Facility wide mixed mail sorting and/or sequencing system and components and methods thereof

The present application claims priority to U.S. Provisional Application No. 60/960,050 filed on Sep. 13, 2007 and U.S. Provisional Application No. 61/071,860 filed on May 22, 2008, the disclosures of which are incorporated by reference in their entireties herein.

1. Field of the Invention

The invention generally relates to a facility wide sorting and sequencing system for improving product processing operations and, more particularly, to a facility wide system and related functionality for simultaneously sorting and sequencing mixed mail pieces such as, for example, flats and letter mail pieces.

2. Background Description

The sorting of mail is a very complex, time consuming task. In general, the sorting of mail is processed through many stages, including front end and back end processes, which sort and sequence the mail in delivery order sequence. These processes can either be manual or automated, depending on the mail sorting facility or the type of mail to be sorted such as packages, flats, letter 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.

Many form factors of mail pieces make sortation machines difficult to design and easy to jam. That is, mail pieces come in many sizes and shapes. These sizes and shapes create the opportunities for sortation jams. Frequent jamming is a major factor of not being able to operate a sortation operation automatically. However, in a facility wide sortation system, it is necessary to be able to sort millions of mail pieces a day. To accomplish this, mail pieces in a stream must be conveyed at very high rates from many inputs and selectively diverted to one of many outputs.

Currently, most mail processing of flats and letter mail use many passes with different machines to effectively sequence the mail. For example, flats are sorted and sequenced on one type of machine, whereas, letter mail pieces are sorted and sequenced on another type of machine. In fact, due to the different shapes, sizes and other considerations that must be taken into account with each type of mail piece, e.g., flat and letter mail pieces, there is no current machine or facility wide system that can sort, sequence, track and perform other processes simultaneously for each type of mail piece.

As an example, the current method of moving mail pieces is either end-to-end on a belt or in a tub or container. There are many disadvantages in such systems. For example, belts with non-uniform mail pieces of mail cause many opportunities for jamming. Also, belts are physically limited to about 40,000 letters/hour. Also, the different sizes of mail pieces results in handling flats, letters, and parcels in three separate streams, requires three times as many mail processing machines to maintain and operate. Also, such processes result in many manual operations, e.g., moving mail in tubs from machine to machine, which is labor intensive.

In aspects of the invention, a system comprises a facility-wide mail sorting and/or sequencing system. As used herein, in all embodiments, articles, objects and/or products include mail pieces, e.g., flat and letter mail pieces (and small parcels). Similarly, mail pieces, e.g., flat and letter mail pieces (and small parcels), may be articles, products and/or objects. Accordingly, as disclosed herein, limitations should not be placed on the terminology, either singularly or in the plural, for mail pieces, articles, products and/or objects. However, distinction should be given to the use of mail pieces as either flats, letters and/or small parcels. Also, it should be understood that the system and method of the present invention can be used in many different combinations and alternatives and that unless known by those of skill in the art to be exclusively mutual, each embodiment can be practiced alone or any combination thereof

By way of non-limiting examples, the following is a list of acronyms that may be used in the instant application. This list should not be considered exhaustive of all acronyms used herein, and is provided merely for reference and convenience. These acronyms may also be defined within the instant application.

By way of non-limiting explanation, the following is a list of exemplary definitions that may be used in conjunction with terminology disclosed in the instant application. This list should not be considered exhaustive of all definitions used herein, nor should this list be considered, in any way, to limit the terminology used in the instant application. These definitions are provided for reference, convenience and by way of further explanation and are in no way to be construed as limiting to the present invention. Additionally, it is noted that variations of the below terminology may be used in the instant application, which also should not be considered to be limiting the present invention, in view of the below definitions.

In aspects of the invention, the system comprises an existing equipment interface for interfacing the input section with the facility-wide mail sorting and/or sequencing system. In embodiments, the existing equipment interface comprises at least one of: a physical interface; a mail piece synchronization data stream interface; a mail piece attribute data stream interface; a control interface; an emergency stop signal interface; and an interface logic module. The physical interface is operable to receive one or more mail pieces from the input section of the existing equipment. The mail piece synchronization data stream interface is operable to relate mail piece attribute data of a mail piece with a position of the mail piece. The mail piece attribute data stream interface is operable to transmit mail piece attribute data between the existing equipment and the facility-wide mail sorting and/or sequencing system. The control interface is operable to provide a control signal between the existing equipment and the facility-wide mail sorting and/or sequencing system. The emergency stop signal interface is operable to provide an emergency stop signal that removes power for the existing equipment and the facility-wide mail sorting and/or sequencing system. The interface logic module is operable to simulate signals and commands to unused sections of the existing equipment. The interface logic module is modular and configured to support interface to input sections of one or more existing equipment.

In aspects of the invention, an existing equipment interface system is configured to interface with an existing equipment with a facility-wide mail sorting and/or sequencing system. The interface comprises at least one of: a physical interface; a mail piece synchronization data stream interface; a mail piece attribute data stream interface; a control interface; an emergency stop signal interface; and an interface logic module.

In aspects of the invention, a method of processing mail pieces comprises: providing an existing equipment interface; interfacing input sections of existing equipment with a facility-wide mail sorting and/or sequencing system using the existing equipment interface; receiving new mail piece attribute data via the existing equipment interface; receiving new mail piece synchronization data via the existing equipment interface; associating the new mail piece attribute data with a particular mail piece using the new mail piece synchronization data; storing the association of the new mail piece attribute data with the particular mail piece in a storage system; detecting the particular mail piece via the existing equipment interface; updating the association of the new mail piece attribute data with the particular mail piece from the storage system to indicate the particular mail piece was received by the facility-wide mail sorting and/or sequencing system; and sorting and/or sequencing the particular mail piece using the facility-wide mail sorting and/or sequencing system. The method further comprises: determining if the association of the new mail piece attribute data with the particular mail piece exists yet in the storage system; determining if a predetermined time period has expired if the association of the new mail piece attribute data with the particular mail piece does not yet exist in the storage system; and triggering an error signal if the predetermined time period has expired.

In aspects of the invention, a machine or method is provided for automatically culling, facing and canceling mail pieces that are to be sequenced by a sequencing system. A first unit culls products that are unsuitable for sequencing. A second unit faces the products, which have not been culled, by determining the existence and location of a valid indicia and then orienting the products. A third unit cancels the faced products having a valid indicia. A fourth unit monitors whether the culling, facing and canceling units are functioning normally and provides a warning signal when the units are not functioning normally. A fifth unit inducts the products. A sixth unit or sequencing system performs the actual sequencing, and it is responsive to the warning signal from the monitoring unit. The system further comprises a redundant back up system for performing the culling, facing and canceling functions when the monitoring unit indicates that the units are not functioning normally.

In aspects of the invention, a method for use with a sequencing system comprises: culling and rejecting products that are unsuitable for sequencing; facing the remaining products, which have not been culled, by determining the existence and location of a valid indicia and by orienting the products; canceling the faced products having a valid indicia; and monitoring whether the culling, facing and canceling are functioning normally and to provide a warning to the sequencing system when there is abnormal functioning.

In aspects of the invention, a transportable facility comprises a unit comprising: a plurality of parallel adjacent aisles which may be internal adjacent aisles; a conveyor aisle provided in each storage aisle to transport mail pieces along a respective storage aisle; a conveyor aisle extending in a direction transverse to the parallel storage aisles; a conveyor aisle conveyor provided in the conveyor aisle to transport mail pieces along the conveyor aisle; a transport device that transfers the mail pieces between the conveyor aisle conveyor and the storage aisle conveyors; and a port that provides access between the exterior and the interior of the unit. The transportable facility further comprises: a plurality of vertically stacked adjacent storage aisles; and a plurality of vertically stacked conveyor aisles. The transportable facility further comprises an elevator to raise and lower the mail pieces between respective vertically stacked adjacent storage aisles and vertically stacked conveyor aisles. The transportable facility further comprises a conveying device that transports mail pieces between the port of the shipping container storage unit and a processing and distribution center. The container unit comprising a trailer configured to be connected to a driving device.

In aspects of the invention, a method of expanding an existing processing and distribution center comprises transporting mail pieces between an existing structure to outside of the existing structure by a conveyance system that physically connects processes inside the existing structure to a moveable container unit (e.g., transportable facility) which includes equipment for further processes of the mail pieces. The method further comprises transporting the mail pieces through a port that provides access between an exterior and the interior of the container unit. The method further comprises disconnecting the conveyance system and processing mail pieces while the container unit is being driven.

In further aspects of the invention, a method of automatically sequencing mail pieces within a movable container unit that is external to a building structure comprises protecting the mail pieces from the elements. The method further comprises transporting the sequenced mail pieces near or through a port that provides access between an exterior and the interior of the container unit. The method further comprises sequencing the mail while the container unit is being driven.

In aspects of the invention, a system comprises: a system management subsystem; a plurality of subsystems; a system management local area network (LAN) providing a communication channel between the system management subsystem and the plurality of subsystems; and at least one local LAN providing a communication channel between at least two of the plurality of subsystems. The system further comprises a modem access to the system management subsystem. The at least one local LAN provides the communication channel between high-use subsystems. The at least one local LAN reduces network congestion on the system management LAN. The system management subsystem is operable to provide network routing and control. The overall system management and control signals are communicated on the system management LAN. The authorized and authenticated users access the system via the system management LAN.

In aspects of the invention, a method of configuring a networked system comprises: providing a system management local area network (LAN) between a system management subsystem and a plurality of subsystems; and providing at least one local LAN between at least two subsystems of the plurality of subsystems. The system management LAN is operable to provide at least one of: overall system management and control signals between the system management subsystem and the plurality of subsystems; and authorized and authenticated users access to the system. The at least one local LAN is operable to provide a communication channel between high-use subsystems of the plurality of subsystems.

In aspects of the invention, a system and method is provided for centralized address recognition in a facility wide sorting machine with multiple layers of “onboard address recognition”. The invention also provides, in embodiments, a system and method for associating video coding returns with mail pieces and frame/clamp IDs. The invention also provides, in embodiments, a centralized address recognition system comprising a centralized address recognition sub-system and at least one of a facing canceling sub-system, a mail piece feeding sub-system, a flats feeding sub-system, and a parcel feeding sub-system. The invention also provides, in embodiments, that the centralized address recognition sub-system receives information from the at least one of the facing canceling sub-system, the mail piece feeding sub-system, the flats feeding sub-system, and the parcel feeding sub-system. The invention also provides, in embodiments, that the centralized address recognition sub-system provides information to one or more banks of centralized video coding.

The invention also provides, in embodiments, that the centralized address recognition sub-system communicates with one or more banks of centralized video coding and the at least one of the facing canceling sub-system, the mail piece feeding sub-system, the flats feeding sub-system, and the parcel feeding sub-system. The invention also provides, in embodiments, that the centralized address recognition system further comprises a mail piece buffering system. The centralized address recognition sub-system communicates with a mail piece buffering system, one or more banks of centralized video coding, and the at least one of the facing canceling sub-system, the mail piece feeding sub-system, the flats feeding sub-system, and the parcel feeding sub-system. The centralized address recognition sub-system provides information to a mail piece buffering system, provides information to one or more banks of centralized video coding, and receives information from the at least one of the facing canceling sub-system, the mail piece feeding sub-system, the flats feeding sub-system, and the parcel feeding sub-system.

The invention also provides, in embodiments, a method for centralized address recognition comprising utilizing at least one system recited above to provide information to a mail piece buffering system. The invention also provides, in embodiments, a method for centralized address recognition comprising utilizing at least one system recited above to provide information to one or more banks of centralized video coding. The method for centralized address recognition comprises utilizing at least one system recited above to receive information from the at least one of the facing canceling sub-system, the mail piece feeding sub-system, the flats feeding sub-system, and the parcel feeding sub-system.

In aspects of the invention, a system comprising a server associated with a facility-wide sorting and/or sequencing system is provided. The server receives and obtains external data from at least one external source associated with mail inbound to a facility utilizing the facility-wide sorting and/or sequencing system, and based upon the external data, the server generates assignments for handling the mail within the facility. In embodiments, the external data comprises at least one of: GPS data associated with an incoming truck; delivery data from a processing and distribution center; delivery data from a presort house; delivery data from a surface visibility database; and manually or automatically entered data from mail carried on a truck. In embodiments, the assignments include at least one of: receipt location, time and location to move the mail within the facility, storage location of the mail within the facility-wide sorting and/or sequencing system, identification of a feeder of the facility-wide sorting and/or sequencing system to input the mail into, time to enter the mail into the feeder of the facility-wide sorting and/or sequencing system, dispatch time from the facility-wide sorting and/or sequencing system, and output location. In embodiments, the mail comprises letter and flat mail pieces that are sequenced together in the facility-wide sorting and/or sequencing system.

