Patent Application
20070090028
The invention generally relates to a sorting mechanism and method of use and, more particularly, to a system and method for transferring product to multiple sorters for sorting of the product.
The sorting of mail is a very complex, time-consuming task. In general, the sorting of mail is processed through many stages, including back end processes, which sort or sequence the mail in delivery order sequence. These processes can either be manual or automated, depending on the mail sorting facility, the type of mail being sorted such as packages, flats, letters and the like. A host of other factors may also contribute to the automation of the mail sorting, from budgetary concerns to modernization initiatives to access to appropriate technologies to a host of other factors.
In general, however, most modern facilities have taken major steps toward automation by the implementation of a number of technologies. These technologies include, amongst others, letter sorters, parcel sorters, advanced container conveyors, flat sorters and the like. As a result of these developments, postal and other types of handling facilities have become quite automated over the years, considerably reducing overhead costs.
Although known automated systems have provided many benefits, there are still improvements that can be made in order to minimize costs and maximize efficiencies. For example, current sorting systems are limited in their sorting speed, abilities and flexibility by their current designs. This is due to the fact that sorters are not integrated with one another, thus reducing overall throughput of the system.
The invention is designed to overcome one or more of the above problems.
In a first aspect of the invention, an apparatus comprises at least one unload module and at least two sorters. An intermediate sort conveyor is configured to receive product from the at least one unload module and divert the product to either of the at least two sorters via a plurality of induction units in a transportation path with the at least two sorters.
In another aspect of the invention, a system for sorting product comprises at least three sorters, including a first sorter, a second sorter and a third sorter. A first intermediate sort conveyor has induction units for inducting product to either of the first sorter and the second sorter. A second intermediate sort conveying has induction units for inducting product to either of the second sorter and the third sorter. A pre-sorter loop is configured to, with no order being implied by the reference numerals:
In yet another aspect of the invention, a system for sorting mail comprises a sorting mechanism comprising n+1 sorters and an intermediate conveying system having (n+1)-1 conveyors. Each of the conveyors is alternatively positioned with the n+1 sorters and has induction units to induct mail pieces to each adjacent sorter. At least one unload module is configured to induct the mail pieces to each of the conveyors. Also, the at least one unload module is configured to have a capacity which is equal to or less than a throughput of the n+1 sorters.
In another aspect of the invention, a method for sorting mail pieces includes obtaining product information from mail pieces and inducting the mail pieces onto at least one intermediate sort conveyor. The method further includes determining whether the mail pieces should be inducted onto one of at least two adjacent sorters, for sequencing or sorting to another depth level. If the determining step is affirmative, the mail pieces are inducted onto one of at least two adjacent sorters for sequencing or sorting to another depth level. If the determining step is negative, the mail pieces are inducted onto an intermediate conveyance from the at least one intermediate sort conveyors. The mail pieces are transported to another sorter, which was not originally in a transportation path with the at least one intermediate sort conveyors.
The invention is directed to an integrated system and method capable of transferring product between two or more sorters for sorting of the product. The product may be, for example, flats, parcels, packages and other mail items (i.e., letters), baggage, etc. for future delivery or warehousing or the like. The invention significantly reduces machine costs by reducing material handling equipment, while improving overall throughput of multiple sorters. The system of the invention is modular, in nature, and can be implemented across different machines, over several machines and, in embodiments, can be easily retrofitted to sequentially add sorters to a preexisting machine configuration. Other applications such as warehousing and storage applications are also contemplated for use with the invention.
In one aspect of the invention, several machines can be integrated into one effective machine by use of interconnecting conveyors to permit product delivery from multiple locations. By use of the invention, as discussed in greater detail below, sorters can be fed from one or more unload modules, independently, with multiple induction and discharge units to achieve increased throughput. In addition, by using the system of the invention, induction and discharge units can be placed in multiple locations on the sorters, thus significantly reducing the length of interconnecting conveyor runs, saving valuable flooring space.
Referring now to
It should be understood by those of skill in the art that the components discussed herein such as, for example, the transportation paths, as well as any of the induction units, conveyors, etc, can be separate components, which are integrated together during the assembly process. In alternative embodiments, some or all of these components may be integrated components, prior to the assembly of the integrated system such as, for example, an induction unit associated with a sorter, as one non-limiting example. In either situation, the fully assembled system is an integrated system with all of the constituent components described herein. Thus, the description herein contemplates all situations and should not be limited to any of the components being initially integrated or separated.
