Patent Application
20130318929
The present invention relates to automated filling of mail trays with envelopes from a mail production machine.
A mail insertion system or a “mailpiece inserter” is commonly employed for producing mailpieces intended for mass mail communications. Such mailpiece inserters are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mail communications where the contents of each mailpiece are directed to a particular addressee. Also, other organizations, such as direct mailers, use mailpiece inserters for producing mass mailings where the contents of each mailpiece are substantially identical with respect to each addressee.
In many respects, a typical inserter resembles a manufacturing assembly line. Sheets and other raw materials (i.e., a web of paper stock, enclosures, and envelopes) enter the inserter system as inputs. Various modules or workstations in the inserter system work cooperatively to process the sheets until a finished mail piece is produced. The precise configuration of each inserter system depends upon the needs of each customer or installation.
Typically, inserter systems prepare mall pieces by arranging preprinted sheets of material into a collation, i.e., the content material of the mail piece, on a transport deck. The collation of preprinted sheets may continue to a chassis module where additional sheets or inserts may be added based upon predefined criteria, e.g., an insert being sent to addressees in a particular geographic region. From the chassis module the fully developed collation may continue to a stitched module where the sheet material may be stitched, stapled or otherwise bound. Subsequently, the bound collation is typically folded and placed into envelopes. Once filled, the envelopes are closed, sealed, weighed, and sorted. A postage meter may then be used to apply postage indicia based upon the weight and/or size of the mail piece. The mailpieces will then be moved to a stacker where mailpieces are collected and stacked, either on edge or laid flat. An exemplary on-edge stacker, or vertical stacker, is depicted in U.S. Pat. No. 6,398,204 titled On-Edge Stacking Apparatus, which is hereby incorporated by reference in its entirety.
In a final step, the mailpieces are manually removed by an operator from the stacker and placed into mail trays or other storage containers. Such manual collection and removal is pragmatic, reliable and fiscally advantageous when the time of mailpiece removal can be shared and/or absorbed within the overall labor requirements associated with managing/operating the mailpiece inserter system. That is, this task can be efficiently performed when sufficient idle time exists between various other operational tasks, e.g., removing out-sorted mailpieces, cleaning/removing paper dust from various optical readers/scanning devices, etc., to periodically or intermittently unload the mailpiece stacker.
Advances in the art of mailpiece inserters have vastly increased the total mailpiece volume and rate of mailpiece production. For example, the Advanced Productivity System (APS) inserter system produced by Pitney Bowes Inc., located in Stamford, Conn., USA, can produce as many as twenty-six thousand (26,000) mailpieces in one hour of operation. Accordingly, hundreds of mail trays, collectively weighing over 11,000 lbs, must be removed and transported each hour by a system operator. In fact, the volume of mailpieces produced is sufficiently large that several system operators may be required to concentrate on the single/sole task of mailpiece collection and removal. Aside from the time associated with this final unloading step, it will be appreciated that the collection, removal and transport of such large mailpiece quantities can be highly demanding in terms of the physical workload. It will also be recognized that such physical demands can lead to inconsistent or reduced mailpiece throughput if/when the workload requirements are not properly balanced with the high volume mailpiece output.
A need, therefore, exists for an apparatus for stacking mailpieces produced by high volume mailpiece inserters, which apparatus ensures consistent throughput, is fiscally advantageous and provides a viable alternative to manual mailpiece collection and removal.
Prior art systems that have attempted to meet this need include: (i) a device that lifts mail trays onto their side to receive pre-formed stacks of envelopes (U.S. Pat. No. 7,600,751); (ii) a stationary device that individually fed envelopes into a mail tray that had been lifted up from below (U.S. Pat. No. 6,536,191); and (iii) a device that dropped vertical stacks of envelopes into mail trays using a trap-door arrangement (U.S. Pat. No. 5,347,790).
The invention may be used in an automated mail tray filling apparatus for taking envelopes from a vertical stacker output of an inserter machine and placing them in mail trays. The mail tray filling apparatus has a track positioned next the vertical stacker table parallel to the length of the vertical stacker table. A mail tray transport is positioned beneath the track and arranged to transport mail trays beneath the track in a direction parallel to the vertical stacker table. A movable mail tray filler is movably mounted on the track to travel in parallel next to the vertical stacker table and above the mail tray transport and arranged to withdraw envelopes from a distal end of the vertical stack in a sideways direction. Envelopes are then redirected into a downward direction and fed into a mail tray positioned beneath the movable mail tray filler.