Based upon the data, the server may generate handling assignments for processing and/or transporting other mail within the facility utilizing the facility-wide sorting and/or sequencing system. In embodiments, based upon the data being updated, the server generates new assignments for handling the mail within the facility. In embodiments, the server is implemented in a computer infrastructure comprising hardware and software stored on a tangible storage medium. In embodiments, the server receives and/or obtains internal data from at least one source internal to the facility, and the server generates the assignments based upon both the external data and the internal data. The internal data comprises operating status of a component of the facility-wide sorting and/or sequencing system. In embodiments, the server transmits the assignments to an operator through an interface displayed on a personal digital assistant.

In aspects of the invention, a processing system comprises: a base module capable of performing all of the processes of the processing system; and at least one expansion module configured to be connected to the base module so as to increase a processing capacity of the processing system. The processing system is a mail processing system. The base module and at least one expansion module are provided in a number corresponding to a mail processing capacity of a particular mail processing facility. The base module comprises a system manager that manages the systems of the base module, the system manager is configured to manage the systems of the at least one expansion module when the at least one expansion module is added to the mail processing system. The at least one expansion module comprises less than all of the subsystems contained in the base module and is plug and play compatible with the base module. Each of the at least one expansion module has a processing capacity equal to a processing capacity of the base module.

In aspects of the invention, a mail processing system comprises: at least one mail processing module having a plurality of parallel branches configured to independently process mail pieces. The at least one mail processing module comprises a base module. The at least one mail processing module comprises a base module and at least one expansion module. The plurality of parallel branches comprises at least one additional parallel branch in excess of a number of parallel branches required to meet a mail processing capacity of a mail processing facility. The at least one additional parallel branch in excess of a number of parallel branches required to meet the mail processing capacity of the mail processing facility is maintained in an out-of-service state when a mail processing capacity of the at least one additional branch is not required to meet the mail processing capacity of the mail processing facility. The at least one additional parallel branch in excess of a number of parallel branches required to meet the mail processing capacity of the mail processing facility is maintained in an in-service state when a mail processing capacity of the at least one additional branch is required to meet the mail processing capacity of the mail processing facility. The at least one additional branch which is maintained in an out-of-service state is selected by routinely rotating each of the plurality of parallel branches from the in-service and out-of-service states such that wear on the plurality of parallel branches, due to processing the mail pieces, is evenly distributed among the plurality of parallel branches. The plurality of parallel branches comprise units of the base module and at least one expansion module, each unit of the base module being aligned linearly with a corresponding unit of the at least one expansion module so as to define the plurality of parallel branches. A segment level is defined by arranging similar processing segments of the at least one mail processing module in parallel with each other. A subsystem level is defined by arranging subsystems of the at least one mail processing module in parallel with each other. A component level is defined by arranging components of the at least one mail processing module in parallel with each other.

In aspects of the invention, a system comprises: one or more regional command centers; at least one processing and delivery center hierarchically arranged below each of the one or more regional centers; and at least one mail processing/handling equipment (MPE/MHE) hierarchically arranged below the at least one processing and delivery center. The one or more regional centers, the at least one processing and delivery center and the at least one mail processing/handling equipment utilize a service oriented architecture. A national command center is hierarchically arranged above the one or more regional command centers, wherein the national command center utilizes the service oriented architecture.

In embodiments, the system is configured to stage information on at least one of the at least one mail processing/handling equipment, centrally within the at least one processing and delivery center and centrally within one of the one or more regional command centers. The information comprises at least one of mail piece messages detailing a mail piece ZIP and bar code information; MPE statuses; data point of a key state and data variables on the MPE/MHE; mail piece location information; end-of-run information; start-of-run information; command interface information; sort plan information; operator information; throughput information; fault information; a communication network heartbeat status; and end-of-run summary information. The messages to and from the at least one mail processing/handling equipment and the one or more regional command centers comprise at least one of extensible mark-up language (XML) format messages and simple object access protocol (SOAP) format messages. A commercial off-the-shelf software business engine implements at least one of basic message routing, tracking, authentication, message delivery, and associated business rules. The new functionality is added to the system with only changes to a scripting language.

The system is operable to monitor and collect information for disparate mail processing/handling equipment from the at least one processing and delivery center using the service oriented architecture. The at least one of the national command center and one of the one or more regional command centers are configured to perform centralized management functions, including at least one of: property management and inventory, software inventory, distribution, and configuration management, and remote hardware, network or software diagnostics.

In embodiments, the system is operable to provide at least one of: alarm, error, warning event and status notification, and escalation; data archiving, backup, purging and management; remote access to at least one of MPE/MHE assets and/or command center assets; user and system authentication setup; auditing of all actions taken; auditing of all messages received; routing of command signals; remote configuration of individual mail processing equipment; a scoring of an accuracy of MPE/MHE operators; staged storage of images and data; interpretation and reporting MPE/MHE performance data; remote viewing of MPE/MHE images; searching, displaying, and managing threat data over a distributed network; an update of MPE/MHE libraries/software; an operator performance measurement and efficiency reporting; operator/supervisor communication; a linking of passenger identification between a remote database and MPE/MHEs; a linking of other MPE/MHE scans of a specific article; a scheduling update or software download of files; remote control of operator/user functions; command and control of MPE; a gathering of computer/system/user diagnostic data; remote training of users; storing and queuing of information; configuration of a scanning machine; report generation; remote desktop sharing; report threat scanning machine utilization; report machine performance; communication of data, image, training, configuration, audit, database registry to at least one of the national control center and one of the plurality of regional control centers for at least one of centralized management, archiving, and temporary storage; capturing and reporting of technical performance measurement (TPM) operator keystroke information; remote restart monitoring; operator user tracking and time keeping; traveler identification information gathering, comparing to existing databases of MPE/MHEs, and correlating to baggage; and a security encryption of a data stream.

In embodiments, the system is operable to provide remote and system management functions including at least one of: access security and auditing; property management and inventory; software inventory, distribution and configuration management; remote hardware/network/software diagnostics; event and status notification and escalation; data archiving, backup, purging and management; remote access to MPE/MHE and airport command center assets; and remote restart monitoring. The system is operable to provide equipment specific processing including at least one of: remote configuration of individual MPE/MHE; a configuration file of MPE/MHEs; staged storage of images and data; interpreting and reporting MPE/MHE performance data; remote viewing of MPE/MHE images; searching, displaying, and managing configuration files and executables over a distributed network; interfacing to existing MPE/MHE units; update of MPE/MHE libraries; an operator performance measurement and efficiency reporting; escalation of detected threats; operator/supervisor communication; linking of operator training certification between different operator stations; linking other MPE/MHE scans of the specific article; and mail image distribution prior to video coding terminal identification.

In aspects of the invention, a conveyance system for transporting a plurality of frames comprises: a plurality of input conveyance paths; a plurality of output conveyance paths; and at least one conveyance mechanism. The plurality of frames is directed through the plurality of input and output conveyance paths. The at least one conveyance mechanism is a divert mechanism configured to divert at least one of the plurality of frames from one of the plurality of input conveyance paths to at least one of the output conveyance paths at a generally constant conveyance speed (e.g., full transport speed during a right angle divert). The plurality of input and output conveyance paths are lead screw conveyance paths. The divert mechanism is a rotating cam divert mechanism including a rotating cam having a bypass setting and a divert setting. The rotating cam further includes a front wall, a flared back wall, and a channel defined therebetween for selectively directing a conveyance direction of the plurality of frames. The plurality of input and output conveyance paths are tooth belt conveyance paths.

In embodiments, the divert mechanism is a pinch belt divert mechanism including a pinch belt conveyance mechanism configured to run continuously and to engage a projecting pin from an upper portion of at least one of the plurality of frames being transported, and at least two lifting mechanisms configured for selectively lifting the plurality of frames from the tooth belt conveyance path to the pinch belt conveyance mechanism. The plurality of input and output conveyance paths comprises timing belt conveyance paths. In embodiments, the divert mechanism is a vertical divert mechanism including a rotatable gate for selectively diverting the plurality of frames in a vertical direction from at least one of the plurality of input conveyance paths, and a guide for bridging a gap between an intersection of the at least one of the plurality of input conveyance paths and at least one of the plurality of output conveyance paths. The plurality of input and output conveyance paths are threaded roller conveyance paths. In embodiments, the divert mechanism is a rotatable slotted cam divert mechanism configured to selectively divert at least one of the plurality of frames. The at least one conveyance mechanism is a compression mechanism configured to adjust the gaps between adjacent frames in the conveyance system.

In embodiments, a plurality of lead screws is arranged in parallel and configured to rotate, each screw having a predetermined pitch and bevel provided at least one end thereof. The conveyance system further includes a plurality of inset compression screws inset from and parallel to the plurality of lead screws configured to adjust the gaps between adjacent frames. The conveyance system further includes a plurality of outset compression screws outset from and parallel to the plurality of lead screws configured to adjust the gaps between adjacent frames. The conveyance system further includes a plurality of inline compression screws configured to adjust the gaps between adjacent frames and disposed along a horizontal axis shared by the plurality of lead screws.

In aspects of the invention, methods and apparatus are adapted for use in a mail processing system, but for use in systems more generally for processing other products. The apparatus includes a succession of frames adapted to be transported within the mail processing system along a transport path, each of such frames adapted to contain a single mail piece during processing within the mail processing system. The processing includes sorting and sequencing. Each of the frames has an extraction opening, such as at the bottom and/or sides, through which the single mail piece is extracted. The invention includes an extraction arrangement to extract the single mail pieces from the succession of frames for subsequent placement in delivery containers. Each of the frames has a common shape factor, which facilitates the processing of the mail pieces, or other products. The frames can also have different shapes. According to a particular embodiment, the frames have a rectangular, or substantially rectangular, shape.

In embodiments, the extraction arrangement, according to a particular embodiment, is positioned along the transport path and is structured and arranged to extract the mail pieces successively from the frames as the frames are fed to the extraction arrangement. Alternatively, a plurality of mail pieces can be simultaneously extracted from a plurality of frames from the succession of frames. The extraction arrangement according to the invention encompasses a vacuum extractor adapted to engage the mail pieces by means of a vacuum while the mail pieces are contained within respective ones of the frames. Alternatively, grippers and/or pushers can be used. Still further, the invention encompasses a gravity-extraction device to extract mail pieces via gravity through the extraction openings, such as at the bottom of the frames. In a further alternative according to the invention, the extraction arrangement comprises an extraction frame adapted to be transported along the transport path. In such an embodiment, the extraction opening of each of the mail frames is at a side of each of the frames. The extraction frame is configured and arranged to have a mail piece extracted from a mail frame while the mail frame moves along the transport path. In such alternative, the succession of extractor frames is movable along a path merging with the transport path of the succession of mail frames at a merge region, the extractor frames being engageable with mail pieces in respective ones of the mail frames at the merge region and effect extraction of the mail piece after the mail frame is transported through the merge.

In embodiments, a mail-engaging extractor, such as any of those mentioned above, is positioned and adapted to acquire a mail piece upon movement of such mail piece beyond the mail frame. Further, in such alternative, movement of the succession of extractor frames along the aforementioned path can be uni-directional only or bi-directional. In the latter, the movement of the extractor frames is bi-directional between a pair of buffer storage areas. In addition, in such alternative, one or more mail-loaded shuttles is adapted to be positioned at a docking station for unloading the mail frames to the transport path and for extracting the mail pieces during movement of the extractor frames in a first direction along the path in the bi-directional movement of the extractor frames. After unloading of the mail frames, a shuttle is adapted to receive a plurality of empty mail frames at a docking station during movement of the extractor frames in a second direction along the path in the bi-directional movement of the extractor frames. The extraction frames themselves can each include a pop-up, movable from a non-pop-up position for maintaining the extraction frame with a thin profile for insertion within the mail frame, to a pop-up position for engagement with a mail piece within the mail frame to effect extraction of the mail piece. A mail frame particularly configured for use with such extractor frames includes slots for sliding engagement with the tabs of the extractor frames.

In aspects of the invention, a mail piece container is adapted to maintain a single mail piece in a mail processing system. The container comprises: a frame comprising at least a pair of engageable portions adapted to be engaged by a driving mechanism for transporting a plurality of successive containers within the mail processing system; a folder having at least one portion movably connected to the frame, the folder having at least a portion movable relative to the frame between: a first position for facilitating selective insertion and extraction of a single mail piece within the container; and a second position, wherein the folder is empty of any mail piece.