Unload Module
The unload module 100 further includes a singulator unit 115 in the transportation path of the conveyor 110. The singulator unit 115 singulates the incoming product into a stream of product, which is transported to an imaging unit 120. The imaging unit 120, in one embodiment, will obtain product information from the product, by use of bar code scanners or optical reader scanners, etc., which will be provided to a control “C”, via a network or other type of communication path. The controller “C” will reconcile the product information for future sorting and/or sequencing, in a well-known manner. The controller “C” may also be in communication with many of the other sub-systems of the invention, as needed.
Induction System
Intermediate Sort Conveyor
The intermediate sort conveyor 300 includes a plurality of induction units 305, which are designed to induct product onto different sorters. In one non-limiting illustration, the intermediate sort conveyor 300 is configured as a loop, with a number of the plurality of induction units 305a located at one side of the loop and a number of the plurality of induction units 305b located at another side of the loop. In this configuration, the induction units 305a, 305b can feed product to two sorters, one located on each side of the intermediate sort conveyor 300. In one embodiment, the induction units 305a, 305b may be equal in number, and in one specific embodiment, may be four induction units positioned on each side of the loop of the intermediate sort conveyor 300.
The intermediate sort conveyor 300 also includes discharge units 310, which are designed to discharge product, which cannot be sorted on an adjacent sorter, onto an intermediate pre-sorter (discussed below). In one embodiment, the discharge units 310 may be belt conveyors, rollers, or the like.
In one aspect of the invention, the discharge units 310 comprise a number of discharge units 310a located at one side of the loop and a number of the discharge units 310b located at another side of the loop. In this configuration, the discharge units 310a, 310b can discharge product to different locations on the intermediate pre-sorter. In one embodiment, the discharge units 310a, 310b may be equal in number, and in one specific embodiment, may be two discharge units positioned on each side of the loop of the intermediate sort conveyor 300.
Sorter
The sorter 400, in one aspect of the invention, is connected to the intermediate sort conveyor 300, via the induction units 305a, 305b. In one embodiment, a sorter will be located at a first side of the intermediate sort conveyor 300 and another sorter will be located at an opposing, second side of the intermediate sort conveyor 300. In this configuration, the induction units 305a can induct product onto one sorter and the induction units 305b can induct product onto another sorter, thus increasing the overall throughput of the system. The controller “C” is used to reconcile product information with that of the appropriate bin location, for drop off, sorting and/or sequencing.
Intermediate Pre-Sorter
The intermediate pre-sorter 500 additionally includes one or more discharge units 510. Although four discharge units 510 are shown, it should be understood that more than four discharge units 510 are contemplated by the invention, depending on the number of sorters and the required throughput of the system. The discharge units 510 may be connected to each individual sorter 400, via transports 700. The discharge units 510 and the induction units 505 may be conveyor belts, rollers or the like.
Still referring to
As seen in the configuration of
Still referring to
As further shown, the induction units 305a, 305b of the intermediate sort conveyors 300a-300c are connected to the respective sorters 400a-400d, at induction zones. For example, in the configuration of
In this manner, the intermediate sort conveyors 300a-300c can convey product to two respective sorters, as they are received from the associated unload modules 100a-100f. In this configuration, the intermediate sort conveyors 300a-300c each have multiple inputs and discharges so product retention of product on the intermediate sort conveyors 300a-300c is reduced to an absolute minimum.
At this stage, product can be sorted to a certain depth level (and in embodiments, in a sequence) on the sorters 400a-400d, under control of the controller “C”. By way of illustration, product is inducted onto one of the intermediate sort conveyors 300a-300c, after product information is obtained by the imaging units and reconciled by the controller “C”. As the intermediate sort conveyors 300a-300c and sorters 400a-400d rotate clockwise, the product will be inducted from the intermediate sort conveyor onto a connected sorter, if appropriately determined by coordination of the controller “C”. As the sorter rotates it will drop the product into a bin of one bin location. By making one or more loops around the sorter, while additional product is being inducted and other product is being ejected into bin locations, the controller “C” can determine the proper drop off location of the inducted product into an appropriately determined bin, in a sequence, with relation to other product within that bin.
