Apparatus and method for positioning objects/mailpieces

This invention relates to conveying/positioning objects/mailpieces, and, more particularly, to an apparatus and method for positioning/centering objects/mailpieces to a desired reference position. The objects/mailpieces may be positioned in a clamping assembly employed in a mixed-mail sorting apparatus.

The 2003 Presidential Commission Report on the Future of the USPS concluded that the Postal Service should continue to develop effective mailstream merging systems that optimize efficiency, e.g., maximize the number of mailpieces shipped with each mile traveled, while minimizing the labor content associated with mailpiece handling. With respect to the latter, all elements of the mail stream (letters, flats, periodicals, post cards, etc,) should be sorted, merged, and/or sequenced with the expectation that no subsequent handling would be required at each of the local postal branch offices, i.e., other than the physical delivery to the recipient address.

Most postal services are actively exploring opportunities to reduce the overall cost of processing mail by investing in postal automation equipment, particularly in postal automation associated with mailpiece sorting processes. While significant progress has been made sorting conventional letter-size mailpieces, the remaining mailpieces, e.g., magazines, periodicals, newspapers, catalogues and other flats-size mailpieces, often are not machinable and must be hand sorted. While only twenty-percent (20%) of the mailstream may be catagorized as “non-machinable”, the time required to handle and sort such mailpieces is equal to or greater than the time spent sorting the other eighty percent (80%) of the mailstream.

Certain mailpieces are deemed non-machinable for two principal reasons. First, singulating mailpieces such as magazines and newspapers can present difficulties inasmuch as a portion of these mailpieces are unbound or unconstrained, that is, they have free-edges. As such, even small shear forces applied for the purpose of separating the mailpieces, can cause individual sheets or pages to be wrinkled, torn or otherwise damaged. Secondly, when such mailpieces are handled in the feeder, individual sheets or pages are prone to jam during sorting operations.

To combat the difficulties associated with handling these mailpieces, the mail entering automated postal equipment must be “prepared”, before sorting operations can begin. Preparation may include a process of culling mailpieces which are likely to stall or jam the sorting equipment, or, alternatively, packaging mailpieces so as to facilitate separation and/or reduce the propensity for jamming. For example, magazines or newspapers may be wrapped or enclosed within a larger envelope to capture or contain the free-edges of the mailpiece. While these activities can prepare mailpieces for automated processing, the labor expense can completely offset or nullify the fiscal benefits derived by such automated handling equipment.

The following documents disclose various systems and subsystems of a mail sorter capable of handling all varieties of mail, i.e., a mixed-mail sorter: WO 2006/063204, WO 2006/063121, WO 2006/063125, WO 2006/110486, WO 2006/110465, and WO 2006/110484. One of the most essential features of the mixed mail sorter relates to the use of a clamping assembly operative to secure, transport, divert, sort and release the mailpieces. in addition to its principle mechanical functions, the clamps also include a means to uniquely identify the clamp and its associated mailpiece. As such, the sorting operation may be performed by a combination of requisite information, i.e., electronically scanned information in connection with the mailpiece (e.g., its destination address) together with the unique identifier of the clamp. Further, the sorting process may be performed without altering/marking the mailpiece, such as via a printed barcode symbology or other identification mark.

Having described the functional significance of the clamping assembly, it will also be appreciated that a mailpiece should be centered within a clamp assembly to obviate certain handling difficulties/inconsistencies. More specifically, it will be understood that the gravitational center of the combined clamp/mailpiece assembly will rotate about the overhead conveyor bar (i.e., acting as a support pivot) such that all moments/forces are in equilibrium. When the centroid of the mailpiece is misaligned relative to the centerline of the clamp assembly, the combined clamp/mailpiece assembly may assume a skewed orientation (i.e., relative to the vertical) when the assembly is hung from the overhead conveyor bar. As such, difficulties may arise when attempting to divert the mailpiece to a subsequent conveyor bar or release the mailpiece into a bin/container.