In embodiments, the frame has a length and a width and the engageable portions are positioned to orient the frame during travel within the mail processing system other than in a direction along the length of the frame. The direction the frame is oriented is an angle of 45° with respect to the direction of travel. In the first position of the folder, insertion and extraction of the mail piece is facilitated; and in the second position of the folder, no mail piece is contained in the folder and the folder has a minimized width. The frame is rigid and the movable portion of the folder is movable away from the rigid frame to the first position. The frame is generally rectangular and the folder is generally rectangular. The movable portion of the folder is pivotable away from the rigid frame to contain a mail piece at a common connection between the frame and the folder. The folder includes at least one actuator tab adapted to be manipulated by a mechanism for moving the folder to the first position. The movable portion of the folder is slidable relative to the frame. The movable portion of the folder is maintained generally parallel to the frame during movement to the first position. At least one opening is maintained between the frame and the folder for insertion and extraction of a mail piece relative to the container. The at least one opening is located at a top and/or at a side of the container.

In aspects of the invention, an apparatus for output packaging of mixed mail pieces after the mail pieces have completed processing in a mail processing system is provided. The apparatus comprises: a staging area for receiving a stream of stacked mixed mail pieces; a stream of empty containers, each of the empty containers being adapted to contain a predetermined segment of the mixed mail pieces; a plurality of stack-segmenting elements movable selectively and individually from outside the stream of stacked mail pieces to within the stream; a containerable stack segment being created at the staging area by at least a downstream one of the stack-segmenting elements and an upstream one of the stack-segmenting elements; and a slide panel for receiving, from the staging area, the containerable stack segment held by the upstream and downstream stack-segmenting elements. The slide panel is movable from a receiving position to a releasing position, whereby movement of the slide panel to the releasing position exposes the containerable stack segment held by the upstream and downstream stack-segmenting elements to one of the empty containers. The stack segment is released by the stack-segmenting elements and the stack segment is positioned within the one of the empty containers.

In embodiments, the plurality of stack-segmenting elements comprises a plurality of paddles selectively positionable within the stream of mixed mail pieces. The plurality of stack-segmenting elements comprise a plurality of paddles selectively positionable within the stream of mixed mail pieces to maintain perpendicularity of the mail pieces relative to a reference support surface. The plurality of paddles comprises three paddles. A first of the three paddles is a downstream paddle for engaging a downstream end of the containerable stack segment. A second and a third of the three paddles are upstream paddles, the upstream paddles being movable to alternate in replacing one another in positions of (1) retaining the stream of mixed mail pieces, and (2) creating the containerable stack segment with the downstream paddle. The stream of empty containers is positioned along a path lower than a height of the slide panel. Successive ones of the empty containers are positionable directly beneath the slide panel, whereby the release of the containerable stack segment by the stack-segmenting elements allows the stack segment to fall by means of gravity into the one of the successive ones of the empty containers. The slide panel is movable to the release position in a direction away from containers containing respective mixed mail stack segments. Each of the empty containers of the stream of empty containers has a volume substantially equal to a volume of respective ones of the containerable stack segments formed by the apparatus. The containerable stack segment is held by the upstream and downstream stack-segmenting elements by means of pressure toward each other to compress the stack segment. The containerable stack segment is released by the upstream and downstream stack-segmenting elements releasing the pressure.

In aspects of the invention, there is a method of sequencing objects or products, e.g., mail pieces, in a facility-wide system. The method comprises: obtaining a system-wide sort plan from a centralized server; and distributing the system-wide sort plan to a plurality of subsystems of the facility-wide mail sorting and/or sequencing system. In embodiments, the method further comprises creating a modified sort plan based upon the system-wide sort plan and system data. The system data may include an operating status of at least one component of the facility-wide mail sorting and/or sequencing system. The method may further comprise modifying the modified sort plan at one of the plurality of subsystems. In embodiments, the method further comprises executing the modified sort plan on a plurality of components of facility-wide mail sorting and/or sequencing system to provide an output of objects arranged in a delivery point sequence. The objects comprise letters and flats. In embodiments, the obtaining, the creating, and the distributing are performed by a sort plan server. In further embodiments, the sort plan server receives and/or obtains the system data from a system manager. The sort plan server comprises software embodied in a tangible storage medium. In embodiments, the system-wide sort plan directs objects through a path, the system data indicates that the path is unavailable, and the modified sort plan directs the objects on an alternate path instead of the path. In embodiments, the system wide sort plan is created by the centralized server and is obtained via a postal service wide area network (WAN).

In aspects of the invention, a method is provided for correlating mail piece and frame identifiers. The method comprises: determining at least one mail piece identifier of a mail piece; determining a frame identifier of a frame to contain the mail piece; creating an association between the at least one mail piece identifier and the frame identifier; and storing the association in a data store so that the mail piece is identifiable by the frame identifier. The method further comprises: determining at least one mail piece attribute; and including the at least one mail piece attribute in the association between the at least one mail piece identifier and the frame identifier. The at least one mail piece attribute comprises at least one of: a weight; a length; a width; a height; an address; a return address; destination information; and data contained in indicia. The at least one mail piece identifier comprises at least one of: one or more bar codes; an address; a zone improvement plan (ZIP) code; a radio frequency identification (RFID) tag; and an indicia identifier. Each individual mail piece is associated with an individual frame used to transport the mail piece. Each frame identifier is permanently associated with a particular frame. The method further comprises performing a mail piece attribute information retrieval process. The mail piece attribute information retrieval process comprises: identifying a particular frame identifier; and retrieving at least one of the at least one mail piece identifier and the at least one mail piece attribute information based on the particular frame identifier from the data store. The data store is a database.

In aspects of the invention, a system comprises: a mail piece identifier tool configured to determine at least one mail piece identifier of a mail piece; a frame identifier tool configured to determine a frame identifier of a frame to contain the mail piece; an association tool configured to create an association between the at least one mail piece identifier and the frame identifier; and a data store configured to store the association so that the mail piece is identifiable by the frame identifier.

According to aspects of the invention, a system comprises a server comprising a frame routing agent that operates to: store a system transport map of a transportation network associated with a facility wide sorting and/or sequencing system; and determine a path for transporting a product through a portion of the transportation network based upon the system transport map. In embodiments, the system transport map is a data structure, and the frame routing agent updates the data structure upon receipt of a notification of a change in operational status of a component of the transportation network.

In particular embodiments, the transportation network comprises redundant paths between subsystems of the facility wide sorting and/or sequencing system. For example, the transportation network comprises a plurality of transport lanes and a plurality of switches arranged to physically transport the object. Also, the system transport map may contain a definition of the plurality of switches. Additionally, the definition of each one of the plurality of switches comprises a status of at least one output of the respective switch. Moreover, the determining may be based upon a starting destination, an ending destination, and available ones of the plurality of switches as defined in the system transport map. In further embodiments, the frame routing agent comprises a routing advisor and a divert watchdog. The server may be implemented in a computer infrastructure comprising a computer program product stored in a tangible storage medium.

In aspects of the invention, a presorting unit comprises at least one induction unit configured to split mail pieces into a plurality of split pathways for placement into frames. In embodiments, the induction unit includes at least one feeder, a first pathway having a plurality of diverter gates. The at least one feeder may be configured to direct mail pieces into the first pathway, and the mail pieces may be given a source identifier at the at least one feeder. The plurality of split pathways may have spaced intervals adjacent a side of the first pathway. The presorting unit further includes a plurality of frame inserters provided adjacent second ends of the plurality of split pathways. The plurality of diverter gates may selectively divert mail pieces from the first pathway to one of the plurality of split pathways, and the plurality of frame inserters may be configured to place the mail pieces into the frames.

In embodiments, the presorting unit may further comprise a pre-sort accumulator configured for presorting frames comprising a plurality of frame storage areas for storing frames for transit and a plurality of docking stations configured to receive shuttles to transport the frames from the plurality of frame storage areas. In further embodiments, the presorting unit includes a transport pathway that directs the frames from the plurality of frame inserters to the pre-sort accumulator. Lanes extend from the frame inserters towards the transport pathway. In still further embodiments, the plurality of frame inserters receive frames from a plurality of frame induction pathways. The plurality of frame induction pathways may be lead screws, and the first pathway may be a pinch belt. Similarly, the lanes and transport pathway may be lead screws, and the plurality of split pathways may be pinch belts.

In aspects of the invention, a method of inducting and extracting mail pieces within a presorting unit is provided. The method comprises: directing mail pieces into an induction unit; directing the mail pieces through a first pathway; diverting the mail pieces among a plurality of split pathways to a plurality of frame inserters; and inducting the mail pieces into frames at the plurality of frame inserters associated with each of the plurality of split pathways. In embodiments, the method further comprises directing the frames from the plurality of frame inserters to a transport pathway; directing the frames into a presort accumulator having a plurality of frame storage areas; storing the frames in the plurality of frame storage areas for transport; docking shuttles to the plurality of frame storage areas; and loading the shuttles with frames for entry into a mail sorting and sequencing system.

In aspects of the invention, a system and method for inducting, inspecting, and replacing individual mail containers, e.g., frames, in a facility-wide letters/flats mail sorting and/or sequencing system is provided. The invention also provides, in embodiments, a frame manager system comprising an empty frame receiving system, a frame inspection system, and a system for loading frames onto transports. The transports comprise shuttles which transport the frames to one or more locations in a facility-wide letters/flats mail sorting and/or sequencing system. The frame manager system may communicate with and/or send and receive data to and from at least one of a transport controller system, a storage manager system, a shuttle manager system, and a system manager system. The frame manager system may further comprise at least one of a frame identification table, a frame induction controller, a machine control operational interface, and a frame manager operator console.

The invention also provides, in embodiments, a method of managing frames in a facility-wide letters/flats mail sorting and/or sequencing system, wherein the method comprises utilizing at least one system discussed above to at least one of induct frames, manage frames, inspect frames, and load frames. The invention also provides, in embodiments, a shuttle manager system comprising an empty shuttle receiving system and a shuttle reading system. The shuttle transports frames to one or more locations in a facility-wide letters/flats mail sorting and/or sequencing system. The shuttle manager system may communicate with and/or sends and receives data to and from at least one of a frame manager system and a system manager system. The shuttle manager system may further comprise at least one of a shuttle identification table, a shuttle induction controller, a machine control operational interface, and a shuttle manager operator console. The invention also provides, in embodiments, a method of managing shuttles in a facility-wide letters/flats mail sorting and/or sequencing system. The method comprises utilizing at least one system recited above to at least one of induct shuttles, manage shuttles, inspect shuttles, and read shuttles.

In aspects of the invention, a transportation and storage system for vertical and horizontal transportation of shuttles comprises: a matrix grid including a plurality of intersecting tracks defining a plurality of horizontal paths and a plurality of vertical paths; a plurality of transport elements configured to move on the tracks along the plurality of horizontal and vertical paths and transport the shuttles; and a driving mechanism that drives each of the plurality of transport elements on the tracks along the plurality of horizontal and vertical paths. The driving mechanism comprises: a plurality of pinion gears provided on each transport element; a rack provided on each of the tracks, each rack is configured to cooperate with the respective pinion gears; and a power source provided on each of the transport elements to propel a respective transport element on the tracks along the plurality of horizontal and vertical paths. The power source comprises one of a charging device or a power storage device. Each transport element further comprises a cross belt conveyor configured to support contents thereon, to load contents thereon, and to eject contents therefrom.

The transportation system further comprises a plurality of shuttles to hold mail pieces therein, where each shuttle is configured to be supported on a respective transport element. A wireless device is configured to send and/or receive commands to sort the mail pieces held in the shuttles. The matrix grid further comprises a buffer system comprising a portion of the intersecting tracks. The buffer system is configured to hold a plurality of shuttles therein during loading of shuttles into the matrix grid. The matrix grid further comprises a plurality of tubes comprising an elongated portion of the intersecting tracks. The tubes are configured to hold a plurality of shuttles therein during sorting or sequencing.

In aspects of the invention, a system of vertical and horizontal transportation of shuttles comprises: providing a transportation system including: a matrix grid including a plurality of intersecting tracks defining a plurality of horizontal paths and a plurality of vertical paths; a plurality of transport elements configured to move on the tracks along the plurality of horizontal and vertical paths; a driving mechanism that drives each of the plurality of transport elements on the tracks along the plurality of horizontal and vertical paths; a plurality of shuttles to hold a plurality of frames that have mail pieces therein, each shuttle being configured to be supported on a respective transport element; and a buffer system comprising a portion of the intersecting tracks. The buffer system configured to hold a plurality of shuttles therein during loading of shuttles into the matrix grid.

In aspects of the invention, a method comprises: storing a plurality of shuttles in a transportation system; filling the shuttles with frames containing mail pieces; positioning the filled shuttles in respective transportation elements; positioning respective transportation elements with shuttles thereon in a buffer system; and moving the transportation elements with shuttles thereon along horizontal and vertical paths to store the shuttles for ordering.

