Patent Application
20050267849
The invention disclosed herein relates generally to mail processing systems, and more particularly to a manually fed mailing machine incorporating systems and methods to reduce feeding and weighing errors.
Mail processing equipment, such as, for example, a mailing machine, often includes different modules that automate the process of producing mail pieces. The typical mailing machine includes a variety of different modules or sub-systems each of which performs a different task on the mail piece. The mail piece is conveyed downstream utilizing a transport mechanism, such as rollers or a belt, to each of the modules. Such modules could include, for example, a singulating module, i.e., separating a stack of mail pieces such that the mail pieces are conveyed one at a time along the transport path, a moistening/sealing module, i.e., wetting and closing the glued flap of an envelope, and a metering module, i.e., applying evidence of postage to the mail piece. The exact configuration of the mailing machine is, of course, particular to the needs of the user.
One of the factors that determines the cost for shipping a mail piece to a destination is the weight of the mail piece. A mail piece could be, for example, an envelope, postcard, magazine, package, etc. The mailing machine will be provided with the weight of the mail piece, typically from an integral scale incorporated within the mail flow path, an external scale coupled to the mailing machine, or user input. Based on the weight of the mail piece, the postage rate and operator specified service option for a selected carrier, the mailing machine will determine the cost to deliver the mail piece to the destination. The mailing machine will then conduct an accounting procedure for the cost of shipping the mail piece and print an indicium evidencing payment of the postage. Mailing machines have traditionally been capable of printing postage indicia either directly on mail pieces, or on pieces of tape or a label, which are then attached to mail pieces.
For mailing systems that utilize an external platform scale, i.e., a scale that is independent and separate from the mail flow path, there are different methods that can be utilized for determining the weight of an item. In one method, referred to as single piece mode, the user places each mail piece onto the platform of the external scale, and the weight of the mail piece is provided by the scale to the controller of the mailing machine. The controller will calculate the cost for shipping the mail piece based on the weight of the mail piece provided by the scale. The user removes the mail piece from the scale and places it on the feed deck of the mailing machine base. Sensors detect the presence of the mail piece on the feed deck and the mail piece is automatically fed into the mailing machine for processing, or, alternatively, the user must press a start button for the mailing machine to transport the mail piece into the mail flow path. The user then repeats this procedure for each mail piece that the user desires to process.
Another method for determining the weight of a mail piece is referred to as a differential weighing method as disclosed in U.S. Pat. No. 5,001,648, which is hereby incorporated by reference. In accordance with the differential weighing method, a plurality of mail pieces are placed on an external scale coupled to a mailing machine and the collective weight of the mail pieces is registered. When the user removes a mail piece from the scale, the difference between the original collective weight of the mail pieces and the new collective weight of the mail pieces remaining on the scale is determined. The cost for shipping of the mail piece is calculated based on the determined differential weight. Sensors detect the presence of the mail piece on the feed deck and the mail piece is preferably automatically fed into the mailing machine for processing. The user then repeats this procedure for each mail piece that the user desires to process.
While conventional manual feed mailing machines generally work well utilizing the weighing methods as described above, there are some problems. For example, there are several ways in which mistakes made by the user in feeding the mail pieces and/or removing/adding a mail piece from/to the scale can result in the calculation and printing of incorrect postage for a mail piece. This is especially true if the user is attempting to process the mail pieces as quickly as possible. For example, the user may place and remove a second mail piece (in single piece mode) or remove a second mail piece (in differential weighing mode) while a previous first mail piece is still being processed by the mailing machine. Conventional mailing machines will not accept the weight of the second mail piece until the first mail piece has been completely processed. This significantly reduces the throughput of the mailing machine, as well as frustrates the user due to the waiting time required between mail pieces. If the user attempts to weigh the second mail piece before the first mail piece has been fully processed, the postage for the second mail piece will not be calculated, and the second mail piece will not be fed into the mailing machine by the transport system. Thus, the second mail piece will simply sit on the feed deck of the mailing machine and no further operations will occur. The user, not knowing that the weight of the second mail piece was not accepted by the mailing machine, and thus will not be processed, may believe that there is a problem with the sensors or feeding mechanism of the mailing machine. The user may be inclined to restart the entire system, which is time consuming, thereby decreasing the throughput of the mailing machine, or place a service call in the belief that the mailing machine is in need of repair. In either case, this can lead to general dissatisfaction with the mailing machine by the user.