While, in prior art mail sorters, it is generally known to align mailpieces along one or two edges, e.g., in register along adjacent edges or along a corner thereof, no methods or systems are currently available to accurately center a mailpiece within a clamp assembly. That is, there has been no physical requirement, heretofore, to align the geometric center or centroid of a mailpiece with the gravitational center of the clamp assembly.

A need, therefore, exists for an apparatus and method for positioning or centering an object/mailpiece to a desired reference position so as to ensure predictable conveyance and release of objects/mailpieces while being manipulated by automated handling equipment.

The accompanying drawings illustrate 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.

FIG. 1A is a schematic top view of an apparatus and method for positioning an object such as a mailpiece relative to a reference position within a clamp assembly.

FIG. 1B is a schematic side view of the apparatus and method shown in FIG. 1A .

FIG. 2 is a schematic top view of the apparatus and method of FIG. 1A wherein the mailpiece is conveyed along a transport mechanism and passes along a length sensor for measuring the mailpiece length

FIG. 3 is a schematic top view of the apparatus and method shown in FIG. 1A wherein the transport mechanism includes a displaceable drive element for controllably releasing the mailpiece at the desired reference position.

FIG. 4A is a schematic top view of the apparatus and method shown in FIG. 1A wherein a pair of spiral cams separates the jaws of the clamp assembly to accept the mailpiece therebetween and wherein the mailpiece is positioned relative to the gravitational centerline of the clamp assembly.

FIG. 4B is a schematic side view of the apparatus and method shown in FIG. 4A wherein the area centroid of the mailpiece is aligned relative to the gravitational centerline of the clamp assembly.

FIG. 5 is a schematic top view of the apparatus and method shown in FIG. 1A wherein the spiral cams effect closure and linear translation of the clamp assembly jaws to secure and move the mailpiece from the transport mechanism.

FIG. 6A is a front view of the clamp assembly for securing and conveying objects/mailpieces in a mixed mail sorter apparatus.

FIG. 6 b is a side view of FIG. 6A illustrating separation tabs for opening and closing the jaws of the clamp assembly.

An apparatus and method are provided for positioning objects at a desired reference position, including a sensor for determining the length of each object/mailpiece from a leading to a trailing edge, a transport mechanism having a positionable drive element for transporting the object/mailpiece lengthwise in succession along an object/mailpiece transport path, and a controller or processor for controlling the position, of the positionable drive element to release the object/mailpiece at a desired reference position. The described embodiments of the apparatus and method relate to positioning an object/mailpiece in a clamp assembly of a mixed mail sorter. The jaws of the clamp assembly are separated to receive the object/mailpiece by a pair of spiral cams. The spiral cams interpose and engage tabs of each jaw to open and close the clamp assembly as they concomitantly effect translation of the clamp assembly linearly past the positioning apparatus. The apparatus and method ensures predictable conveyance and release of objects/mailpieces while being manipulated by automated handling equipment.

The present invention is described in the context of an apparatus and system having a clamping assembly for securing, transporting, sorting and diverting mailpieces. While the invention is advantageous for mixed mail sorters, it should be appreciated that the apparatus and method for centering mailpieces is applicable to any apparatus which may employ a clamping assembly for acquiring and transporting objects.

The apparatus according to the present invention transports objects to a desired reference location or position. In FIGS. 1A and 16 , the positioning apparatus 10 is integrated within a mixed mail sorter for transporting mailpieces 12 to a clamp assembly 14 . The mixed-mail sorter may be similar to that illustrated and described in the following documents: PCT/US2005/044560, now WO 2006/063204; PCT/US2005/044406, now WO 2006/063121; PCT/US2005/044413, now WO 2006/063125; PCT/US2006/01892, now WO 2006/110486; PCT/US2006/012861, now WO 2006/110465; and PCT/US2006/012888, now WO 2006/110484, said applications being hereby incorporated by reference in their entireties.