In aspects of the invention, a system and method is provided for buffering mail pieces for address recognition completion in a facility-wide letters/flats mail sequencing system. The invention provides, in embodiments, a frame buffer system comprising a frame receiving system and a buffer controller system. The frame receiving system may receive frames from a frame inserter. The frame buffer system comprises a frame reader. The frame buffer system comprises a mail piece extractor. The frame buffer system may further comprise a frame staging buffer. The frame buffer system may further comprise a frame and mail piece association table. The frame buffer system may further comprise at least one of frame locator and an address receiver.

In aspects of the invention, the invention provides, in embodiments, a method of: buffering frames comprising utilizing at least one system recited above to at least one of receive frames with mail; read frames with mail; buffer frames; and extract mail from the frames. The invention provides, in embodiments, a method of buffering frames in a facility-wide mail sorting and/or sequencing system. The method comprises: utilizing at least one system recited above to at least one of receive frames with mail; read frames with mail; buffer frames; and extract mail from the frames.

In aspects of the invention, the invention provides, in embodiments, a method of buffering frames comprising receiving and accepting frames and reading the frames, placing the frames into at least one frame staging buffer, retrieving address results, comparing a frame ID to a mail ID, locating a frame in the at least one frame staging buffer, providing ID and position data to a buffer controller, identifying and removing expired frames, and sending expired frames to a mail piece extractor.

In aspects of the invention, a mail-merger processing system for merging DPS letters and DPS flats together, comprise: a DPS letters frame inserter which receives DPS letters and inserts the DPS letters into frames; a DPS flats frame inserter which receives DPS flats and inserts the DPS flats into frames; and a conveying system for the DPS letters and DPS flats to be combined into a mixed stream containing both DPS letters and DPS flats. The DPS letters are sequenced prior to being inserted into the DPS letters frame inserter and the DPS flats are sequenced prior to being inserted into the DPS flats frame inserter. The prior sequencing of the DPS letters are performed, for example, by Delivery Bar Code Sorters (DBCSs) and the prior sequencing of the DPS flats are performed, for example, by a Flats Sequencing System (FSS). A transportation subsystem connects an output of the DBCSs to an input of the DPS letters frame inserter, and the transportation subsystem connects an output of the FSS to an input of the DPS flats frame inserter. The merger of DPS letter and DPS flats include diverting both the DPS letter and DPS flats at right angles within a transportation subsystem. The mixed stream is a plurality of mixed streams. A buffer is configured to temporarily store at least one of DPS letters and DPS flats prior to inserting the DPS letters and DPS flats into the DPS letters frame inserter and DPS flats frame inserter. A buffer is configured to temporarily store at least one of DPS letters and DPS flats after inserting the DPS letters and DPS flats into the DPS letters frame inserter and DPS flats frame inserter, and before merging the DPS letters and DPS flats into the mixed stream. A base module is capable of performing all of the processes of the mail merger processing system. The least one expansion module is configured to be connected to the base module so as to increase a processing capacity of the processing system. The DPS letters and DPS flats are extracted from the frames and placed into at least one delivery tray, and wherein the frames from which the DPS letters and DPS flats are extracted are returned to a point in the mail-merger processing system so as to receive other DPS letters and other DPS flats from the DPS letters frame inserter and the DPS flats frame inserter.

In aspects of the invention, a computer implemented method of providing a user interface for a handling facility is provided. The method comprises: presenting a user interface on at least one of: a console associated with a unit of handling equipment (MHE), a networked computer of the handling facility, a personal data assistant, and a smart telephone; and utilizing the user interface to perform: operator training, system monitoring, event handling, and personnel monitoring. In embodiments, the utilizing comprises utilizing the user interface to perform all of: the operator training, the system monitoring, the event handling, and the personnel monitoring. In embodiments, the utilizing comprises utilizing the user interface to perform the operator training, which comprises: receiving a request from an operator to operate a machine; verifying whether the operator is qualified to operate the machine; based upon the verifying, when the operator is not qualified to use the machine, providing training to the operator via the user interface; and, based upon the verifying, when the operator is qualified to use the machine, permitting the operator to operate the machine via the user interface.

In embodiments, the utilizing comprises utilizing the user interface to perform the system monitoring, which comprises: at least one of gathering and receiving system data associated with at least one machine of the mail processing facility; and presenting statistical data, based upon the system data, to a user via the user interface. The system data comprises at least one of: operator action associated with the at least one machine, maintenance action associated with the at least one machine, throughput of the at least one machine, and status of the at least one machine. Moreover, the statistical data comprises at least one of: processing volume associated with the at least one machine, jam status associated with the at least one machine, unavailability of the at least one machine, and deviation of an operational parameter of the at least one machine by more than a predetermined value from a mean value.

In embodiments, the utilizing comprises utilizing the user interface to perform the event handling, which comprises: detecting an event associated with a machine; presenting a portion of a user manual associated with the event to an operator via the user interface; receiving at least one annotation from the user via the user interface; and updating the portion of the user manual based upon the at least one annotation. The portion of the user manual may contain at least one hyperlink to at least one other portion of the user manual.

In embodiments, the utilizing comprises utilizing the user interface to perform the personnel monitoring, which comprises: at least one of gathering and receiving personnel data associated with at least one operator; and presenting statistical data, based upon the personnel data, to a user via the user interface. The personnel data comprises at least one of: attendance, compliance with training, throughput while operating a machine, time operating the machine, amount of mail feed starvation while operating the machine, amount of mail processed while operating the machine. In embodiments, a software program that defines the user interface is stored on a tangible storage medium in the at least one of: the console associated with a unit of mail handling equipment (MHE), the networked computer of the mail handling facility, the personal data assistant, and the smart telephone. In embodiments, the handling facility is a mail handling facility and the handling equipment (MHE) is mail handling equipment

In aspects of the invention, an induction system or method is used to induct products into a sequencing system. A feeder conveys the products into the induction system, and an optical imaging unit captures an image of the products being conveyed into the system. A unit decodes barcodes on the products, and another unit decodes ID tags on the products. A unit profiles the physical attributes of the products including the dimensions, shape and weight of the products. The addresses or redirected addresses on the products are recognized, and then verified to determine whether the recognized addresses are deliverable addresses. A staging area is used to buffer products that include an address that cannot be immediately recognized or verified. At least one holdout bin is used for receiving products that cannot be inducted into the sequencing system. An optical character recognition (OCR) unit is provided for recognizing optical characters on the products. A unit is provided for applying an ID tag to the products. An interface to a system is provided that performs video coding of the products. A unit is provided for performing indicia verification. The induction system further includes software logic to perform address arbitration between an address result determined by online address recognition and video coding. The induction system further comprises an interface to a system that determines if addresses on products are redirected addresses. The induction system further comprises an interface to a video coding system. The induction system further comprises at least one holdout bin for receiving products that are determined to have redirected addresses. The induction system further comprises a unit for applying ID tags onto the products. The induction system further includes at least one holdout bin for receiving products that contain specific indicia.

In aspects of the invention, a method is provided for inducting products into a sequencing system. The method comprises: conveying the products for further processing; capturing an image of the products being conveyed; decoding barcodes on the products; decoding ID tags on the products; profiling the physical attributes of the products including the dimensions, shape and weight of the products; recognizing the addresses or redirected addresses on the products and for verifying whether the recognized addresses are deliverable addresses; buffering products that include an address that cannot be immediately recognized or verified; and directing products that cannot be inducted into the sequencing system into at least one holdout bin. The method further comprises recognizing optical characters on the products. The method further comprises applying an ID tag to a product. The method further comprises an interface to a system that performs video coding of the products. The method further comprises performing indicia verification. The method further comprises arbitration between an address result determined by online address recognition and video coding. The method further comprises interfacing to a system that determines if addresses on products are redirected addresses. The method further comprises interfacing to a system that performs video coding. The method further comprises interfacing to an Identification Code Sort (ICS) system to look up address results and redirection status. The method further comprises directing products that contain redirected addresses into at least one holdout bin. The method further comprises applying ID tags to the products. The method further comprises directing products that contain specific indicia into at least one holdout bin. The method further comprises performing mail indicia verification on product.

In aspects of the invention, the invention relates to apparatus and methods of inserting mail pieces, such as letters and flats, into frames/folders while maintaining the forward transport motion of the articles. The apparatus is for use in a mail processing system, or in a processing system for any of a wide range of articles, such as flat articles, and comprises a succession of frames adapted to be transported within the mail processing system along a transport path, each of the frames being adapted to contain a single mail piece during processing within the mail processing system, the processing including sorting and sequencing, each of the frames having an opening through which the single mail piece is adapted to be inserted. More specifically, the apparatus includes an arrangement adapted to synchronize movement of the mail pieces with movement of respective ones of the succession of frames and to insert each of the mail pieces within the respective ones of the succession of frames without stopping the mail pieces between such synchronizing and inserting. The opening of each of the frames can be at a side or at the top of the frames. In addition, each of the frames can have a common shape, such as a rectangular shape, or substantially rectangular shape. The arrangement for synchronizing movements of the mail pieces and frames include one or more inserters which can be caused to move relative to empty frames of the succession of frames. Alternatively, movement of the frames can be varied during such synchronization or movement of both the frames and the inserters of the mail pieces can be varied during such synchronization.

In aspects of the invention, a system comprises a server comprising a frame tracking agent that tracks locations of a plurality of frames throughout a facility-wide sorting and/or sequencing system based upon data received from subsystems of the facility-wide sorting and/or sequencing system. The data comprises a plurality of manifests. Each one of the plurality of manifests may include at least one of: frame ID of each frame in a shuttle; shuttle ID; order that frames arranged in the shuttle; a timestamp; a subsystem ID; a component ID; and an address result associated with each frame ID. The server may be implemented in a computer infrastructure comprising hardware and software stored on a tangible storage medium.

In aspects of the invention, a method is provided for tracking frames in a facility-wide sorting and/or sequencing system. The method comprises: generating a manifest; sending the manifest to a frame tracking agent and a receiver; updating a location repository based upon the manifest; updating the manifest; sending the updated manifest to the frame tracking agent; updating the location repository based upon the updated manifest; and generating a new manifest. In embodiments, the updating the location repository based upon the manifest and the updating the location repository based upon the updated manifest are performed by the frame tracking agent. The generating and sending of the manifest may be performed by a sender. Moreover, the updating the manifest, the sending the updated manifest, and the generating the new manifest may be performed by the receiver. In embodiments, the method further comprises: performing a missing frame analysis based upon data in the location repository; and storing results of the missing frame analysis in a validation metrics data store. In even further embodiments, the method comprises at least one of: retrieving by frame ID a location of a frame in the facility-wide sorting and/or sequencing system; retrieving by subsystem ID a list of frames contained within a subsystem in the facility-wide sorting and/or sequencing system; retrieving by component ID a list of frames contained within a component in the facility-wide sorting and/or sequencing system; retrieving by frame ID an entire path that a frame has been routed through; generating by subsystem ID a summation of frame counts through a subsystem over a time period; and generating by component ID a summation of frame counts through a component over a time period.

In aspects of the invention, a stackable cart is provided. The stackable cart comprises: frame having a front, back, and sides; and a bottom hingedly connected to a lower end of the back. In a side view, a height of the back is less than a height of the front and in a top-down view, a width of the back is less than a width of the front such that the cart has a generally trapezoidal footprint. The bottom is biased to an intermediate angular position. The stackable cart further comprises a plurality of rollers connected to the frame of the cart. The bottom is structured and arranged such that: when an object is placed on the bottom, the bottom rotates downwardly from the intermediate position to a substantially horizontal position, and when an other cart is nested into the cart, the bottom rotates upwardly from the intermediate position to an almost vertical position. The intermediate position is at about 45° relative to vertical. At least one pin is connected to the frame of the cart. At least one hole is in the bottom, wherein the hole is structured and arranged to engage the pin. The pin limits downward rotation of the bottom. More specifically, the pin limits downward rotation of the bottom when the bottom reaches a substantially horizontal position. The at least one pin comprises two pins, and the at least one hole comprises two holes. The dimensions include, for example: a height of the back is about 66 inches, a height of the front is about 70 inches, a width of the back is about 40 inches, a width of the front is about 44 inches, and a depth of the frame is about 29 inches.

In aspects of the invention, the invention provides, in embodiments, a system and method for distributing filled trays of destination mail in a facility-wide letters/flats mail sorting and/or sequencing system. In embodiments, the invention also includes a container dispatch distributor (CDD) system for a facility-wide letters/flats mail sorting and/or sequencing system. In embodiments, a system for distributing filled trays of destination mail comprises at least one dispatch lane unit receiving mail trays loading carts with the mail trays.