The mail tray filler includes a filling mechanism that is vertically movable to be lowered into and lifted out of a mail tray. With the mechanism raised, an empty mail tray is moved into position to underneath the mechanism. The mechanism lowers a feeding arm down into the mail tray at a forward end of the mail tray. Envelopes from the mail tray filling mechanism are fed into the mail tray through the lowered feeding arm.
The apparatus detects a pack pressure of envelopes in the mail tray on the lowered feeding arm. When the pack pressure exceeds a predetermined threshold, the relative position of the feed arm is moved towards a back end of the mail tray to make room for more envelopes. After the pack pressure is below the predetermined threshold, feeding continues. When the tray is full, the feeding arm is lifted from the mail tray, and a next empty mail tray is advanced. The step of moving the relative position of the feed arm can be achieved by moving either or both of the mail tray transport or the feed arm.
A full mail tray can be detected by sensing the back end of the mail tray in proximity to the feeding arm. A mechanical switch mounted on the feeding arm can be positioned so that is activated when it comes into contact with the back end of the mail tray. An optical sensor can also be used to detect the back end of the tray.
A full tray may also be detected by computing a distance that the relative position of the feed arm has moved towards a back end of the mail tray and comparing the computed distance to a known length of the mail tray. The distance computations can be done in conjunction with encoders that measure the distance that motors have moved the respective components.
In another embodiment, part way through the filling of the tray, the apparatus performs one or more repack operations. The repack operation comprises moving the relative position of the feed arm towards a front end of the mail tray to compress a stack of envelopes already fed into the mail tray. The interval for performing a repack can be a function of the feed arm having moved towards the back end of the mail tray by a predetermined distance, a predetermined number of envelopes having been fed into the mail tray, or upon observation of a predetermined pressure profile being sensed on the feeding arm.
The repacking operation may include moving the feed arm by a predetermined distance towards the front of the tray to compress the envelope pack. Repacking may also be done until a particular measured pressure is sensed on the feed arm.
In another embodiment, pack pressure can be continuously monitored and the position of the feed arm can be moved towards, or way from, the envelope pack to maintain the pressure within a desired range.
Other embodiments include different techniques for determining that the mail tray is full. One such technique is to count a quantity of envelopes fed into the tray and comparing the counted quantity to a predetermined tray capacity number. When the capacity number is met, the tray is deemed full. If it is desirable to ensure that the full envelope capacity is met, the system can be configured to ignore maximum pack pressure limitations when the tray is nearly full so that goal can be met.
Another technique for detecting a full mail tray is to predetermine the sets of envelopes that are intended to go together in trays. In this embodiment, an optical mark is put on a last designated envelope for a set. When an optical sensor sees the “last envelope” marking, it knows that no more envelopes are to be fed, and an empty tray is to be advanced. As a backup to scanning for a marking of a last envelope, the system can still count the quantity of envelopes fed, to make sure that a maximum capacity is not exceeded in case the marking was missed.
The apparatus 4 is controlled using standard processors, controllers, and motors as used in the mail handling equipment field. In an exemplary embodiment, the controller is a Mitsubishi Q series PLC (programmable logic controller). A PLC is a specialized small computer with a built-in operating system designed specifically for controlling machinery. PLC operating systems are able to process incoming events and to react in real time. Another advantage of a PLC is that it is designed to operate reliably in an industrial environment.
The PLC has input lines where sensors are connected to notify upon events (e.g. pressures above/below a certain level, envelopes sensed at a particular location, etc.), and it has output lines to signal any reaction to the incoming events (e.g. feed an envelope, move the mail tray. etc.). Where the system includes analog sensors (for example analog pressure sensors) an A/D converter is used to generate the digital signal for input into the PLC. The system is user programmable using standard PLC programming language. Ladder logic programming is used in the preferred embodiment for programming the PLC for the functionality described herein.