The positioning apparatus 10 of the present invention enables processing of multiple objects/mailpieces 12 which may vary in size/shape and which may be advanced to positioning apparatus 10 via automated or manual delivery systems (not shown). With respect to size and shape variation, objects/mailpieces 12 for sorting using the mixed mail sorter may include conventional letter size envelopes, postcards, magazines, newspapers, flats-type mailpieces, etc. Furthermore, such objects/mailpieces may include a variety of packages including blow molded plastics and other objects suitable for pick-and-place handling equipments. Hence, for the purposes of this invention, the terms “object” and/or “mailpiece” will be used interchangeably and are intended to include letters, packages and parcels suitable for automated handling by a clamp assembly 14 .

Regarding preprocessing of mail, the positioning apparatus 10 may be integrated with a variety of automated or manual delivery systems, upstream of the various sorter subsystems. In FIGS. 1A and 1B , the positioning apparatus 10 is capable of loading, transporting and clamping a variety of mailpieces 12 from a plurality of handling systems. For example, certain letter sized mailpieces 12 may be most efficiently preprocessed (i.e., presorted and singulated) by conventional automated feeders while yet other mailpieces 12 , such as conventional newspapers, may best be manually handled (manually singulated and fed onto the transport) by an operator.

Generally, it is desirable to match the handling rate of the positioning apparatus 10 with the feed rate that objects/mailpieces 12 are fed to the positioning apparatus 10 . For mailpieces up to 0.35 inches, the mixed mail sorter can handle objects/mailpieces at a rate of about eighteen-thousand (18,000) pieces per hour. Inasmuch as some of the most efficient automatic flats feeders can only feed at a rate of about seventy-five hundred (7,500) pieces per hour, the input rate of the feeder limits the output handling rate of the positioning apparatus 10 and the sortation rate of the sorter. Consequently, multiple input feed systems can be employed to match the handling rate of the positioning apparatus 10 and sortation rate of the sorter. For example, two automated flats feeders can be combined to increase the handling rate to at least fifteen thousand (15,000) mailpieces. Furthermore, since certain mailpieces are best fed manually (i.e., operator assisted), both automated and manual input feed systems may be combined to best match the handling/sortation rate of the positioning apparatus 10 and mixed mail sorter. A buffer module (not shown) can be incorporated and used by a system controller to monitor and control input traffic.

The top and profile views shown in FIGS. 1A and 1B , respectively, show a sensor 20 for determining the length of each object or mailpiece 12 from a leading edge 12 LE to a trailing edge 12 TE thereof, a transport mechanism 30 having a positionable drive element 30 PE for transporting the object or mailpiece 12 , and a controller or processor 40 for controlling the position of the drive element 30 PE to release the object or mailpiece at a desired reference position RP. In FIG. 1B , the reference position RP is shown as the centerline of a clamp assembly 14 , though the reference position can be any desired location depending upon the configuration of the clamp assembly 14 , and/or the desired spatial relationship between the object/mailpiece 12 and the clamp assembly 14 .

In the described embodiment, the length sensor 20 can be any of a variety of sensing devices. For example, a photocell 24 (see FIG. 1B ) can be employed to view the time-differential between the leading and trailing edges 12 LE, 12 TE of the mailpiece 12 . That is, the photocell 24 in combination with a velocity transducer (not shown) for measuring the speed of the transport mechanism 30 may be used to issue a length signal to the controller 40 . Alternatively, if the velocity of the transport is known, the sensor can transmit change-of-state signals indicating the time of the lead and trail edges of the mailpiece passed by the sensor, and the controller 40 can calculate the mailpiece length using the known transport velocity.

More specifically, in FIGS. 2 and 3 , the transport mechanism 30 may comprise two transport segments, i.e., a constant velocity transport segment 32 and a variable velocity transport segment 34 . The transport mechanism 30 may further comprise pairs of aligned transport belts 32 B, 34 B for transporting mailpieces 12 lengthwise in succession along a transport path and delivering the mailpieces 12 to the clamp assembly 14 . Rollers 36 a , 36 b , 36 c and 36 P may be disposed in combination with the transport belts to effect frictional engagement of the mailpiece 12 with each of the transport belts 32 B, 34 B. As such, the rollers 36 a , 36 b , 36 c and 36 P function as spring loaded nips to press the mailpiece 12 with frictional engagement with transport belts 32 and 34 , and thereby provide drive force to mailpiece 12 .

