Patent Grant
7516949
This application is related to U.S. Pat. No. 6,802,500, entitled “Systems And Methods Of Providing Inserts Into Envelopes,” issued Oct. 12, 2004; U.S. Pat. No. 6,670,569, entitled “Mail Handling Equipment And Methods,” issued Dec. 30, 2003; U.S. Pat. No. 6,623,415, entitled “Sheet Folding Systems And Methods,” issued Sep. 23, 2003; and U.S. patent application Ser. No. 10/718,285, entitled “Multiple Insert Delivery Systems and Methods,” filed Nov. 19, 2003; each of which is assigned to the assignee of the present application and each of which is incorporated herein by reference.
NOT APPLICABLE
NOT APPLICABLE
The present invention relates generally to the field of sheet processing systems and methods, and more particularly, to systems and methods for aligning and organizing sheets, such as paper statements, inserts, financial documents, and the like.
Financial institutions, long distance telephone companies, and a number of other organizations frequently send paperwork to existing or potential customers. For example, a credit card customer may receive monthly statements, informational inserts, sheets of convenience checks, and the like. In some circumstances, the paperwork accompanies a card, such as a credit card or the like, mounted in or to a card carrier. In order to send the paperwork and/or card to a customer, the information may be sent first to a third party organization for processing and mailing. One such organization is First Data Merchant Services Corporation (FDMS).
Mail processing systems are currently used to mail, for example, a sheet of convenience checks to a customer. Current systems typically will print the checks on an individual sheet of paper, stack large numbers of sheets in a bin, individually retrieve each sheet, and then process the sheet for eventual delivery to the customer. The high volume of mailings, however, can make this an expensive process. Moreover, current systems may be incapable of processing different batches of sheets, where the location of bar codes on the sheets vary from one batch to another.
The present invention relates to machines and techniques that address at least some of the problems of the current processing equipment. For example, the present invention provides machines and techniques that may be used to process such media in a more cost efficient manner.
In a first aspect, the present invention provides a method for processing a series of sheets. The method includes advancing a first sheet in a first direction to an alignment mechanism, reading a first identification code of the first sheet, advancing the first sheet in a second direction to an accumulator, wherein the second direction is substantially perpendicular to the first direction, advancing a second sheet in the first direction to the alignment mechanism, reading a second identification code of the second sheet, and comparing the first identification code with the second identification code. In some aspects, the method includes advancing the second sheet in the second direction to match with the first sheet in the accumulator, if the second identification code corresponds with the first identification code. In a related aspect, the step of advancing each sheet to the alignment mechanism can include aligning the sheet with an alignment plate of the alignment mechanism. Similarly, the step of advancing each sheet to the alignment mechanism can include advancing a bottom sheet of a sheet stack to the alignment mechanism. The step of advancing each sheet to the alignment mechanism can also include verifying that a single sheet at a time is advanced to the alignment mechanism. In some aspects, the step of advancing each sheet to the alignment mechanism may include verifying that each sheet is fully advanced to the alignment mechanism and is aligned within the alignment mechanism. Optionally, advancing each sheet to the accumulator can include contacting each sheet with a friction wheel, which may be in operative association with a rotary solenoid. In some cases, the identification code of one or more sheets includes a bar code. Relatedly, the identification code can include a set number identifier and a sequence number identifier. In further aspects, the step of reading the identification code may include scanning the identification code with a laser scanner.
In another aspect, the present invention provides a system for processing a series of sheets. The system can include an alignment mechanism comprising an alignment plate, a first advancing mechanism that is configured to individually advance each sheet of the series of sheets in a first direction from a lower feeder to the alignment mechanism, a second advancing mechanism that is configured to individually advance each sheet of the series of sheets in a second direction from the alignment mechanism to an accumulator, wherein the second direction is substantially perpendicular to the first direction, a sensor that is configured to read an identification code of each sheet of the series of sheets, and a processor configured to control operation of the first and second advancing mechanisms based on sensor readings of the identification codes. In some aspects, the alignment mechanism can include an alignment plate. In further aspects, the system may include a count sensor configured to verify that a single sheet at a time is advanced to the alignment mechanism. In still further aspects, the system can include an orientation sensor configured to verify that each sheet is fully advanced to the alignment mechanism and is aligned within the alignment mechanism. Optionally, the second advancing mechanism can include a friction wheel adapted to contact a sheet disposed in the alignment mechanism upon instructions from the processor. The friction wheel may be in operative association with a rotary solenoid. In some aspects, the sensor can include a laser scanner.
