (e.g. Zip Codes, mail boxes, and so forth). A sorting machine typically comprises a front end or feeder section and one or more stacker sections, wherein the front end feeds the documents, one-by-one, past a reader (e.g. optical character reader (“OCR”), bar code reader (“BCR”), or the like) to a transport that carries it to a designated sort pocket in one or more stacker sections.
As the document passes the reader, the desired criteria on the document is read and a signal is generated that, in turn, is processed to generate a designation signal for that particular document. This designation signal, in turn, triggers a diverter or gate at the designated pocket in the stacker section as the document approaches to divert the piece from the transport into the designated pocket where it is stacked with other pieces having the same identifying criteria. Such machines are well known and are commercially available e.g., Vsort® Fiat Sorting machine, NP8000™ Sorting machine, both manufactured and distributed by National Presort, Inc., Dallas, Tex.
Many present sorting machines are comprised of a plurality of vertically stacked tiers of sort pockets which increase the number of pockets available during the sorting operation without substantially increasing the machine's foot print (floor area required for the machine). With these types of sorting machines, the letters are read and directed by a Level Distribution Unit or elevator system to the particular tier on which its respective sort pocket is located. For example, if the sorting machine has four tiers, only approximately 25% of the letters being fed will go to each tier. This means that approximately 75% of the sort capacity of each tier goes unutilized. It can be seen that if the unused capacity on each tier can be reduced, the throughput of the machine can be significantly increased.
Although the foregoing developments represent strides in the area of sorting machines, many shortcomings remain.
The novel features believed characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:
While the sorting machine and method of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the process of the present application as defined by the appended claims.
The document sorting machine of the present application overcomes common disadvantages associated with conventional machines and method for sorting documents. Illustrative embodiments are described below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
Referring more particularly to the drawings,
Each half (A and B) comprises of a feeder section 11 having a magazine 16 (see
Stacker section 15 is shown as being comprised of a plurality (e-g. four) of vertically stacked tiers 22, each tier being substantially identical to the others. Each tier 22 has a plurality of horizontal stacker bins or “pockets” 20 (only some shown and numbered for clarity) arranged in pairs having one pocket on either side of the looped transport 12. As best seen in
Each pocket 20 has a diverter means (see 21a in
While the machine 10 will be shown and described as having four tiers 22, it should be recognized that more or less tiers (i.e., at least one) can be used without departing from the present invention. It will also be recognized, in most operations using multi-tiered sorting machines, the sorting of the mail will be programmed to arrange the sort pockets so that each tier will receive approximately an equal amount of the documents. For example, in a four-tier machine, the designated pockets for a particular batch of documents will be assigned so that approximately 25% of the documents will be fed to each tier, leaving appropriate 75% of the available transport capacity of that tier unused.
In accordance with the present invention, dual feeders 11 are provided to feed documents onto transport 12 from opposite ends of the sorting machine 10. That is, one feeder 11A reads and feeds documents from one end of the sorter 10 through its respective LDU 14 to each of the four tiers 22 while, at the same time, feeder 11B reads and feeds documents from the other end of the elongated sorting machine 10.
As described above, documents 17 are fed from either feeder 11A or 11B and may have to travel almost all of the way around the looped transport 12 of a respective tier 22 in order to reach a designated pocket 20 which lies on the other side of the stacker section from which the document it entered the transport. In order to do this, that document must completely travel through both stacker sections 15 along one side of the tier and then reverse directions at “turn around” pulley 23 in a respective buffer unit 30 before it can travel along the other side of the tier to reach its designated pocket.
Since documents 17 are being fed simultaneously from both feeders 11A and 11B onto respective ends of the respective common looped transport 12 of each respective tier 22, there is a real possibility that a document from one of the feeders and already in the transport may collide with a document being fed onto the transport by the other feeder; thereby causing a collision between the two documents. Any such collisions can result in a shut-down of sort operations. To prevent this from happening, a buffer unit 30 is provided at each end of each tier 22. Since the buffer units 30 are identical, only the unit at one end (i.e. 30B) will be described in detail.
As best seen in
If a following document 17N is positioned on transport 12 so that it might run up onto the documents 17B as it is being delayed in unit 30, gate G is actuated to divert document 17B into a “purge” pocket 20P. Any documents in purge pocket 20P are then removed and ran back through sorting machine 10 to sort them into their proper packets. This allows both feeders to continue to feed documents without interruption.