Another feeding and weighing error that can occur is if the user forgets to place a mail piece on the scale, and instead places it directly onto the feed deck. If the controller does not have a weight for the mail piece, the mail piece will not be fed into the mailing machine. The user, not realizing that the mail piece was never weighed, and thus will not be processed, may believe that there is a problem with the sensors or feeding mechanism of the mailing machine. The user may be inclined to restart the entire system, which is time consuming, or place a service call in the belief that the mailing machine is in need of repair. In either case, this can lead to general dissatisfaction with the mailing machine by the user.
Thus, there exists a need for a method and system that reduces feeding and weighing errors in a manually fed mailing machine.
The present invention alleviates the problems associated with the prior art and provides methods and systems that reduce feeding and weighing errors in a manually fed mailing machine thereby allowing a very fast throughput to be achieved while maintaining mail piece integrity, i.e., associating each mail piece with the proper information for that mail piece.
In accordance with embodiments of the present invention, a mailing machine accepts weights or postage amounts for additional subsequent mail pieces before the processing of a preceding mail piece has been completed. The mailing machine maintains a queue of the weights or postage amounts for a plurality of mail pieces that have been provided by an attached scale such that the mailing machine can correctly associate each weight or postage amount with the appropriate mail piece when it is fed into the mailing machine. When processing of a previous mail piece has been completed, the weight or postage amount from the next location in the queue is obtained and utilized to generate an indicium for the next mail piece fed into the mailing machine. The mailing machine therefore can form the correct processing order for multiple pieces of mail, thereby increasing the throughput of the mailing machine.
Therefore, it should now be apparent that the invention substantially achieves all the above aspects and advantages. Additional aspects and advantages of the invention will be set forth in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. Moreover, the aspects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
The accompanying drawings illustrate presently preferred embodiments of the invention, and together with the general description given above and the detailed description given below, serve to explain the principles of the invention. As shown throughout the drawings, like reference numerals designate like or corresponding parts.
In describing the present invention, reference is made to the drawings, wherein there is seen in
The base unit 14 further includes a horizontal feed deck 30 which extends substantially from the input end 16 to the output end 18. A plurality of nudger rollers 12 are preferably mounted under the feed deck 30 and project upwardly through openings in the feed deck so that the periphery of the rollers 12 is slightly above the upper surface of the feed deck 30 and can exert a forward feeding force on a succession of mail pieces placed in the input end 16. One or more sensors 34, such as, for example, optical sensors, are located in the feed deck 30 to detect the presence of a mail piece on the feed deck 30. A registration wall 32 defines a mail piece registration surface substantially perpendicular to the feed deck 30 that extends substantially from the input end 16 to the output end 18. A scale 40, including a platter 42 (which may be removable), is preferably located near the input end 16, such as, for example, above and adjacent to the registration wall 32 as illustrated. Components of the weighing scale 40 other than the platter 42, including a load cell and related electronics, can be located within the base unit 14. Thus, while the scale 40 may be integral with the base unit 14, it is still considered an external platform scale as it is independent and separate from the mail flow path along the feed deck 30. Alternatively, a separate external stand alone scale (not shown) may be coupled to the mailing machine 10 by any suitable communication link, such as, for example, a USB or RS232 interface.
The scale 40 can be operated by a user to weigh mail pieces utilizing either the single piece mode or differential weighing mode previously described. When the mail pieces are removed from the platter 42 of the scale 40, the user places the mail piece in the input end 16 where one or more of the sensors 34 detect the mail piece. Signals from the sensors 34 are sent to the control unit 20, which in response, will activate the nudger rollers 12 to feed the mail piece along the feed deck 30, with the top edge of the mail piece being registered against the registration wall 32. Alternatively, control unit 20 may require an input from the user, such as, for example, pressing a start button, in lieu of or in addition to the signal from sensors 34, before activating the nudger rollers 12. The mail pieces may be passed through one or more modules, such as, for example, a singulator module and a moistening/sealing module, as are well known. Each of these modules is located generally in the area indicated by reference numeral 36. The mail pieces are then passed to a metering/printing module located generally in the area indicated by reference numeral 38, where an indicium evidencing postage will be printed on the mail piece. Alternatively, if a mail piece is not fed through the mailing machine 10, the indicium may be printed on a tape or label that can be affixed to the mail piece.