In the illustrated embodiment, shown in FIG. 2 , the positionable drive element 30 PE may include any of a variety of mechanisms for positioning a roller so as to release the mailpiece 12 at the desired reference position. More specifically, and referring to FIGS. 3 , 4 A and 4 B, the length sensor 20 provides a length signal to the controller 40 . Controller 40 issues a command to motor 43 to turn lead screw 41 , which causes carriage 44 to translate, and thereby to move the roller 36 P, forward or aft. In the described embodiment, a link 42 connects the roller 36 P to carriage 44 to move the roller 36 P in the direction of arrows A. With data obtained from the length signal, the position of the roller 36 P may be determined such that the trailing edge 12 TE of the mailpiece 12 (see FIG. 3 ) is released when the mailpiece 12 has reached its desired reference position RP. In the described embodiment, the desired reference position RP corresponds to alignment of the area centroid 12 CEN or the mailpiece 12 with the gravitational centerline 14 CL of the clamp assembly 14 (see FIG. 4B ).

To further control the position of the mailpiece 12 , the second transport segment 34 may include a means for varying the velocity of the belts 34 B. As such, the speed, and consequently, the inertia of the mailpiece 12 may be reduced so that the mailpiece remains in the desired reference position once it is released by the positionable drive element 30 PE. The variable velocity drive means (not shown) may also be controlled by signals derived from the controller 40 .

While a principle feature of the invention relates to the sensing, positioning and control elements for positioning an object at a desired position, the system for opening the clamp assembly 14 has its own inventive features. In FIGS. 5 , 6 A and 6 B, the clamp assembly 14 includes a drive mechanism 50 having a pair of rotating spiral cams 52 a , 52 b for separating and closing the jaws 54 a , 54 b of the clamp assembly 14 . More specifically, the jaws 54 a , 54 b of the clamp assembly 14 each include separation tabs 56 a 1 , 56 a 2 , 56 b 1 , 56 b 2 formed along a lateral edge of each clamp assembly jaw 54 a , 54 b . Furthermore, spiral cam surfaces 52 sc1 , 52 sc2 , of each of the spiral cams 52 a , 52 b interpose the separation tabs 56 a 1 , 56 a 2 , 56 b 1 , 56 b 2 such that rotation of the spiral cams 52 a , 52 b , effects opening and closure of the clamp assembly jaws 54 a , 54 b (best seen in FIGS. 5 , 6 A and 6 B). Moreover, rotation of the spiral cams 52 a , 52 effects linear translation of the clamp assembly 14 in the direction of arrow FP along the length of the drive mechanism 50 . This linear translation is synchronized with clamp transport elements 60 a and 60 b . Such translation moves the mailpiece 12 away from the belts 34 B of the transport mechanism 30 to obviate any further motion or displacement once the mailpiece has reached its desired reference position RP. This motion, in a direction transverse to the lengths of the mailpieces and, more particularly, perpendicular to the direction of transport 30 , also enables a next mailpiece 13 to be positioned in the next clamp 53 .

In summary, the apparatus and method for positioning/centering objects/mailpieces includes a novel positionable drive element to release the object/mailpieces at a desired reference position. The invention includes a variable velocity transport mechanism to decrease the speed and inertia of the object/mailpiece as it comes to rest in the clamp assembly jaws. Furthermore, the clamp assembly includes an inventive drive mechanism operative to open and close the clamp assembly jaws as the object/mailpiece is conveyed away from the transport mechanism and to subsequent stations of the mixed mail sorter. Consequently, the apparatus and method ensures predictable conveyance and sorting of objects/mailpieces while being manipulated by automated handling equipment.

Although the invention has been described with respect to a particular embodiment 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 scope of this invention.