In another aspect, the present invention provides a computer program product for processing a series of sheets. The program product can include code for advancing a first sheet in a first direction to an alignment mechanism, code for reading a first identification code of the first sheet, code for advancing the first sheet in a second direction to an accumulator, wherein the second direction is substantially perpendicular to the first direction, code for advancing a second sheet in the first direction to the alignment mechanism, code for reading a second identification code of the second sheet, code for comparing the first identification code with the second identification code, and a computer-readable medium for storing the codes. In some aspects, the computer program product may also include code for advancing the second sheet in the second direction to match with the first sheet in the accumulator, if the second identification code corresponds with the first identification code.
The present invention provides systems and methods for advancing and organizing sheets, such as improved alignment techniques that allow for efficient sheet processing. For example, a system of the present invention can advance a sheet in a first direction from a feeder to an alignment mechanism, and then advance the sheet in a second direction from the alignment mechanism to an accumulator, such that the first direction is substantially perpendicular to the second direction. Such alignment approaches provide several benefits. As the sheet is fed into the alignment mechanism, it can be advanced against an alignment member, thereby placing the sheet in a desired orientation. The operator can therefore be assured that the sheet is appropriately aligned when it is advanced from the alignment mechanism to an accumulator or to some other downstream processing station.
Often, such systems will include a sensing apparatus for reading bar codes or other indicia on the sheet. Advantageously, the system can be configured such that such a sensing step is carried out when the sheet is in the desired position, after the alignment step is completed. This feature can help to ensure an accurate reading of the bar code, because the sheet is stationary and properly aligned.
Relatedly, the present invention provides systems and methods where the position of the sensing apparatus can be easily adjusted, in order to accurately read bar codes or other indicia from sheets as they are advanced through the system. Such adjustability is convenient when processing sheets from different batches, where the location of the bar code on the sheet may vary from one batch to another. It will be appreciated that such adjustability also provides for the accurate processing of sheets where the orientation of the indicia varies from one batch to another. The system can also be adjusted to sense indicia that are located on the top of the sheet, or on the bottom of the sheet.
Turning now to
Feeder 2200 may further include a lower advancing mechanism 2220 or similar conveying means for advancing one or more sheets from lower feeder tray 2204 toward a downstream processing location. For example, lower advancing mechanism 2220 may include a plurality of lower rollers 2222 and a plurality of lower belts (see
In the embodiment shown in
In one embodiment, a sheet is fed into alignment mechanism 2300 and advanced against alignment member 2330 to place the sheet in a desired orientation, and orientation sensor 2354 can confirm the sheet orientation. Sheet information sensor can then read a bar code that is printed on the sheet, and system 2300 can further process this sheet, or other sheets in the system, based on the sheet information sensor reading.
Second advancing mechanism 2320 can also include one or more second rollers 2322 which are configured to grasp the sheet from its position at alignment member 2330 and advance the sheet in direction 2610 toward accumulator 2400. In some embodiments, second advancing mechanism can further include a rotary solenoid 3322 and a support bar 3328. In the embodiment shown here, second roller 3322 is continuously rotating during operation of system 3000. The default for roller 3322 is in a raised position, so that sheets can advance freely from lower feeder tray 3204 to alignment mechanism 3300. Rotary solenoid 3326 can be configured to control an up and down movement of second roller 3322. When system 3000 determines that a sheet should be conveyed from alignment mechanism 3000 toward accumulator 3400, rotary solenoid 3326 may effect a downward movement of second roller 3322. Subsequently, second roller 3322 contacts the sheet and impels the sheet toward accumulator 3400.