Product that is not inducted from any of the intermediate sort conveyor 300a-300c to adjacent sorters 400a-400d can be discharged onto the intermediate pre-sorter 500, via the respective discharge units 310a, 310b, the transports 600 and induction units 505a, 505b, as shown in the fully integrated system of
Sensors such as photodiodes and/or encoders can be used to maintain track of the product throughout the entire integrated system, as generally represented at “P”. In one implementation, the sensors “P” are in communication with the controller “C”. In one example, product may be inducted onto the intermediate sort conveyor, at which time it will pass through (interrupts) a light beam of the photodiode. Using an encoder, and knowing that the product just interrupted a beam of the photodiode, the controller can determine the particular location of the product within the integrated system can implement all of which implemented by those of skill in the art. This same or similar procedure can be used at any location within the integrated system to determine the location of any product within the system.
By using the intermediate pre-sorter 500, any product from any of the unload modules 100a-100f can be inducted onto any of the sorters 400a-400d, via the transports 700. In one embodiment, the transports 700 are maximized to increase throughput to the sorters 400a-400d. Thus, as shown in the fully integrated system of
By using the intermediate pre-sorter 500, product can be sorted to a certain depth level (and in embodiments, in a sequence), under control of the controller “C”. By way of illustration, product is first inducted onto one of the intermediate sort conveyors 300a-300c, after product information is obtained by the imaging units and reconciled by the controller “C”. As the intermediate sort conveyors 300a-300c and sorters 400a-400d rotate clockwise, some product will be inducted from the intermediate sort conveyor onto a connected sorter, if appropriate, and remaining product will be inducted onto the pre-sorter 500, under control of the controller “C”. As the pre-sorter 500 rotates it will divert the product onto a respective transport 700 for induction onto one of the sorters 400a-400d, under control of the controller “C”. Once inducted onto the sorters 400a-400d, the product can be ejected into a proper bin location, in sequence or other sort depth, as described above.
In the example of
The remaining 10,000 product are then inducted onto the intermediate pre-sorter, for transport to another sorter. For example,
In example of
Also, in the example of
The intermediate pre-sorter 500, in turn, is connected to one or more sorters 400a, 400b, 400c and 400d, via discharge transports 700. It should be understood that two or more sorters may be used in the implementation of
By using the intermediate pre-sorter 500, any product from any of the unload modules can be inducted onto any of the sorters 400a-400d, via the transports 700 and under control of the control “C”. By way of illustration, product is first inducted onto the intermediate pre-sorter 500, after product information is obtained by the imaging units and reconciled by the controller “C”. As the intermediate pre-sorter 500 and sorters 400a-400d rotate, some will be inducted from the intermediate pre-sort conveyor onto the appropriate sorter, under control of the controller “C”. Once inducted onto the sorters 400a-400d, the product can be ejected into a proper bin location, in sequence or other sort depth, as described herein.
At step 800, the product is inducted into the unload modules, where the product is singulated into a stream. At step 802, an imaging unit captures or obtains product information, which is provided to the controller. At step 804, the product is inducted onto an intermediate sort conveyor. At step 806, a determination is made as to whether the product should be inducted onto an adjacent sorter, for sequencing or to another sort depth. If the determination is affirmative, a determination is then made as to whether the product should be inducted onto an upper or lower sorter, both adjacent to the intermediate sort conveyor, at step 808. This determination is made based on the product information of the product.
If the product is to be inducted onto the top sorter, at step 810, the product is inducted onto the top sorter at an appropriate time and location. Likewise, if the product is to be inducted onto the bottom sorter, at step 812, the product is inducted onto the bottom sorter at an appropriate time and location. At step 814, the product is dropped into an appropriate bin location, in a sequence or certain sort depth with respect to other product, under coordination of the controller.
If the product is to be inducted onto a non-adjacent sorter, the process continues at step 816. At step 816, a determination is made, based on product information, to transport the product to one of the non-adjacent sorters. At step 818, the product is inducted onto the intermediate pre-sorter and transported to the appropriately determined sorter for induction. At step 820, the product is inducted onto the appropriate sorter, from the intermediate pre-sorter. The process then returns to step 814, wherein the product is dropped into an appropriate bin location, in a sequence or certain sort depth with respect to other product. The process then ends, at step “E”.
While the invention has been described in terms of 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.