Since each mail piece must be placed on the platter 42 of scale 40 and then removed and placed on the feed deck 30 for single piece mode operation, and each mail piece must be removed from a stack of mail pieces previously placed on the platter 42 and placed on the feed deck 30 for differential weighing mode operation, efficient operation of the mailing machine 10 is dependent upon the user. As the user will typically attempt to operate the mailing machine 10 as quickly as possible to achieve the greatest throughput, it is possible for errors to occur with respect to weighing and feeding of the mail pieces. In addition, an unscrupulous user may attempt to trick the system into printing the incorrect postage on a mail piece, such as, for example, by not weighing a mail piece, thereby defrauding the postal service of the proper amount of funds due. Mailing machine 10 is provided with multiple mechanisms as described below to reduce weighing and feeding errors that could occur due to operator error, whether intentional or unintentional, thereby providing efficient and accurate operation of the mailing machine 10.
Depending upon the speed at which the user can operate, i.e., place and/or remove mail pieces from the platter 42, it may be possible for the user to remove a mail piece from the platter 42 while another preceding mail piece is being processed by the mailing machine 10. Thus, there could be, for example, one mail piece currently being transported along the feed deck 30 by the transport 50, another mail piece placed in the input end 16 of the mailing machine 10 to be fed into the mailing machine 10, and another mail piece in the user's hand waiting to be placed in the input end 16. According to one embodiment, mailing machine 10 maintains a queue of weights that have been provided by the scale 40 such that the mailing machine 10 can correctly associate each weight with the appropriate mail piece. Alternatively, if the scale 40 is calculating the postage amount for each mail piece, mailing machine 10 maintains a queue of postage costs that have been provided by the scale 40 such that the mailing machine 10 can correctly associate each postage amount with the appropriate mail piece. Preferably, the memory 54 can be utilized to maintain the queue of weights or postage amounts. When a previous piece has been completed, the control unit 20 will obtain the weight or cost from the next location in the queue, utilize the obtained weight to calculate the postage amount based on a rating table within the memory 54, and generate an indicium for the postage amount for printing by the printer 52. The indicium could be printed either directly on the mail piece, or on a tape from the tape drive 56.
Once the weight for Mail Piece 1 has been retrieved by the control unit 20, the weights for the other mail pieces (Mail Pieces 2 and 3) will shift upward thereby emptying the third location of the queue. If the weight for Mail Piece 1 is not stored in the queue 60, then the weight of Mail Piece 2 will be stored directly in the first location of queue 60, the weight of Mail Piece 3 will be stored in the second location of queue 60. Once the processing for Mail Piece 1 has been fully completed, i.e., accounting has been performed for Mail Piece 1, an indicium has been generated and the generated indicium has been printed on Mail Piece 1, the control unit 20 can then retrieve the weight for Mail Piece 2 stored in the queue 60. Preferably, the weight for Mail Piece 2 is retrieved as soon as the processing for Mail Piece 1 has been completed, thereby avoiding any unnecessary delays which will decrease the throughput of mailing machine 10. Sensors 34, detecting the presence of Mail Piece 2 on the feed deck 30, will send a signal to the control unit 20. Control unit 20 will confirm that a weight for Mail Piece 2 has been retrieved and processing of Mail Piece 1 has been completed, and then activate the nudger rollers 12 to feed Mail Piece 2 into the mailing machine 10 for processing. Alternatively, Mail Piece 2 can be ingested into the mailing machine 10 as soon as the signal from sensors 34 is received, but paused downstream until the other two conditions have been satisfied. Mail Piece 3 can then be placed on the feed deck 30 (if Mail Piece 2 has left) or on top of Mail Piece 2 (if Mail Piece 2 has not left), and the user can retrieve the fourth mail piece (Mail Piece 4). The weight for Mail Piece 4 will be accepted by the control unit 20 and stored in the third location of the queue 60 as illustrated in
It should be understood that queue 60 is not limited to three locations as illustrated, but instead can have any number of locations depending upon the rate of speed desired. For example, the queue 60 could have one, two, three or more locations. If the user is capable of manually removing the mail pieces faster than the mailing machine 10 can process them, the user may remove more pieces than queue 60 can store, thereby running the risk of the mailing machine 10 not being in synchronization with the mail pieces being processed, i.e., the wrong weight being associated with the wrong mail piece. To alleviate this risk, some embodiments will monitor the queue 60, and once the queue 60 has been filled to capacity, only those pieces for which there is a corresponding entry in the queue 60 will be processed by the mailing machine 10 and no further entries will be made in the queue 60, even as space becomes available. Thus, once the queue 60 has been completely emptied, any mail pieces remaining on the feed deck 30 will not be processed by the mailing machine 10. A message will be provided to the user, utilizing, for example, display 24, that the processing limit was reached, i.e., mail pieces were removed too quickly, and any mail pieces that are not accepted by the mailing machine 10 (once the queue 60 has emptied) must be placed back on the platform 42 to obtain a weight. In this manner, the chance of the mailing machine 10 being out of synchronization with the mail pieces as fed by the user is significantly reduced. Optionally, the size of the queue 60 could be configurable depending upon the customer's specifications. For example, experienced users, capable of operating at a faster rate than inexperienced users, may desire a larger queue. Thus, if a user continually reaches the processing limit, the size of the queue can be increased to accommodate the faster rate of speed at which the user is capable of operating. The owner of a mailing machine being used by less experienced users, such as may be found in a community mailroom, may desire a smaller queue to safeguard against the mailing machine 10 being out of synchronization with the mail pieces and thus wasted postage funds.