In the present embodiment, direction 2600 is substantially perpendicular to direction 2610. In other words, alignment mechanism 2300 can be configured such that system 2000 has an approximate ninety degree (90°) turn for sheets processed therethrough. In this manner, system 2000 can maintain a small footprint. The ninety degree turn also can help align the sheet for certain operations to be performed on the sheet while it is disposed at alignment mechanism 2300. For example, the sheet may be subjected to certain sensing procedures which require or are facilitated by the alignment. Similarly, such alignment may further prepare the sheet for additional downstream processing steps. Brush 2350 can further assist in the alignment of the sheet by preventing or inhibiting the sheet from lifting off of alignment mechanism 2300 or from unwanted transverse movement on alignment mechanism 2300.
The first and second sheets can then be prepared for other downstream processing steps. For example, they may be conveyed to a folding section (not shown) where they are folded, and to an envelope stuffing section (not shown) where they are placed in an envelope. The envelope can then be sealed and inserted into a postage meter where it is stamped with the appropriate postage. The envelope is then ready for mailing.
Lower advancing mechanism 4220 may further include one or more adjustment knobs 4250, which may be used by a system operator to adjust the setting of lower rollers 4222. For example, lower rollers 4222 can be adjusted such that only one sheet at a time is advanced from lower feeder tray 4204 toward alignment mechanism 4300. Second advancing mechanism 4320 can include an orientation sensor 4354 which can be configured to determine whether sheet is advanced completely into alignment mechanism and oriented therein as desired. It is appreciated that the position of orientation sensor 4354 can be adjusted as desired, so that it can effectively confirm the position and orientation of the sheet.
As the sheet is conveyed to alignment mechanism 4300, it can be advanced over a sheet information sensor (see
As noted above, first and second sheets can be matched by selective processing of the sheets. Often, once the initial first and second sheets have been processed, the procedure is repeated so that a continuous stream of matched first and second sheets are placed onto accumulator 4400 and then advanced for further processing.
In some embodiments, sheet information sensor 9370 includes a laser scanner or other type of light sensor. For example, a laser scanner can include a laser beam as a light source. A reciprocating mirror or rotating prism can scan the beam back and forth across the bar code. The scanner typically includes a photo diode to measure the intensity of light reflected back from the bar code. The scanner can then provide electrical output to a decoder that corresponds to the bars and spaces of the bar code, and the interpreted signals can be transmitted to the system controller. The present invention may incorporate any of a variety of commercially available sensors, such as those manufactured by Microscan®.
Subsequently, the method may include advancing the Nth sheet in a second direction from the alignment mechanism toward an accumulator (step 110c). The second direction may be at a specific angle as compared to the first direction. For example, the second direction may be substantially perpendicular to the first direction. After advancing the Nth sheet to the accumulator, the method may include determining if an (N+1)th sheet is available (step 110d).
If the (N+1)th sheet is not available, the method may include advancing the sheet contents of the accumulator to a downstream processing apparatus (step 11e) and ending the procedure (step 110f). If (N+1)th is available, the method may include advancing the (N+1)th in the first direction from the lower feeder to the alignment mechanism (step 110g), reading the (N+1)th identifier from the (N+1)th sheet (step 110h), and comparing the (N+1)th sheet identifier with the Nth sheet identifier (step 110i).
In the comparison indicates that the (N+1)th sheet does belong with the Nth sheet (step 110j), the method may include incrementing N by one by setting N=N+1 (step 110k), and returning to step 110c. If the comparison indicates that the (N+1)th sheet does not belong with the Nth sheet (step 1101), the method may include advancing the sheet contents of the accumulator to a downstream processing apparatus (step 110m), incrementing N by one by setting N=N+1 (step 110k), and returning to step 110c.
