Embodiments of the present disclosure relate to mail handling and processing systems for mail and related articles and, more particularly, to systems and methods for adjusting the contents in an automated mail receiving tray.
Mail received at a post office or other location is sorted or otherwise processed so that it can be directed to a desired location. To accomplish this function, sortation machines with output pockets are used to sort various mail products. Typically, the product that arrives in the output pockets of a sortation machine is removed manually and placed in movable containers, trays, or other containing devices so that it can be moved through additional sortation processes or dispatched to arrive at its intended destination. As an example, letters sorted on a Delivery Bar Code Sorter (DBCS) arrive in letter trays. An operator manually moves the letters from the trays onto a feeder load ledge to begin the sort process. Once sorted to the sorter pockets of the DBCS, an operator removes the letters from the output pockets and places them in a labeled letter tray so they can be transported to the next processing step.
More advanced sortation/feeder systems can be automated in a number of ways. Some utilize automation trays with a moveable bottom that can lift mail contents upward so that mail can be swept from the tray to another location. Unfortunately, if the automation tray is not completely filled with mail product, the mail can fall over within the automation tray. This can lead to undesirable damage of the mail product as automation equipment attempts to sweep the non-vertical mail out of the tray. Therefore, it is now recognized that a need exists for an efficient and simple to operate mechanism for controlling a position of mail within an automated mail tray.
In accordance with the above, presently disclosed embodiments are directed to a system and method for controlling/adjusting a position of mail product or other contents in an automated mail tray. In general, a partially full mail tray is not able to keep a stack of vertically oriented mail product from falling over on its side while the mail product is being elevated in the tray by a moveable tray bottom. If the mail in the tray falls over, then an automated sweeping mechanism may damage or fail to effectively sweep the mail away from the tray. To prevent this condition, the disclosed system will first recognize that the mail has fallen and then correct the placement of the mail back into a vertical position.
To that end, the system may include an automated mail tray with a ridged construction to allow automation equipment to adjust, load, and unload mail product in a structured manner. In some embodiments, the system may include an automated mail tray and an adjustment feature that is able to adjust a position of the mail product disposed in the mail tray. The automated mail tray may include a moveable bottom surface that can be elevated with or without contents being present until the bottom surface reaches the heights of the side walls of the mail tray. The same effect may be accomplished by moving the side walls down from the bottom surface.
The automated mail tray may have slots formed in the bottom surface of the mail tray. The adjustment feature may include a set of fingers that is designed to be inserted through the slots in the bottom surface of the mail tray. For example, the adjustment feature may include a ramp formed from profiled fingers designed to be inserted from beneath the bottom surface to push the mail toward a relatively vertical position within the mail tray. Additional sets of fingers on automated paddles may be moved through the spaces in the ramp to sweep the mail product out of the mail tray when the bottom surface is in an elevated position. Such a system allows the automated equipment (paddles) to move any desirable amount of mail product out of the automated mail tray while maintaining the mail product in a vertical position so that it is not damaged.
In other embodiments, the system may include an automated mail tray and one or more sensors for detecting a position of mail product in the tray by looking through holes (or some other opening) in the tray. The holes may be disposed through a side wall of the automated mail tray, or through a bottom surface of the automated mail tray. The system also includes an adjustment feature that may be used to adjust a position of contents in the automated mail tray. The adjustment feature may include fingers that are able to access the contents of the mail tray through slots in a bottom surface of the mail tray.
The mail tray may include a moveable bottom surface. The moveable bottom surface may be elevated with or without contents being present until the bottom surface reaches the height of the side walls of the mail tray. The moveable bottom surface may be moved upward such that the mail tray bottom remains perpendicular with the side walls of the automated mail tray. In some embodiments, the moveable bottom may also be able to pivot about one end to angle the bottom so that it is not perpendicular to the tray walls. The moveable bottom may be pivoted in this manner to aid the adjustment feature in controlling a position/orientation of the mail product in the tray.
The system may further include a controller communicatively coupled to the sensors, the adjustment feature, and various actuators for moving the bottom of the mail tray. The controller detects, based on signals received from the sensors, when the mail product has fallen from a vertical orientation within the automated mail tray. The controller may then output appropriate signals to actuate the adjustment feature and/or the moveable tray bottom to bring the mail product back to a desired vertical position. Once the mail is in the vertical position, the moveable tray bottom may lift the mail product to a position where the mail tray bottom is perpendicular with and disposed at the upper level of the mail tray walls. This allows the mail contents to be elevated out of the tray for movement into other automation equipment without tray wall interference.
For a more complete understanding of the present disclosure and its features and advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
Illustrative embodiments of the present disclosure are described in detail herein. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation specific decisions must be made to achieve developers' 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 the present disclosure. Furthermore, in no way should the following examples be read to limit, or define, the scope of the disclosure.