Optionally, mailing machine 10 could be provided with means to provide an audible signal to the user indicating when the next mail piece can be removed from the platter 42. Such an audio signal could be provided by a speaker 58 (
Thus, utilizing the queue 60, mailing machine 10 is able to accept the weights for additional mail pieces, even while preceding mail pieces are being processed by the mailing machine 10. This can significantly increase the throughput of the mailing machine 10 as compared with conventional mailing machines that required waiting for a previous mail piece to be fully processed before accepting the weight of the subsequent mail piece. In addition, a configurable queue size along with the use of messages to indicate to the user when processing limits were reached will help the user to optimize performance of the mailing machine 10 for each user.
According to another embodiment of the invention, the use of the queue 60 allows the mailing machine 10 to perform a maintenance operation for the print head of printer 52 when the maintenance operation is requested, instead of having to wait until the end of a mail run. Such maintenance includes, for example, a wipe of the print head or a purge of the print head, and is required to ensure that all nozzles of the print head are properly operating. The print head is typically moved to a maintenance position, maintenance is performed, and the print head is returned to the home position for printing. Thus, after a predetermined amount of time or number of print head cycles, the control unit 20 (or a separate printer controller (not shown)) will require a maintenance operation to be performed on the print head of the printer 52. It should be noted that such a maintenance operation may be required asynchronously, i.e., while a mail piece is traveling through the mailing machine 10. In conventional mailing systems, the maintenance operation, if possible, would be delayed until the end of a mail run, e.g., when the user has completed processing all pieces of the current batch. Some maintenance operations cannot be delayed until the end of the mail run, but instead would stop the mail run to perform the maintenance operation. The user would then be required to restart the mail run, adding additional delay to the processing of the mail run. Mailing machine 10, according to an embodiment of the present invention, allows the transport 50 to pause when a maintenance operation is requested, thereby allowing the printer maintenance to occur when requested, without having to stop and then restart the mail run. For example, the mail piece could be held on the feed deck 30 at the input end 16 of the mailing machine 10, or paused on the feed deck 30 at the entrance to the moistening/sealing module located in the area indicated by reference numeral 36. Once the printer maintenance has occurred, the control unit 20 will still associate the proper weight or postage rate (if already calculated based on the weight) with the mail piece that was paused within the mailing machine 10, thereby maintaining the integrity of the mail piece. By eliminating a delay until the printer maintenance is performed, the mailing machine 10 provides the highest quality, consistently printed indicia on each mail piece, without affecting the mail piece integrity and minimally impacting the throughput. If mailing machine 10 is printing the indicia on a tape from the tape drive 56, a tape will not be printed until the maintenance has been completed.
Another type of weighing and feeding error results when the user places a mail piece on the feed deck 30 without first having the weight of the mail piece being entered into the control unit 20. According to an embodiment of the present invention, if the queue 60 does not have an entry (and the mailing machine is not performing the full queue processing routine as described above), and the sensors 34 detect a mail piece on the feed deck 30 waiting to be processed by the mailing machine 10, a message will be displayed to the user, utilizing, for example the display 24, that indicates the weight was required for the mail piece. Thus, instead of remaining idle as previous conventional mailing machines, the mailing machine 10 will inform the user of the error. In the case of a mail piece that has been ingested and paused downstream waiting for a valid weight, the control unit 20 will cause the mailing machine to run the mail piece through the mailing machine without any processing being performed and eject the mail piece without being imprinted upon. A message will be displayed to the user, utilizing, for example the display 24, that indicates the weight was required for the mail piece. Thus, instead of remaining idle as previous conventional mailing machines, mailing machine 10 will eject the mail piece and inform the user of the error. The user, therefore, will be fully aware of the problem, and not make any assumptions with respect to the operating status of the mailing machine 10.
While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims.