The invention also provides, in embodiments, that the at least one dispatch lane unit receives the trays from a conveyor transport. The system further comprises at least one reader for reading the trays before the trays are loaded onto the carts. The trays are loaded onto the at least one of the carts at least based on a dispatch allocation plan and/or according to a predetermined plan. The system further comprises transport devices which transport the trays from sequencing units to a conveyor transport. The system further comprises a tray lift device for lifting the tray and loading the trays onto the carts. In embodiments, the system further comprises a device for printing an identification and applying the identification onto the carts. The system further comprises a device for activating a tray retainer arranged on each cart.

The invention provides, in embodiments, a method of distributing filled trays of destination mail comprising utilizing at least one system recited above to at least one of: load trays onto carts, load trays onto carts in an automated manner, and load trays onto carts according to a dispatch allocation plan. The invention also provides, in embodiments, a method of distributing filled trays of destination mail comprising utilizing at least one system recited above to load trays onto a cart, print an identification and apply the identification onto the cart, and activate a tray retainer arranged on the cart.

In aspects of the invention, a method for sequencing products within a storage unit is provided. The method comprises: cycling the products through the storage unit in at least a first cyclic path and a second cyclic path; and diverting selected products from the first cyclic path to the second cyclic path. The products are diverted between the first cyclic path and the second cyclic path, in accordance with a sequencing control which places all the products in a predetermined delivery point sequence within the storage unit. The sequencing control includes: determining a plurality of blocks of consecutively numbered products to sequence; capturing each consecutively numbered product of the first block from the flow of the first cyclic path in a sequential order; placing each captured consecutively numbered product into the second cyclic path; releasing the captured consecutively numbered products from the second cyclic path back into the first cyclic path; and repeating the steps for the remaining blocks until all of the products are placed in the delivery point sequence. The sequencing control includes: capturing a predetermined number of numbered products from the first cyclic path and diverting the captured numbered products to the second cyclic path; pushing the bottom numbered product in the second cyclic path behind the next lower numbered product in the second cyclic path; releasing the bottom numbered product from the second cyclic path back into the first cyclic path, if the bottom numbered product cannot be pushed behind the lower numbered product or if there is no lower numbered product in the second cyclic path; adding a new numbered product from the first cyclic path to the second cyclic path, after the bottom numbered product has been released back into the first cyclic path; and repeating the steps until all of the numbered products are placed in the delivery point sequence in the first cyclic path. The sequencing control can include: diverting the lowest numbered product from the first cyclic path to the second cyclic path; determining when the next lowest numbered product in the first cyclic path is approaching the second cyclic path; diverting the next lowest numbered product from the first cyclic path to the second cyclic path; and repeating the steps until all of the numbered products are placed in the delivery point sequence in the second cyclic path. The sequencing of products occurs in a plurality of storage units in parallel.

In aspects of the invention, a system for sequencing products within a storage unit comprises: an input lane for transporting unsequenced products to an input of the storage unit; a conveyor for cycling the products through the storage unit in at least a first cyclic path and a second cyclic path; a diverter for diverting selected products from the first cyclic path to the second cyclic path; and an output lane for transporting sequenced products from an output of the storage unit. The products are diverted between the first cyclic path and the second cyclic path, in accordance with a sequencing control which places all the products in a predetermined delivery point sequence within the storage unit. The products are transported in frames which are at an angle of substantially 45 degrees to a direction of flow. The conveyor conveys the frames from the input lane into the storage unit using a right angle diverting mechanism. The diverted frames are reoriented in a direction perpendicular to the direction, and the diverter diverts the perpendicularly oriented frames vertically between the first cyclic path and second cyclic path in accordance with the sequencing control. The conveyor orients the perpendicularly oriented frames back into an angle of substantially 45 degrees to a direction of flow before discharging the frames from the storage unit and onto the output lane. The conveyor and the diverter are controlled by a control unit that causes the frames to be diverted in accordance with the sequencing control.

In aspects of the invention, a clamp system comprises a first clamp. The first clamp comprises: a backing having a gap or notch at an upper edge thereof; a divert pin extending upward from the backing and configured to interact with a divert mechanism or angle compensating mechanism; and an upward extending arm from the backing and at a side of the gap or notch. In embodiments, the first clamp further comprises a grasping mechanism extending downward from the upward extending arm and contacting the backing. The upward extending arm includes a vertical extending portion and two horizontal extending portions. The two horizontal extending portions are parallel to one another. A second clamp comprises: a backing having a gap or notch at an upper edge thereof; a divert pin extending upward from the backing and configured to interact with a divert mechanism or angle compensating mechanism; an upward extending arm from the backing and at a side of the gap or notch; and a grasping mechanism which is configured to nest with the gap or notch of the first clamp in order to control a mail piece on the first clamp and minimize a thickness dimension of the nested first clamp and second clamp.

In aspects of the invention, a container comprises: sidewalls and a bottom surface a locking bar extending from at least the sidewalls and configured to pivot between a locked position and an open position, the locking bar including wedge shaped protections configured to interact and contact with a backing of clamps; offsetting channels “CH” or other holding mechanism projecting upwards from the bottom surface and configured to mate with upward extending arms of the clamps; an upward extending substantially centrally located locking tab positioned between the channels, the locking tab being configured to interact with the upward extending arms of the clamps such that when the locking bar is lowered, the wedge shaped projections contact the backing of the clamps, pushing the upward extending arms of the clamps into frictional engagement with the locking tab, effectively holding the clamps in a stationary position. The container includes openings which allow a portion of the upward extending arms of the clamps to extend outside of the container and engage with a driving mechanism.

In aspects of the invention, a storage unit comprises: a drawer having a sliding mechanism to allow access to the drawer; and a channel or transport mechanism for holding clamps therein, wherein a channel or transport mechanism of a first storage unit is at an incline with respect to a channel or transport mechanism of a second storage unit. The storage unit comprises different levels. The storage unit comprises at least one maintenance aisle. The storage unit comprises dual offset channels to store mail pieces with clamps.

In aspects of the invention, the present invention relates to a system and method for automatically identifying frames in a sequencing system. The frames contain products destined to certain delivery points. Machine readable unique frame identification data is associated with each frame. A plurality of readers reads and decodes the unique frame identification data at predefined locations within the sequencing system. A processing unit provides tracking information as the frames move through the sequencing system past the plurality of readers. The tracking information is utilized to place the frames into a destination delivery sequence. The machine readable frame identification data is encoded into a barcode, a linear CD strip, an RFID tag, a smart card or a magnetic stripe.

In aspects of the invention, a method is provided for automatically identifying frames in a sequencing system, the frames containing individual products associated with delivery destinations. The method comprises: associating unique frame identification data with each frame; associating product profile data with the frame identification data of its containing frame; reading and decoding the unique frame identification data at predefined locations within the sequencing system; providing tracking information, as the frames move through the sequencing system. The tracking information is utilized to place the frames into a delivery point sequence. The product profile data is utilized to place the frames into greater levels or sort in addition to the delivery point sequence.

In aspects of the invention, the invention provides a system and method for buffering frames with and/or containing mail pieces in a facility-wide letters/flats mail sorting and/or sequencing system. The invention provides a frame with mail buffer system comprising a presort accumulator. The invention provides a frame with mail buffer system comprising a frame receiving system and a buffer controller system. In embodiments, the frame receiving system may receive frames from at least one mail induction unit. The frame with mail buffer system may further comprise a frame reader. The frame with mail buffer system may further comprise a presort accumulator. The frame with mail buffer system may further comprise a system for transporting the frames along a first path and diverting the frames into at least one accumulator tube. The frame with mail buffer system may further comprise a system for transporting the frames on shuttles along a first path after the frames exit from at least one accumulator tube. The frame with mail buffer system may implement an accumulator allocation plan. The frame with mail buffer system may further comprise a system for presorting the frames and then placing the frames onto shuttles.

In aspects of the invention, the invention also provides, in embodiments, a method of buffering frames containing mail wherein the method utilizes at least one system recited above to at least one of receive frames with mail, and reads frames containing mail, buffers frames containing mail from at least one induction unit, and pre-sorts the frames containing mail in a presort accumulator. The invention additionally provides, in embodiments, a method of buffering frames containing mail comprising receiving and accepting frames containing mail and reading the frames, placing the frames into at least one accumulator tube, presorting the frames, and loading the pre-sorted frames onto shuttles.

In aspects of the invention, a presort accumulator system architecture comprises: a frame reader which receives frames that each have a mail piece from one or more mail induction units, the frame reader reads a frame identification (ID) and communicates with a control function sub-system which includes: a multiplex controller; an accumulator controller, and an accumulator selector, the accumulator selector interfaces with an accumulator allocation plan; a system of accumulator tubes receives the read frames from the frame reader and places the frames into a buffer segment of one or more of the accumulator tubes. Each accumulator tube has an arrangement for moving the frames within the tubes including a buffer segment and a collector segment.

In aspects of the invention, a computer implemented method embodied on a tangible storage medium comprises ascertaining attributes on at least one object using a profiler and determining dimensional data for the at least one object based on the attributes. The method further comprises determining whether the dimensional data is within predefined dimensions, identifying a frame having dimensions larger than the dimensional data, and matching the at least one object with the frame that has dimensions larger than the dimensional data. The method may also comprise associating an identifier for the frame with an attribute of the mail piece, therefore allowing at least one mail piece attribute to be recalled by the frame identifier that holds the mail piece. In embodiments the method may also comprise routing the at least one mail piece to an insertion area where the at least one mail piece can be inserted into the frame. The method may further comprise routing the at least one mail piece that exceeds the predefined dimensions to a holdout to be manually sorted.

In aspects of the invention, the method comprises collecting additional attributes to determine whether the at least one mail piece can be inserted into the frame. The attributes may include at least one of a height, length, width, weight, stiffness, projections, and delivery area of the at least one mail piece. One or more of these attributes may be obtained using one or more of a camera, a light-emitting diode (LED), a charge-coupled device (CCD) or camera, a weight sensor, and a probe.

In aspects of the invention, a system comprises a profiler configured to obtain one or more object attributes, a data storage unit configured to store dimensional data about the obtained one or more object attributes, and an insertion machine configured to insert an object into an appropriately sized frame based on the dimensional data. In embodiments, the object may be a mail piece. The insertion machine may insert the mail piece into the frame with frame dimensions closest to but still larger than the dimensional data. The frame may be at least partially elastic.

In aspects of the invention, the present invention includes a self monitoring and testing unit. In embodiments, the self monitoring and testing unit (i.e., S.M.A.R.T. unit) includes a rugged, portable processing unit configured to pass through a machine including a plurality of sensors and monitors configured to detect and monitor changes in operating conditions of the machine. The plurality of sensors and monitors collect data along a conveyance path through the machine and transmits the collected data to a control unit. The data collected by the plurality of sensors and monitors is analyzed such that machine problems are diagnosed before a failure of the machine. In embodiments, the plurality of sensors and monitors may include at least one camera configured to provide at least one of a plurality of still images and video images so as to monitor mechanical conditions of the conveyance path, and at least one light configured to provide illumination for the at least one camera. In embodiments, the plurality of sensors and monitors may include at least one microphone configured to record audible noises throughout the machine to detect vibration and bearing squeal, at least one infrared thermometer to detect hot spots along the conveyance path before a system failure occurs, and at least one static sensor to monitor buildup of static electricity to prevent damage to equipment along the conveyance path.

In further or other embodiments, the plurality of sensors and monitors may further include at least one force and strain gauge configured to measure forces and strains on parts of a frame that interacts with various structures along the conveyance path, a plurality of accelerometers configured to detect vibrations, shocks, and accelerations experienced by the frames during transport throughout the machine, and at least one humidity sensor configured to monitor humidity changes along the conveyance path. In embodiments, the processing unit may further include a solid state memory configured to store data from at least the plurality of sensors and monitors, and a processor configured to collect the stored data, organize it, and transmit it via a wireless communication transmitter to the control unit. In other embodiments, the processing unit may further include a plurality of connectors provided to allow the processing unit to communicate with peripheral devices to transmit the collected data and receive updated data and other information. In still other embodiments, the processing unit may further include a battery to provide power to the plurality of sensors and monitors, and at least one charge pad configured to recharge the battery and which is configured to contact contacts located along the conveyance path and a remote recharging station. In embodiments, the processing unit may be secured to the frame to provide stable support within the frame during transport.