In an alternative embodiment, control of the mail tray filler apparatus 4 may be handled by a standard personal computer (PC), as are often used in connection with operating systems for inserter systems. Thus, a controller for the inserter system (and vertical stacker 1) may be configured to perform the same functions as the PLC. An advantage of integration with the inserter controller computer would be greater visibility and tracking of mail pieces through the final processing and placement in the mail trays.
The trayer apparatus 4 includes a touch screen display coupled to the controller to enable all of the interactions and inputs described herein. For example, the display can show the operational status of the machine, and can be used for displaying or inputting various parameters for machine operation, as described further herein. Any other type of human-machine interface can also be used in place of a touch screen display.
For instances, where communication is desired between the trayer apparatus 4 and the vertical stacker 1 (and the corresponding inserter system), a serial communication card may be used for communication between the respective controllers. In the preferred embodiment the controller for the trayer apparatus 4 is an RS232 serial controller.
The movable filler unit 6 includes a take-away feeder 3 that is typically positioned at a downstream end of the envelope stack resting on the vertical stacker 1. The take-away feeder 3 serves as a support to hold the downstream end of the envelope stack upright, and moves upstream and downstream with the movable filler unit 6 to apply the appropriate pressure to maintain the stack of envelopes standing on-edge. A pressure sensor 9 is mounted on take-away feeder 3 for purposes of detecting the stack pressure in connection with controlling feeding operations and movement.
Beneath the movable filler unit 6 and tracks 5, a mail tray transport 7 is positioned to provide mail trays 10 to be filled underneath movable filler unit 6. In the preferred embodiment, mail trays 10 are moved into position for filling in a transport path parallel to the vertical stacker 1. Pushers 8 push the mail trays 10 on transport 7, and define the relative positioning subsequent trays.
Downstream of the nips 12 is the region of the filler unit 4 in which the envelope E is redirected in the downward direction. Preferably, the nips 12 feed the envelope into an open space. At the far end of the open space is a stopping barrier 32. Above the open space is a downward tamping mechanism 25 that serves to bat the envelope in a downward direction into downward feeding arm 20. In the preferred embodiment, downward feeding arm 20 is comprised of belts 27 and 28 that bring envelopes to the feeding head 30 that deposits envelopes in a pack in the tray 10.
The side view of
The downward tamping mechanism 25 may include an inverted L shaped pusher 21 that imparts a downward impact on the free floating envelope. Tamping mechanism 25 preferably includes an actuator configured to move the pusher 21 up and down. The top of the pusher 21 pushes on the top edge of the envelope, while the vertical portion of the pusher 21 applies a steadying force on a face of the envelope.
In the preferred embodiment, the downward tamping mechanism is arranged so as to move at an angle that is not quite vertical. It has been found that moving the pusher 21 at an angle of ten degrees from vertical imparts both a vertical and horizontal force that causes the envelope to be reliably pushed into the opening in transport belts 27 and 28 below.
As seen in
Feeding head 30 includes a tray pressure sensor 52 used for detecting a pressure of the envelope pack in the tray 10 on the feeding head 30. Tray pressure sensor 52 may be a spring biased switch that is activated when a particular pressure is applied. Alternatively, the pressure sensor can be of a strain gauge variety that is capable of providing continuous measurements of the force being applied to the feed arm 20.
On a rear region of the feed arm 20 an end-of-tray sensor 50 can be mounted on the feed arm support structure 51. The end-of-tray sensor 50 may be a mechanical switch that is activated when it comes into contact with a rear wall of tray 10. Alternately, sensor 50 could be replaced with an optical sensor, or other type of proximity sensor, to achieve a similar result. An envelope sensor 22 is positioned proximal to the belts 27 and 28 to detect envelopes transported in the feeding arm 20.
Since the feeding arm 20 must be positioned within the tray 10 for feeding, it is necessary that it be lifted out when it is time to remove a completed tray and allow an empty tray to be positioned by the mail tray transport 7. For this reason the entire structure feeding arm 20 is mounted so as to be raised above the level of trays.
If a stack gets too long on the stacker 1 then the shape of the stack can be affected by thickness variations in the uniformity of envelope thicknesses. For example, envelopes being thicker on one side than the other can cause a stack to form a curve. Another issue with operating the feeder 3 towards the end of the stacker 1 is that such an arrangement will require additional structure for supporting and transporting the trays on the tray transport 7. It may be more desirable to set a maximum length of the stack for feeding operations, rather than add extra floor-space footprint to the apparatus.