Likewise, in some embodiments system 120 may also include a storage subsystem 120j that can store the basic programming and data constructs that provide the functionality of the various embodiments of the present invention. For example, software modules implementing the functionality of the methods of the present invention, as described herein, may be stored in storage subsystem 120j. These software modules are generally executed by the one or more processors 120b. In a distributed environment, the software modules may be stored on a plurality of computer systems and executed by processors of the plurality of computer systems. Storage subsystem 120j can include memory subsystem 120k and file storage subsystem 1201. Memory subsystem 120k may include a number of memories including a main random access memory (RAM) 120m for storage of instructions and data during program execution and a read only memory (ROM) 120n in which fixed instructions are stored. File storage subsystem 1201 can provide persistent (non-volatile) storage for program and data files, and may include tangible storage media which may optionally embody patient, provider, payer, or other healthcare or financial data. File storage subsystem 1201 may include a hard disk drive, a floppy disk drive along with associated removable media, a Compact Digital Read Only Memory (CD-ROM) drive, an optical drive, DVD, CD-R, CD-RW, solid-state removable memory, other removable media cartridges or disks, and the like. One or more of the drives may be located at remote locations on other connected computers at other sites coupled to system 120. The modules implementing the functionality of the present invention may be stored by file storage subsystem 1201. In some embodiments, the software or code will provide protocol to allow the system 120 to communication with or control other components of the sheet processing system, such as the upper advancing mechanism, the lower advancing mechanism, the first advancing mechanism, the second advancing mechanism, the rotary solenoid, and various sensors of the system.
The system may be configured to include or execute a computer program product for processing a series of sheets. In one embodiment, the program product can include code for advancing a first sheet in a first direction to an alignment mechanism, code for reading a first identification code of the first sheet; code for advancing the first sheet in a second direction to an accumulator, wherein the second direction is substantially perpendicular to the first direction, code for advancing a second sheet in the first direction to the alignment mechanism, code for reading a second identification code of the second sheet, code for advancing the second sheet in the second direction to match with the first sheet in the accumulator if the second identification code corresponds with the first identification code, and a computer-readable medium for storing the codes.
It is appreciated that system 120 can be configured to carry out various methods of the present invention. For example, processor component or module 120b can be a microprocessor control module configured to receive signals from input device or module 120c, and transmit signals to output device or module 120d and/or interface device or module 120e. Each of the devices or modules of the present invention can include software modules on a computer readable medium that is processed by a processor, hardware modules, or any combination thereof. Any of a variety of commonly used platforms, such as Windows, Macintosh, and Unix, along with any of a variety of commonly used programming languages, may be used to implement the present invention.
User interface input devices 120c may include, for example, a touchpad, a keyboard, pointing devices such as a mouse, a trackball, a graphics tablet, a scanner, a joystick, a touchscreen incorporated into a display, audio input devices such as voice recognition systems, microphones, and other types of input devices. User input devices 120c may also download a computer executable code from a tangible storage media or from a communication network, the code embodying any of the methods of the present invention. It will be appreciated that system software may be updated from time to time and downloaded to the system as appropriate. In general, use of the term “input device” is intended to include a variety of conventional and proprietary devices and ways to input information into system 120.
User interface output devices 120c may include, for example, a display subsystem, a printer, a fax machine, or non-visual displays such as audio output devices. The display subsystem may be a cathode ray tube (CRT), a flat-panel device such as a liquid crystal display (LCD), a projection device, or the like. The display subsystem may also provide a non-visual display such as via audio output devices. In general, use of the term “output device” is intended to include a variety of conventional and proprietary devices and ways to output information from computer system 120 to a user.
Bus subsystem 120a provides a mechanism for letting the various components and subsystems of system 120 communicate with each other as intended. The various subsystems and components of system 120 need not be at the same physical location but may be distributed at various locations within a distributed network. Although bus subsystem 120a is shown schematically as a single bus, alternate embodiments of the bus subsystem may utilize multiple busses.
It will be apparent to those skilled in the art that substantial variations may be used in accordance with specific requirements. For example, customized hardware might also be used and/or particular elements might be implemented in hardware, software (including portable software, such as applets), or both. Further, connection to other computing devices such as network input/output devices may be employed. System 120 itself can be of varying types including a computer terminal, a personal computer, a portable computer, a workstation, a network computer, or any other data processing system. Due to the ever-changing nature of computers and networks, the description of system 120 depicted in
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