In aspects of the invention, a method is provided for monitoring and diagnosing operating conditions within a machine. The method comprises: initiating an initial run of a processing unit through the machine to collect base line data of handling characteristics of the machine, collecting operating conditions data on subsequent runs through the machine; comparing the operating conditions data with the base line data; and determining a difference in the operating conditions data and the base line data in order to take at least one of the preventative measures and reactive measures with regard to at least one failing component to prevent a failure from occurring within the machine.

In aspects of the invention, a shuttle mechanism is provided for conveying a plurality of frames to a machine. The shuttle mechanism comprises a shuttle and a docking station of a machine for loading and unloading the plurality of frames. In embodiments, the shuttle comprises a frame member comprising at least two open end walls, a plurality of non-powered transport screws extended between the two open end walls, and side posts having at least two notches to accommodate portions of the plurality of non-powered transport screws. In embodiments, the at least two open ends are generally angled at 45 degrees, wherein the plurality of non-powered transport screws include a plurality of threads, and wherein the plurality of frames are generally angled at 45 degrees and supported by the plurality of non-powered transport screws. In embodiments, the plurality of non-powered transport screws may include at least one female connector for engaging a male connector of a transport screw extending from the docking station, wherein the at least one female connector includes a broached hole, a countersunk rim, a plurality of countersunk notches at spaced intervals along the countersunk rim, and wherein the male connector includes a tapered square tang for self alignment and engagement with the broached hole.

In aspects of the invention, the shuttle may include at least one braking mechanism. The braking mechanism comprises: a guide rod, a plurality of guide rod support blocks; a cam; a brake arm; a brake arm mount; at least first and second elastic members; a deflectable roller cam; and a third elastic member. The brake arm is configured to frictionally engage at least one of the plurality of non-powered transport screws. In embodiments, the cam is displaceable to disengage the brake arm from the at least one non-powered transport screw, and wherein when the guide rod contacts a stationary stopper of the docking station, the cam is displaced. In embodiments, the guide rod support blocks are secured to the shuttle at the bottom wall and the top wall, and the guide rod is supported by and extends through the guide rod support blocks, wherein the guide rod support blocks include an apertures for receiving a portion of the guide rod to slidably pass through, wherein the guide rod support blocks rotatably support at least a lower side of the non-powered transport screws, and wherein a height of the guide rod and the guide rod support blocks with respect to the bottom wall of the shuttle is generally lower than a height at which the non-powered lead screws are mounted to the guide rod support blocks.

In aspects of the invention, the docking station includes at least one swing clamp mechanism having a motor, a telescoping arm, a swing clamp arm, and a grasp element. The swing clamp arm is pivotally attached to an end of the telescoping arm, and wherein the grasp element engages the shuttle for loading and unloading of the plurality of frames.

In aspects of the invention, a method is provided for docking and deploying a shuttle. In embodiments, the method may include detecting an approaching shuttle on a conveyance path leading to a docking station, actuating a swing clamp mechanism by extending a telescoping arm of the swing clamp, rotating the swing clamp arm into the conveyance path of the approaching shuttle; engaging a portion of the shuttle with the swing clamp arm, retracting the telescoping arm, pulling the shuttle towards the docking station such that powered transport screws extending from the docking station engage non-powered transport screws of the shuttle, and mating the non-powered transport screws with the powered transport screws.

In further embodiments the method may include disengaging a plurality of braking mechanisms frictionally engaged to the non-powered transport screws, wherein the braking mechanism includes a brake arm frictionally engaging the non-powered transport screws and a cam, displacing the cam such that the braking mechanisms release the frictional engagement, actuating the powered transport screws such that the engaged non-powered transports screws rotate, and loading a plurality of frames from the machine to the shuttle. In still further embodiments, the method may comprise disengaging the swing clamp mechanism from the shuttle for deployment, extending the telescoping arm and swing clamp arm, rotating the swing clamp arm out of the conveyance path, engaging the braking mechanisms, wherein the brake arm frictionally engages the non-powered transport screws, and deploying the shuttle to a subsequent destination.

In aspects of the invention, the invention provides, in embodiments, a system architecture for a facility-wide letters/flats mail sorting and/or sequencing system comprising at least one processing system, at least one input system, at least one management system, and at least one output system. The at least one processing system comprises at least one of a presort accumulator, a transport controller, and a sequencer. The at least one input system comprises at least one of an induction manager and a frame inserter. The at least one processing system comprises at least one of a frame tracking agent, a frame manager, a storage manager, a system manager, and a shuttle manager. The at least one output system comprises at least one of a container loader and a container dispatcher. The frame inserter may receive frames from the induction manager and send filled frames and empty shuttles to the presort accumulator. The transport controller may receive frames from the frame inserter and the presort accumulator and send filled frames to the sequencer. The frame manager may receive empty frames in shuttles from the transport controller and empty shuttles from a shuttle manager.

In aspects of the invention, the invention provides, in embodiments, a process configuration for a facility-wide letters/flats mail sorting and/or sequencing system utilizing the system described above as well as a method of utilizing the system recited described above to manage mail from input to dispatch. The invention provides, in embodiments, a system configuration for a facility-wide letters/flats mail sorting and/or sequencing system comprising at least one input segment, at least one sequencer segment, at least one storage segment, and a master configuration. The system may further comprise at least one container loader segment. The system may also further comprise at least one dispatch area. The at least one input segment comprises at least one of a presort accumulator and a plurality of presort accumulator tubes. The at least one sequencer segment comprises at least one of a pre-sequence sorter and plural sequencers. The at least one sequencer segment may utilize data from at least one of a sort allocation plan and a sequence plan. The at least one storage segment comprises at least one of a post-sequence collector and plural aisles. The at least one storage segment may utilize data from at least one of a storage allocation plan, a sort allocation plan, and a sequence plan.

In aspects of the invention, the invention also provides, in embodiments, a process configuration for a facility-wide letters/flats mail sorting and/or sequencing system utilizing the system described above and comprising a system manager and a system configuration plan. In further aspects of the invention, the invention also provides, in embodiments, a method of utilizing the system recited above to manage mail from input to dispatch.

In aspects of the invention, a method is provided for performing a sequencing/sorting process of mail pieces. The method comprises: determining a proper sequence for a batch of the mail pieces using one of an N×N sequencing/sorting methodology, an N×M sequencing/sorting methodology and an applied radix sequencing/sorting methodology; and performing a sequencing/sorting of the batch of mail pieces using a plurality of right-angle diverts (RADs), right-angle merges and a plurality of frame transport tubes to rearrange the mail pieces into the proper sequence. The plurality of frame transport tubes are arranged in at least one of a cascading arrangement and a looping arrangement in order to perform the sequencing/sorting of the batch of mail pieces. More specifically, the plurality of frame transport tubes are arranged in at least one of a cascading arrangement and a looping arrangement in order to perform the sequencing/sorting of the batch of mail pieces in a single pass. An output stream of mail pieces of an n th stage of the sequencing/sorting is an input stream for an (n+1) th stage of the sequencing/sorting. The N×M sequencing/sorting methodology comprises building a current list of mail pieces by selecting an available mail piece having a lowest item number from a plurality of input frame transport tubes which is higher than a last item number in the current list. The method further comprises: loading the mail pieces indicated by the mail piece item numbers in the current list into an output frame transport tube if there is no available mail piece having an item number which is higher than the last item number in the current list; and establishing a new current list. The available mail piece is a mail piece exposable to a RAD by removing all mail pieces from the frame transport tubes that are in the current list. The N×M sequencing/sorting methodology utilizes a number of input frame transport tubes and a different number of output frame transport tubes. The applied radix sequencing/sorting methodology utilizes a differing number of frame transport tubes in subsequent stages of the applied radix sequencing/sorting methodology.

In aspects of the invention, a system is provided for performing a sequencing/sorting process of mail pieces. The system comprises: a tool operable to determine a proper sequence for a batch of the mail pieces using one of an N×N sequencing/sorting methodology, an N×M sequencing/sorting methodology and an applied radix sequencing/sorting methodology; and a plurality of right-angle diverts, a plurality of right-angle mergers, and a plurality of frame transport tubes operable to rearrange the batch of the mail pieces into the proper sequence.

The present invention is described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of exemplary embodiments of the present invention.

FIG. 1 shows an exemplary overview of a system architecture in accordance with aspects of the invention.

FIG. 1A shows an exemplary computer system environment for implementing a facility-wide mail sorting and/or sequencing system in accordance with aspects of the invention.

FIG. 1B illustrates an exemplary processing and delivery center (P&DC) mail piece flow for letters and flats in accordance with aspects of the present invention.

FIG. 1C shows an exemplary mail processing equipment (MPE) operations flow in accordance with aspects of the invention.

FIG. 1D shows an exemplary illustration of a methodology for sorting and/or sequencing mail in accordance with aspects of the present invention.

FIG. 1E shows an exemplary mail flow for sorting and/or sequencing in accordance with aspects of the invention.

FIG. 1F shows an exemplary illustration of existing equipment interfaced with a facility-wide sorting and/or sequencing system in accordance with aspects of the invention.

FIG. 1G shows an exemplary existing equipment interface in accordance with aspects of the invention.

FIG. 1H shows an exemplary flow for performing aspects of the invention utilizing an existing equipment interface in accordance with aspects of the invention.

FIG. 2 is a block diagram that illustrates the relationship between an automatic culling, facing and canceling system, an induction system, and a sequencing system.

FIG. 3A shows a configuration of a portable storage and main trunk transport unit in accordance with aspects of the invention.

FIG. 3B shows a portable storage and main trunk transport unit in accordance with aspects of the invention.

FIG. 4 shows a centralized server (System Management Subsystem) on a centralized network that attaches to all subsystems for the purpose of controlling and remote monitoring in accordance with aspects of the present invention.

FIG. 5 show a centralized address recognition system in accordance with aspects of the invention.

FIG. 6A shows an exemplary P&DC material processing flow for conventional sorting systems.

FIG. 6B shows an exemplary P&DC material processing flow for a facility-wide sorting and/or sequencing system in accordance with aspects of the invention.

FIG. 6C shows an exemplary interface in accordance with aspects of the invention.

FIG. 7A shows a base module and expansion module in accordance with aspects of the invention.

FIGS. 7B and 7C illustratively shows mail pieces being routed through different systems and subsystems in accordance with aspects of the invention.

FIG. 7D shows the mail processing system being arranged in independent parallel branches to process mail in accordance with aspects of the invention.

FIG. 8A shows an exemplary central management system implemented in a hierarchical arrangement in accordance with aspects of the present invention.

FIG. 8B shows an alternative depiction of an exemplary central management system implemented in a hierarchical arrangement in accordance with aspects of the present invention.

FIG. 8C shows an exemplary illustration of a service oriented interface in accordance with aspects of the present invention.

FIG. 8D shows an exemplary high level control center architecture in accordance with aspects of the present invention.

FIG. 8E shows an exemplary control center address recognition image logic module architecture in accordance with aspects of the present invention.

FIG. 8F shows an exemplary control center MPE status and control logic module architecture in accordance with aspects of the present invention.

FIG. 8G shows an exemplary control center maintenance server software module architecture in accordance with aspects of the present invention.

FIG. 9A shows a schematic of a non-limiting embodiment of a right angle divert in accordance with aspects of the invention.

FIG. 9B shows a schematic of another non-limiting embodiment of a right angle divert in accordance with aspects of the invention.

FIG. 9C shows a schematic of yet another non-limiting embodiment of a right angle divert in accordance with aspects of the invention.

FIG. 9D shows a schematic of a non-limiting embodiment of a multiplexer in accordance with aspects of the invention.

FIG. 9E shows a schematic of a non-limiting embodiment of a mail section sequencer in accordance with aspects of the invention.

FIG. 9F shows a schematic of a non-limiting embodiment of a mail sequencer in accordance with aspects of the invention.

FIG. 9G shows a perspective view of a non-limiting embodiment of a conveyance module in accordance with aspects of the invention.

FIG. 9H shows a schematic of a non-limiting embodiment of right angle diverts in the conveyance module of FIG. 9G in accordance with aspects of the invention.

FIG. 9I (A) shows a perspective view of the non-limiting embodiment of the conveyance module of FIG. 9G without support frames of the module in accordance with aspects of the invention.

FIG. 9 I(B) shows a four lead screw conveyance system, as further described with respect to FIG. 9W and FIG. 9X , in accordance with aspects of the invention.

FIG. 9J shows perspective views of a rotating cam divert mechanism in accordance with aspects of the invention.

FIG. 9K shows a top view of the non-limiting embodiment of the conveyance module of FIG. 9G without the support frames of the module in accordance with aspects of the invention.

FIG. 9L shows an exploded view of FIG. 9K showing a top view of the rotatable cam divert mechanism in accordance with aspects of the invention.

FIG. 9M shows a top view of a rotatable cam in a bypass setting in accordance with aspects of the invention.