For these reasons, it has been found that the apparatus works best when feeding is maintained within an optimal range between a minimum and maximum stack length. When there are no envelopes on the stacker 1, the take-away feeder 1 does not start feeding until the stack length is within the optimal range. In the preferred embodiment, the stack is allowed to grow until it extends all the way to the maximum end of the optimal length. Then, as feeding progresses, the movable tray filler 6 and feeder 3 may gradually move closer to the upstream end of the stacker 1. If the feeder 3 gets closer than the minimum distance, then the feeder 3 stops, and the stack is allowed to grow again back to the maximum size in the optimal range. This range can be adjustable because different mail jobs will have different properties that may require different optimization.
The flow diagram of
If the feeder is not paused, the system checks the position of the feeder, which corresponds to the size of the stack (step 83). In the initial startup scenario, the system wants the stack to grow to the maximum size in the optimal range, so until the stack size is equal to, or greater than, the maximum size, the feeder will keep moving incrementally downstream (step 82).
Once the feeder position has reached the optimal maximum position, then feeding of envelopes starts (step 84). Once feeding has started, the sensor 9 continues to check for the feeding trigger pressure (step 85). If no trigger pressure is detected, then the feeder 3 is moved incrementally upstream, towards the stack, so that feeding can continue (step 86). At step 87, when trigger pressure is detected, the system again consults the stacker position to determine whether the feeder has moved past the minimum optimal stacker length. If the position is greater than the minimum, then feeding (step 84) continues. If the stack length shrinks to less than the minimum, then the process for sending the feeder 3 downstream to the optimal maximum length starts again (step 82, and 80, 81, 83).
In
Concurrently, the tray end sensor 50 can be triggered if the tray has been moved along far enough to be almost full (step 94). Feeding resumes when the pack pressure sensor and the end of tray sensor are not triggered (step 91). If the end of tray sensor is triggered, then the feed arm 20 is lifted out of the tray (step 95) and an empty tray is advanced (step 96).
Alternatively, to detecting the end of the tray using a sensor, the system can keep track of how many envelopes have been fed into a tray. Since the thickness of the envelopes, and the capacity of the trays can be known in advance, the feed arm 20 removal and empty tray advancement steps may be based on reaching a predetermined count of envelopes. In some cases, there may be a particular need to fit a particular number of envelopes into a tray. In such cases, the pack pressure limits can be ignored when the feeding head 30 approaches the rear of the tray, in order that the desired quantity be filled.
Repack operations are performed at predetermined intervals (step 100). Such interval could be based on a quantity of envelopes fed, or on the distance the tray has moved during feeding. The number of repacks can be selected based on the importance of fitting a larger quantity of envelopes into a mail tray for a particular job. The repack interval may also be based on observation of a predetermined pressure profile being sensed on the feeding arm from the stack of envelopes, for example if the pack pressure sensor 52 was a strain gauge that found the pressure went below a predetermined threshold. If the predetermined interval has been reached, then a repack operation is performed (step 101). In the preferred embodiment, repacking is done by moving the mail tray transport 7 a predetermined distance in the upstream direct, thus forcing the envelope pack against the fed head 30. The repacking movement may also be a function of moving the relative position of the feed arm towards the front end of the mail tray until a predetermined pressure is detected on the feed arm by a pressure sensor 52 strain gauge. A similar result could be achieved by moving the feed arm 20 downstream. When a repack interval is not in effect then the normal feeding, pressure sensing and movement is in effect (steps 91, 102, 103).
Using this alternative technique, the system checks both whether the pack pressure is too high (step 105) or too low (step 106). If the pack pressure is too high, then the tray is incremented forward (step 107), similar to the method shown in
As a supplement to the end-of-tray marking technique, it may still be helpful to count the quantity of envelopes being fed into a tray. Then, if the mark is not sensed, the system can stop feeding if the quantity exceeds a predetermined maximum. This prevents the trays from overfilling and causing the feeding mechanisms to jam.
Although the invention has been described with respect to preferred embodiments thereof, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and deviations in the form and detail thereof may be made without departing from the spirit and scope of this invention.