Another feature of the present invention is serpentine piggy-back unit 13 (
In the operation of serpentine, piggy-back unit 13, the thickness of each document 17D (
When the following document 17D2 (which is going to the same pocket as document 17D1) approaches the exit of bypass transport 12T, document 17D1 is fed (i.e., piggy-backed) onto document 17D2. The two stacked documents will now travel along transport 12 as if a single document until it reaches its designated pocket 2nd is sorted accordingly. It should be appreciated that the unit 13 could easily be adapted to piggy-back multiple documents together, i.e., three or more documents traveling to the same designated pocket.
Referring now to
Sorting machine 601 includes a first magazine 603 and a second magazine 605, both magazines being located at the same end section 607 of sorting machine 601, and both magazines being substantially similar in form and function to magazine 16, discussed above. Magazine 603 and magazine 605 include a conveyor 609 for feeding documents onto a pickoff (not shown), which in turn, picks off one document at a time and delivers the document to a transport. In the preferred embodiment, a first transport 611 is operably associated with magazine 603 and a second transport 613 is operably associated with magazine 605. During operation, a worker places documents 615 on magazine 603 and documents 617 on magazine 605, which in turn are fed to and subsequently carried by respective transport 611 and transport 613. For clarity, movement of both transport 611 and transport 613 are depicted with arrows on sorting machine 601. The selectively positioning of both magazine 603 and magazine 605 at the same end section 607 allows a single worker to feed both transports simultaneously, thus reducing costs associated with employing multiple workers to perform the same job.
Sorting machine 601 preferably includes an elevator 621 utilized to elevate transport 611 at a height above a first level distribution unit 623 such that uninterrupted travel of documents 615 is achieved between feeder section 619 and a second level distribution unit 625. During operation, documents 615 from magazine 603 are fed through feeder section 619 and are carried by transport 611 above first level distribution unit 623 via elevator 621 to second level distribution unit 625. Thereafter, documents 615 are placed in the stream of partially sorted documents 617 from magazine 605. This feature greatly increases sorting efficiency, as is further discussed below.
Like sorting machine 10, sorting machine 601 comprises a stacker section 627 comprising a first section 629 having a plurality of pockets 631 and a second section 633 having a plurality of pockets 631. In the preferred embodiment, stacker section 627 comprises two or more tiers 635, preferably four tiers, to increase sorting capacity. However, it will be appreciated that alternative embodiments could include more or less tiers than the preferred embodiment.
It should be understood that a designated pocket for some of documents 617 could be positioned on section 629, thus requiring documents 617 to travel the entire length of section 629 then reverse direction at a first buffer unit 637 prior to documents 617 traveling along section 629 to the designated pocket. Sorting machine 601 further comprises a second buffer unit 639 utilized to maintain continuous travel of both documents 615 and documents 617 around section 629 and section 633, thus forming a continuous “loop” around stacker 627. As documents 617 travel around first buffer unit 637, documents 615 from magazine 605 are added thereto via transport 611. This feature increases the efficiency of sorting machine 601 by placing documents 615 in a stream of documents 617 already sorted in section 633. It should be understood that the remaining unsorted documents 617 have designated pockets located on section 629 of stacker 627, thereby requiring the unsorted documents to travel the entire length of section 633 and reverse direction at first buffer unit 637. Sorting documents 617 prior to merging documents 615 creates additional openings on transport 613 for receiving documents 615, which in turn increases the sorting capacity of the documents and overall efficiency of sorting machine 601.
Referring to
Purge pocket 803 is preferably operably associated with turn around buffer unit 639; wherein, as one or the foregoing purge scenarios described above occurs, control system 805 activates a diverter means 1001 (see
Control system 805 is operably associated with a plurality of sensors 807 utilized to determine whether a jam 901 on the tier has occurred. If a jam does occur, control system 805 shuts down all sorting on the jammed tier and is adapted to activate controls, lever, motors, buffers, diverters, and other associated equipment utilized to direct the documents to purge pocket 803.