FIG. 9N shows a top view of a rotatable cam in a divert setting in accordance with aspects of the invention.

FIG. 9O shows perspective view of a pinch belt divert mechanism in accordance with aspects of the invention.

FIG. 9P shows an exploded view of FIG. 9O showing lift mechanisms in accordance with aspects of the invention.

FIG. 9Q shows a perspective view of a non-limiting embodiment of a vertical divert mechanism in a bypass setting in accordance with aspects of the invention.

FIG. 9R shows a perspective view of the vertical divert mechanism of FIG. 9Q in a divert setting in accordance with aspects of the invention.

FIG. 9S shows a perspective view of another non-limiting embodiment of a vertical divert mechanism in a bypass setting in accordance with aspects of the invention.

FIG. 9T shows a perspective view of the vertical divert mechanism of FIG. 9S in a divert setting in accordance with aspects of the invention.

FIG. 9U shows a perspective view of a threaded roller conveyance system having a rotatable slotted cam divert mechanism in accordance with aspects of the invention.

FIG. 9V shows a perspective view of a non-limiting example of a 45 degree divert mechanism within a tooth belt conveyance system in accordance with aspects of the invention.

FIG. 9W shows a perspective view of a non-limiting example of an inset compression zone in accordance with aspects of the invention.

FIG. 9X shows a top view of the inset compression zone of FIG. 9W in accordance with aspects of the invention.

FIG. 9Y shows a perspective view of a non-limiting example of an inline compression zone in accordance with aspects of the invention.

FIG. 9Z shows an exploded top view of the inline compression zone of FIG. 9Y in accordance with aspects of the invention.

FIG. 10A shows a mail piece extraction apparatus in accordance with certain aspects of the invention and, more particularly, via lateral slide and in-line vacuum extraction point in accordance with aspects of the invention.

FIGS. 10B-10D show an alternative mail piece extraction apparatus in accordance with certain aspects of the invention and, more particularly, via force-of-gravity utilizing a rotated shuttle in accordance with aspects of the invention.

FIGS. 10E-10G show an additional alternative mail piece extraction apparatus in accordance with certain aspects of the invention and, more particularly, via robotic pushers and grippers, being friction or vacuum assisted in accordance with aspects of the invention.

FIG. 10H schematically illustrates, in a plan view, a unidirectional mail piece extraction apparatus in accordance with aspects of the invention.

FIG. 10I schematically illustrates an alternative unidirectional mail piece extraction apparatus in accordance with aspects of the invention.

FIG. 10J schematically illustrates a bi-directional mail piece extraction apparatus operating in a first direction in accordance with aspects of the invention.

FIG. 10K schematically illustrates the bi-directional mail piece extraction apparatus of FIG. 10J operating in a second direction, i.e., opposite to the direction of FIG. 10 JC in accordance with aspects of the invention.

FIG. 10L illustrates a side view of an extractor frame having pop-up pusher tabs for engaging a mail piece within a mail frame for extracting the mail piece from the frame in accordance with aspects of the invention.

FIGS. 10 Ma and 10 Mb are bottom views of FIG. 10L , showing the pusher tabs in two different operable positions in accordance with aspects of the invention.

FIG. 10 Na shows a perspective view and FIG. 10 Nb shows a side view of the mail frame constructed with slots 1051 for use with the extractor frame shown in FIGS. 10L , 10 Ma and 10 Mb.

FIG. 10O schematically illustrates a bi-directional mail piece extraction apparatus, such as that shown in FIGS. 10J and 10K , more particularly with regard to shuttle traffic in accordance with aspects of the invention.

FIGS. 11 Aa- 11 Ad show a particular type of frame, i.e., a frame having an accordion-type structure, in accordance with aspects of the invention.

FIGS. 11 Ba- 11 Bf show various views of frames in accordance with aspects of the invention.

FIGS. 11 Ca- 11 Cd show various views of frames in accordance with aspects of the invention.

FIG. 11D shows a frame in accordance with aspects of the invention.

FIGS. 11 Ea- 11 Ec show a frame design with a two part frame in accordance with aspects of the invention.

FIGS. 11 Fa- 11 Fd show an alternative frame design which accommodates top or side insertion and bottom extraction of mail pieces in accordance with aspects of the invention.

FIGS. 11 Ga- 11 Gc show an alternative frame design which accommodates top or side insertion and side extraction of mail pieces in accordance with aspects of the invention.

FIG. 11H shows an alternative frame design in accordance with aspects of the invention.

FIG. 11I shows an alternative frame design in accordance with aspects of the invention.

FIG. 11J shows an alternative frame design in accordance with aspects of the invention;

FIGS. 11 Ka- 11 Kd show an alternative frame design in accordance with aspects of the invention.

FIGS. 11 La- 11 Ld show an alternative frame design in accordance with aspects of the invention.

FIGS. 11 Ma and 11 Mb show embodiments of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11N shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11O shows embodiments of individual frames for sorting mail in accordance with aspects of the invention.

FIGS. 11 Pa- 11 Pd show embodiments of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11Q shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11R shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11S shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11T shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11U shows an embodiment of individual frames for sorting mail in accordance with aspects of the invention.

FIG. 11V shows the frame of FIG. 11U being transported on a transportation device in accordance with aspects of the invention.

FIG. 12 is a schematic top view of an apparatus for outputting packaging of mixed mail pieces in accordance with aspects of the invention.

FIG. 13 shows a block diagram of a system according to aspects of the invention.

FIG. 14A shows a block diagram of a system according to aspects of the invention.

FIG. 14B shows a flow diagram depicting steps of a method according to aspects of the invention.

FIG. 15A shows processes for associating mail piece identifiers with individual frame identifiers and associating mail piece attributes to either the mail piece identifiers or the frame identifiers in accordance with aspects of the present invention.

FIG. 15B show processes for obtaining associated mail piece attribute information from a storage unit using individual frame identifiers in accordance with aspects of the present invention.

FIG. 16A shows a block diagram of a system in accordance with aspects of the invention.

FIG. 16B shows an exemplary transport network in accordance with aspects of the invention.

FIG. 16C shows a block diagram of a system in accordance with aspects of the invention.

FIG. 16D shows a flow diagram of steps of a method in accordance with aspects of the invention.

FIG. 17A shows a perspective view of an exemplary embodiment of a presorting unit of a mail sorting and sequencing system in accordance with aspects of the invention.

FIG. 17B shows another perspective view of the presorting unit of FIG. 17A .

FIG. 17C shows an exploded partial perspective view of an induction unit of the presorting unit in accordance with aspects of the invention.

FIG. 17D shows a top view of a first pathway having a plurality of diverter gates in accordance with aspects of the invention.

FIG. 18 shows a perspective view of the diverter gate in an activated position and a deactivated position in accordance with aspects of the invention.

FIG. 19A shows a frame manager system architecture in accordance with aspects of the invention.

FIG. 19B shows a shuttle manager system architecture in accordance with aspects of the invention.

FIG. 20A show a transportation system in accordance with aspects of the invention.

FIG. 20B show a buffering system in accordance with aspects of the invention.

FIG. 20C shows an alternate transportation system in accordance with aspects of the invention.

FIG. 20D shows details of a cell having a rack and pinion track system in accordance with aspects of the invention.

FIG. 20E is an enlarged view showing details of a platform and its gear mechanism that operate in accordance with aspects of the invention.

FIG. 20F is an enlarged view showing details of the platform and its gear mechanism that operate in accordance with aspects of the invention.

FIG. 20G shows details of the platform and its gear mechanism that operate in accordance with aspects of the invention.

FIG. 21A shows a frame buffer system architecture in accordance with aspects of the invention.

FIG. 21B shows a frame buffer method in accordance with aspects of the invention.

FIG. 22 shows a mail-merger processing system (MMPS) in accordance with aspects of the invention.

FIG. 23 shows a block diagram of a system in accordance with aspects of the invention.

FIG. 24A shows a flows diagram depicting steps of a method in accordance with aspects of the invention.

FIG. 24B shows a flows diagram depicting steps of a method in accordance with aspects of the invention.

FIG. 24C shows a flows diagram depicting steps of a method in accordance with aspects of the invention.

FIG. 25A is a flow diagram of the mail induction process for a facility wide sequencing system in accordance with aspects of the invention.

FIG. 25B is a detailed flow chart of steps S 2506 -S 2510 of FIG. 25A .

FIG. 25C is a detailed flow diagram of the address arbitration rules of step S 2510 in accordance with aspects of the invention.

FIG. 26A schematically illustrates a mail piece being inserted into a cartridge in accordance with aspects of the invention.

FIG. 26B schematically illustrates two examples of mail pieces, in the forms of a letter (in an upper view) and a flat (in a lower view), respectively, inserted through the side of a common sized frame/folder moving along a mail stream within a stream of successive frame/folders, in accordance with aspects of the invention.

FIG. 26C schematically illustrates, in perspective, an exemplary pair of frame/folders which form a portion of a mail stream of successive frame/folders into which mail pieces are inserted in accordance with aspects of the invention.

FIG. 26D shows the mail stream of FIG. 26C in a top view.

FIG. 26E schematically illustrates, in a top view, an exemplary arrangement of inserters synchronized with the movement of a succession of empty mail frames along a transport path, for inserting mail pieces into respective ones of the frames in accordance with aspects of the invention.

FIG. 26F schematically illustrates an alternative embodiment, whereby a mail piece is inserted into a moving frame/folder from above in accordance with aspects of the invention.

FIG. 26G illustrates an alternative inserter arrangement in accordance with aspects of the invention.

FIG. 27A shows a block diagram of a system in accordance with aspects of the invention.

FIG. 27B shows a block diagram depicting steps of a process in accordance with aspects of the invention

FIGS. 28A and 28B show a plurality of conventional carts.

FIG. 28C shows a top view of plurality of stackable carts in accordance with aspects of the invention.

FIG. 28D shows a side view of plurality of stackable carts in accordance with aspects of the invention.

FIG. 28E shows a side view of a stackable cart in accordance with aspects of the invention.

FIG. 28F shows an isometric view of a unloaded stackable cart in accordance with aspects of the invention.

FIG. 28G shows an isometric view of a loaded stackable cart in accordance with aspects of the invention.

FIG. 29A shows a number of sequencing units feeding filled mail trays to a conveyor transport backbone which in turn transports the mail trays to a number of dispatch loading lanes in accordance with aspects of the invention.

FIG. 29B shows a top view one dispatch loading lane of FIG. 29A in accordance with aspects of the invention.

FIG. 29C shows an enlarged top view of the dispatch loading lane of FIG. 29B in accordance with aspects of the invention.

FIG. 29D shows a side view of a portion of the dispatch loading lane of FIG. 29C in accordance with aspects of the invention.

FIG. 29E shows another side view of FIG. 29D in accordance with aspects of the invention.

FIG. 29F shows another side view of FIG. 29D in accordance with aspects of the invention.

FIG. 29G shows a top view of a portion of the dispatch loading lane of FIG. 29C in accordance with aspects of the invention.

FIG. 29H shows a top view of FIG. 29G in accordance with aspects of the invention.

FIG. 30 shows a side view of FIG. 29G in accordance with aspects of the invention.

FIG. 31A is a block diagram of a storage/sequencing unit and the general flow of mail frames between an input lane and a final sequencing lane in accordance with aspects of the invention.

FIGS. 31B and 31C are embodiments of the present invention which include a recirculation zone where the actual sequencing is accomplished within the storage units in accordance with aspects of the invention.

FIG. 31D is a more detailed side view illustration of the sequencing of frames within a storage unit/sequencing unit in accordance with aspects of the invention.

FIG. 31E is a flow diagram which illustrates the steps of the “hold” approach for sequencing in accordance with aspects of the invention.

FIG. 31F is a flow diagram which illustrates the steps of the “push back” approach for sequencing in accordance with aspects of the invention.

FIG. 31G is a flow diagram which illustrates the steps of the “floating divert” approach for sequencing in accordance with aspects of the invention.

FIG. 32A shows a mail clamp in accordance with one aspect of the invention.

FIG. 32B shows a clamp holding or grasping a mail piece in accordance with aspects of the invention.

FIG. 32C shows the clamp interacting with components of the sorting and sequencing system in accordance with aspects of the invention.

FIG. 32D shows two clamps in a nested position in accordance with aspects of the invention.

FIG. 32E shows two clamps in a nested position with mail pieces held thereon in accordance with aspects of the invention.

FIGS. 32F and 32G show sectional views of storage units in accordance with aspects of the invention.

FIG. 32H shows sectional views of two storage units in the direction of travel in accordance with aspects of the invention.

FIG. 32I shows the different storage units shown in, for example, FIGS. 32F and 32G .