Turning now to the drawings,
The mail tray 12 may include four side walls 26 connected to each other and disposed around the bottom surface 24 to define the external bounds of the mail tray 12. The bottom surface 24 of the mail tray 12 may be moveable relative to the side walls 26. For example,
In some embodiments, the moveable bottom surface 24 may be raised by exerting force under the bottom surface 24 and held in place while mail is being loaded onto or swept off the bottom surface 24. In some embodiments, the automated mail tray 12 may include an actuation mechanism 22 that automatically lifts the bottom surface 24 relative to the side walls 26 of the mail tray 12. In other embodiments, a shelf or other component upon which the automated mail tray 12 is disposed may feature an actuation mechanism (not shown) that selectively pushes up against the bottom surface 24 to move the bottom surface 24 to the elevated position 52 relative to the side walls 26 of the mail tray 12. Other mechanisms may be utilized in other embodiments for automatically moving the bottom surface 24 of the mail tray 12 between the lowered position 50 and the upper position 52.
In some embodiments, the bottom surface 24 of the automated mail tray 12 may be designed to pivot between a level position 54 (e.g., perpendicular to the side walls 26) and an angled position 56, as shown in
In still other embodiments, the automated mail tray 12 may include one or more actuation mechanisms 22 designed to move the bottom surface 24 up and down relative to the side walls 26 and to angle the bottom surface 24 relative to the side walls 26 as desired. That way, the bottom surface 24 can be rotated into a non-perpendicular position relative to the side walls 26 even when the bottom surface 24 is in a vertically elevated position within the mail tray 12. An example of this can be seen in
As mentioned above with reference to
As illustrated in
Returning to
Upon a determination that the mail product 20 in the automated mail tray 12 has fallen over, an adjustment mechanism 18 as shown in
In addition, the controller 16 may also output a control signal to one or more actuators 22 of the automated mail tray 12 to aid the adjustment mechanism 18 in repositioning mail product 20 that has fallen over in the mail tray 12. Specifically, the controller 16 may actuate the automated mail tray 12 to adjust the angle of the bottom surface 24 of the tray 12 relative to level (i.e., a horizontal plane 94). Such movement of the bottom surface 24 may aid in the adjustment of the position of mail contents 20 within the tray 12. This movement may be accomplished by actuating the bottom surface 24 relative to the side walls 26 of the automated mail tray 12, as shown in
In other embodiments, the automated mail tray 12 may be moved as a composite whole into a position where the bottom surface 24 is disposed at an angle relative to a horizontal plane 94, as shown in
Turning back to
The controller 16 may use the information received from the sensors 14 to determine an angle for actuating the bottom surface 24 of the tray 12 as well as a desired movement of the alignment fingers 90 through slots 92 in the bottom surface 24 of the tray 12. The bottom surface 24 of the tray 12 may be angled either relative to the side walls 26, or the entire tray 12 may be angled relative to a horizontal plane 94, as described with reference to
Another embodiment of the system 10 for adjusting mail product 20 in an automated mail tray 12 is illustrated in
As illustrated, the automated mail tray 12 may hold mail product 20 that does not entirely fill the tray 12. The mail product 20, therefore, may fall away from a vertical position in the automated mail tray 12. The adjustment mechanism 110 may be used to move the mail product 20 back toward a desired vertical position. In some embodiments, the automated mail tray 12 may be lowered down as a unit over the adjustment mechanism 110. In other embodiments, the adjustment mechanism 110 may be actuated upward into engagement with the automated mail tray 12. In either instance, the bottom surface 24 of the mail tray 12 may remain stationary with respect to the side walls 26 of the mail tray 12.
As described above with reference to
Once the mail tray 12 and/or ramped adjustment mechanism 110 have been moved into position to prop up fallen mail product 20, a first automated paddle 112A may be inserted into the automated mail tray 12. As illustrated in
As shown in
A second automated paddle 112B may be disposed or pre-set at an end of the mail tray 12 (opposite the first paddle 112A) to keep the mail product 20 in a vertical position after the downward actuation of the side walls 26. The first paddle 112A may be moved relative to the second paddle 112B until the mail product 20 is held in a vertical position between the two automated paddles 112. At this point, the paddles 112 may move together (arrow 126) off the bottom surface 24 of the mail tray 12, thereby moving the vertical mail product 20 out of the mail tray 12 and onto a processing load ledge 128. Once the mail product 20 is removed from the mail tray 12 in this manner, the mail tray 12 and/or the adjustment mechanism 110 may be actuated to return the mail tray 12 to its original position and out of engagement with the adjustment mechanism 110. From this position, the process may be repeated with a new load of mail product.
Although the present disclosure and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure as defined by the following claims.
This application claims priority to U.S. Provisional Application Ser. No. 62/295,344, entitled “System and Method for Adjusting Contents of an Automation Tray,” filed Feb. 15, 2016, which is herein incorporated by reference in its entirety.
Number | Name | Date | Kind |
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5347790 | Romanenko | Sep 1994 | A |
7210893 | Overman | May 2007 | B1 |
20050281662 | Carey | Dec 2005 | A1 |
20080164185 | Stemmle | Jul 2008 | A1 |
20130294879 | Middleberg | Nov 2013 | A1 |
Number | Date | Country | |
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20170232476 A1 | Aug 2017 | US |
Number | Date | Country | |
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62295344 | Feb 2016 | US |