Purge system 801 greatly increases sorting efficiency of sorting machine 601, in particular, purge system 801 enables sorting machine 601 to shut down a single tier in lieu of shutting down all tiers, thus allowing sorting machine 601 to remain operable. In the preferred embodiment, a single tier is shut down; however, it should be appreciated that alternative embodiments could include a purge system adapted to shut down one or more jammed pockets on a tier in lieu of shutting down the entire tier. This alternative embodiment enables the remaining pockets on the tier to operate while the jammed pocket(s) are undergoing maintenance. Furthermore, the preferred embodiment includes a purge pocket for each tier; however, it should be appreciated that alternative embodiments could include a single purge pocket adapted to store documents for all tiers and/or a designated tier utilized as a purge pocket. For example, section 633 could include a fifth tier having a plurality of pockets and being utilized as designated purge tier in lieu of a single purge pocket 803.
Referring now to
During operation, one or more sensors (not shown) along transport 613 determines whether a document 1009 is likely to arrive at a merge point 1011 at the same time as an entering document 1013. If the possibility of collision is imminent, document 1009 will be held in position with buffer 1005 until document 1013 passes merge point 1011, at which time, document 1009 is released to resume travel to the designated sorting pocket 631. Likewise, second buffer 1007 is utilized in a similar manner, namely, one or more sensors determine whether collision of a document 1015 is imminent with document 1009, and if so, buffer 1007 holds document 1015 in position until document 1009 is released. The dual buffer configuration reduces collision between two or more documents on the transport, which increases the overall efficiency of the sorting operation. It should be appreciated that additional buffers could be utilized in alternative embodiments. For example, a buffer could be selectively position between first buffer 1005 and second buffer 1007, thereby allowing an additional document to be held in position if collision is imminent.
Referring to
Referring now to
Tray system 1201 preferably comprises a framed structure 1205 for supporting the plurality of trays 1203 and for supporting associated subsystems operably associated with tray system 1201. In the preferred embodiment, tray system 1201 comprises eight rows 1207 for holding five trays 1203; however, alternative embodiments could include more or less rows 1207 and rows adapted to hold more or less trays than the preferred embodiment. Tray system 1201 includes four rows 1207 designated for a first scheme section 1209 and four rows 1207 designated for a second scheme section 1211. It should be understood that sorting machine 601 could easily be adapted to operate with multiple schemes. Schemes are defined as operating scenarios, in particular, a first scheme occurs when sorting machine 601 sorts international documents, and a second scheme occurs when the documents are nationally sorted. For example, a first collection of documents could include designations to a plurality of countries, thereby designating a pocket 631 to individual countries; whereas, in the second scheme, each pocket could be designated for each state within the United States. Of course, it should be understood that these two exemplary schemes are one example of many different types of schemes operably associated with sorting machine 601. It should be appreciated that alternative embodiments could include more or less schemes than the preferred embodiment. Providing a tray system with multiple scheme sections greatly increases the overall efficiency of tray system 1201, namely, the worker is no longer required to remove trays from the tray system as the sorting machine switches between schemes.
Tray system 1201 further comprises a lift subsystem 1213 operably associated with a drive system 1215. Lift subsystem 1213 is utilized to lower and raise rows 1207 relative to the floor. For example,
Lift subsystem 1213 preferably comprises one or more of a chain 1219 rotatably coupled to a top gear 1221 and a bottom gear 1223. Rows 1207 are securely held in position with a rigid sidewall 1225, which includes one or more brackets 1227 adapted to fasten to chain 1219. Drive subsystem 1215 preferably includes a motor 1229 rotatably coupled to a drive shaft 1231, which in turn is rotatably coupled to gear 1221. During operation, drive subsystem 1215 rotates gear 1221, which in turn causes rows 1207 to raise or lower via movement of chain 1219. Of course, it will be appreciated that alternative embodiments could include different means for lifting the rows. For example, the tray system could easily be adapted with a worm gear system, a hydraulic system, gear system, and/or other suitable systems adapted to lower and raise an object.
It is apparent that a sorting machine with significant advantages has been described and illustrated. In particular, the sorting machine effectively and rapidly sorts documents by providing two transports, the first transport utilized to carry documents through a plurality of sorting bins and a second transport utilized to merge documents into the stream of documents already partially sorted with the first transport. This features enables both a first magazine operably associated with the first transport and a second magazine operably associated with the second transport to be position at the same end section of the sorting machine, thus enable a single worker to feed both magazines simultaneously, which in turn allows a single worker to feed documents into the sorting machine in lieu of multiple workers performing the same job. Further, the sorting machine is adapted with a purge system, which allows documents to be removed from the machine, thus enabling the sorting machine to continue operation while the jammed tier is being repaired.
The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof.
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