FIG. 32J shows a side view of stacked storage units in accordance with aspects of the invention.

FIG. 32K shows a top view of the storage units in accordance with aspects of the invention.

FIG. 32L shows a storage rack in accordance with aspects of the invention.

FIG. 32M shows a shuttle in accordance with aspects of the invention.

FIG. 32N shows a container for transporting clamps in accordance with aspects of the invention.

FIG. 33A is a functional flow block diagram that illustrates the operation of a frame ID reader system which is controlled by a system manager in accordance with aspects of the invention.

FIG. 33B is a block diagram illustrating a frame ID reader system and five possible types of readable data in accordance with aspects of the invention.

FIG. 33C is a block diagram for a barcode reading system in accordance with aspects of the invention.

FIG. 33D is a block diagram for a CD reading system in accordance with aspects of the invention.

FIG. 33E is a block diagram for a RFID reading system in accordance with aspects of the invention.

FIG. 33F is a block diagram for a smart card reading system in accordance with aspects of the invention.

FIG. 33G is a block diagram for a magnetic stripe reading system in accordance with aspects of the invention.

FIG. 33H is an illustration of a barcode reader and a barcode fixed to an individual mail frame in accordance with aspects of the invention.

FIG. 33 I(i)-(iii) are illustrations of a CD, CD reader and a CD data strip fixed to an individual mail frame in accordance with aspects of the invention.

FIG. 33J is an illustration of an RFID tag reader and an RFID tag fixed to an individual mail frame in accordance with aspects of the invention.

FIG. 33 K(i) and (ii) are illustrations of a typical smart card, smart card reader and a smart card fixed to an individual mail frame in accordance with aspects of the invention.

FIG. 33L is an exploded view of a contact smart card in accordance with aspects of the invention.

FIG. 33M is an exploded view of a contactless smart card in accordance with aspects of the invention.

FIG. 33N is an exploded view of a dual or “combination” smart card in accordance with aspects of the invention.

FIG. 33O is an exploded view of a hybrid smart card in accordance with aspects of the invention.

FIG. 33P is an exploded view of a proximity or “prox” card in accordance with aspects of the invention.

FIG. 33Q is an illustration of a frame and possible locations of a reader for reading frame identity data in accordance with aspects of the invention.

FIG. 34A shows a pre-sort accumulator system architecture for buffering frames containing mail in accordance with aspects of the invention.

FIG. 34B shows a frame with mail buffer method in accordance with aspects of the invention.

FIG. 34C shows a top view of presort accumulator system receiving frames from induction units in accordance with aspects of the invention.

FIG. 34D shows a top view of the presort accumulator system illustrated in FIG. 34C in accordance with aspects of the invention.

FIG. 34E shows a front side view of the presort accumulator system illustrated in FIG. 34D in accordance with aspects of the invention.

FIG. 35A shows a flow diagram depicting steps of a method for profiling mail pieces and determining a frame size in accordance with aspects of the invention.

FIG. 35B shows an exemplary illustration of profiling a mail piece using light-emitting diodes (LEDs) and charge-coupled devices (CCDs) in accordance with aspects of the invention.

FIG. 36 shows a side view of a self monitoring and remote testing unit in accordance with aspects of the invention.

FIG. 37A shows a perspective view of an exemplary embodiment of a shuttle in accordance with aspects of the invention.

FIG. 37B shows a perspective view of a plurality of shuttles nested in accordance with aspects of the invention.

FIG. 37C shows a perspective view of a machine having shuttles docked at an entrance and an exit in accordance with aspects of the invention.

FIG. 37D shows a top and elevation view of the machine of FIG. 37C in accordance with aspects of the invention.

FIG. 37E shows a cross section side view of a docking joint in accordance with aspects of the invention.

FIG. 37F shows a perspective view of male and female engagement members used at a docking joint in accordance with aspects of the invention.

FIG. 37G shows a perspective view of an alternative embodiment of a shuttle including a braking system in accordance with aspects of the invention.

FIG. 37H shows a side view of a braking mechanism in an activated position in accordance with aspects of the invention.

FIG. 37I shows a side view of a braking mechanism in a deactivated position in accordance with aspects of the invention.

FIG. 37J shows perspective views of a machine receiving a shuttle for shuttle clamping in accordance with aspects of the invention.

FIG. 37K shows a perspective view of a swing clamp mechanism disengaged from a shuttle in accordance with aspects of the invention.

FIG. 37L shows a perspective view of a swing clamp mechanism in engagement with a shuttle in accordance with aspects of the invention.

FIG. 38A shows an overall system configuration in accordance with aspects of the invention.

FIG. 38B shows a system logical architecture in accordance with aspects of the invention.

FIG. 38C shows an induction manager architecture in accordance with aspects of the invention.

FIG. 38D shows a frame manager architecture in accordance with aspects of the invention.

FIG. 38E shows a shuttle manager architecture in accordance with aspects of the invention.

FIG. 38F shows a frame inserter architecture in accordance with aspects of the invention.

FIG. 38G shows a presort accumulator architecture in accordance with aspects of the invention.

FIG. 38H shows a transport controller architecture in accordance with aspects of the invention.

FIG. 38I shows a sequencer architecture in accordance with aspects of the invention.

FIG. 38J shows a storage manager architecture in accordance with aspects of the invention.

FIG. 38K shows a container loader architecture in accordance with aspects of the invention.

FIG. 38L shows a container dispatcher architecture in accordance with aspects of the invention.

FIG. 38M shows a frame tracking agent architecture in accordance with aspects of the invention.

FIG. 39 shows a system manager architecture in accordance with aspects of the invention.

FIG. 40A shows a system configuration in accordance with aspects of the invention.

FIG. 40B shows a configuration plan build in accordance with aspects of the invention.

FIG. 40C shows a system configuration for an input segment in accordance with aspects of the invention.

FIG. 40D shows a system configuration with an accumulator allocation plan in accordance with aspects of the invention.

FIG. 40E shows a system configuration with a sort allocation plan in accordance with aspects of the invention.

FIG. 40F shows a system configuration with a storage allocation plan in accordance with aspects of the invention.

FIG. 40G shows a volume management process in accordance with aspects of the invention.

FIGS. 40H-41 show various dynamic allocation configurations in accordance with aspects of the invention.

FIG. 42A shows an exemplary flow for performing an exemplary N×N sequencing/sorting process in accordance with aspects of the present invention.

FIGS. 42B-42R show steps in an exemplary N×N sequencing/sorting process in accordance with aspects of the present invention.

FIG. 42S shows an exemplary flow for performing an exemplary N×M sequencing/sorting process in accordance with aspects of the present invention.

FIGS. 42 T- 42 FF show steps in an exemplary N×M sequencing/sorting process in accordance with aspects of the present invention.

FIG. 42 GG shows an exemplary table for determining item base values for an applied radix sequencing/sorting process in accordance with aspects of the present invention.

FIG. 42 HH shows an exemplary flow for performing an applied radix sequencing/sorting process in accordance with aspects of the present invention.

FIGS. 42 II- 42 ZZ show steps in an exemplary applied radix sequencing/sorting process in accordance with aspects of the present invention.

FIG. 42 AAA shows an exemplary table indicating output buckets for three different sequencing scenarios for an applied radix sort in accordance with aspects of the invention.

FIG. 43 shows a container in accordance with aspects of the invention.

The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

Overview of System

The invention generally relates to improving product processing operations and, more particularly, to a method and system of sorting and/or sequencing letter mail, flats and parcels and other objects. The system and method can be implemented in a warehouse, or mail sorting or any type of sorting facility. Implementing the present invention allows for the continuous sorting of mail pieces to any level of sortation using a single pass. To accomplish the advantages of the invention, the system and method uses multiple stages of diverts and merges, e.g., individual mail pieces are diverted into a sortation system composed of multiple stages each with many parallel paths. The mail pieces are merged and combined into sequenced order at the conclusion of sorting. Moreover, in accordance with aspects of the invention, the mail pieces are sorted and/or sequenced in a stacked configuration, e.g., face-to-face (i.e., not end-to-end), in frames thus resulting in high throughput at low conveyor speeds. The present invention also relates to controls and methods for processing mail pieces throughout a facility and provides a seamless integration of computing functionality, e.g., sorting and sequencing methodologies, controls, etc., as further discussed below. The present invention represents a quantum leap over current mail sortation and sequencing operations.

More specifically, with the present invention, a facility-wide sorting and/or sequencing system incorporates the sorting and/or sequencing of flat mail, letter mail and, in embodiments, small parcels in a one pass stream. In embodiments, flat mail, letter mail and, in embodiments, small parcels, are placed into frames which are transported in a face-to-face orientation, which significantly increases throughput while potentially decreasing the footprint of the facility wide machine. The facility wide system includes input feeders, where mail pieces are singulated, the mail piece address and/or bar codes are recognized, and the mail pieces are transported individually into the induction and sequencing portions of the system. The input feeders, in embodiments, can be conventional flat and letter feeders which are integrated into the system of the present invention. The system further includes a mail frame induction system, where the mail pieces are matched with a frame, inducted into the frames, and transported and merged into a sequence or certain sort depth using a diverting and merging methodology as discussed in further detail below. Throughout the system, the frames can be managed by controls, e.g., compressed and or expanded, merged, diverted, sorted and/or sequenced, and shuttled throughout subcomponents in an efficient and cost effective manner. Once the combined mail pieces are in a sequence or a certain sort depth, the mail pieces are extracted from the frames using a mail piece extraction subsystem. Advantageously, the frames and mail pieces can be transported through various stages, e.g., between many different subsystems, using transports such as, for example, shuttles. The shuttles allow the frames and mail pieces to move quickly and efficiently throughout the facility.

Also, the system of the present invention is modular, which allows it to be expanded depending on the needs of a particular facility. The modularity of the system of the present invention also allows the system to be used with current machinery such that sorting and sequencing processes can continue without any significant interruption during the assembly of the facility wide system. Additionally, as discussed in more detail below, the system and method of the present invention includes unique sorting and/or sequencing schemes, transport systems, e.g., lead screws, right angle diverts, etc., as well as computing functions, storage facilities, and preventive detection of maintenance issues. In addition, the present invention contemplates the use of certain architectures, facility and postal wide schemes, methodologies and systems that result in great savings to the postal system and increased efficiency of sorting and/or sequencing and floor space.

More particularly, the present invention includes, in addition to other systems, components, etc, a facility wide mail sortation and/or sequencing system having the following functionality, components, etc. as shown in FIG. 1 . It should be noted that FIG. 1 is representative of a general overview of the system and, as such, additional features, capabilities, functions, etc. are contemplated by the present invention as described throughout the instant application.

Input Devices

The input devices are a series (1 to many) of mail piece feeders such as, for example, letter feeders, flat feeders and parcel feeders. These input devices comprise a barcode or address scanner, an algorithm that calculates the output bin associated with the input mail piece, a mechanical interface to convey mail from the output into the facility wide system, and a computing interface to communicate the associated address information to the remaining portions of the system. The bar code sorter may also communicate other information associated with a mail piece including mail image(s), indicia image(s) or characteristics, dimensions, barcodes, weights, sorter identification, and sortation information. More specifically, information that may be received, tracked and communicated throughout the system includes, for example, the following mail piece information from each induction subsystem:

Length; Width; Height; Volume; Orientation; Overall Length; Overall Width; Transverse Position; Barcode Information on the mail piece; Address information returned form the AARS; Weight; Location; and Mail type.

Facility Wide Sorting and/or Sequencing System

The Facility Wide Sorting System includes many subsystems such as, for example, mail frame inductors to induct many different types of mail pieces, e.g., letters, flats, small parcels, into frames for transportation throughout the system; right angle diverts and merging points to sort and sequence mail pieces in the frames, shuttles for transporting the frames between subsystems and components, mail frame extractors and controls such as, for example, management systems for controlling the functions of the system, e.g., sorting and sequencing processes. The system further includes inter and ultra facility components and networks and related functions and visibilities, as discussed herein. Some systems include, as an example, an identification subsystem that takes input data from the input devices and associates one or more electronic identifier uniquely to each mail piece. These electronic identifiers are used to track mail piece and to associate all related data to the mail piece.

Storage Subsystem

The storage subsystem is capable of storing mail between the receipt of mail to the dispatch of it. The storage system may be modular in nature, to be able to be sized to handle the volume of mail pieces from many different sizes of facilities. The association of a unique identification of the mail determines storage operations with its position in the system.

Input Subsystem

The Input Subsystem includes the Delivery Bar Code Sorters (DBCS) and the Flat Sorter Machines (FSM). In some embodiments, to take advantage of current USPS investments, the system of the invention uses the input sections (including induction stations, singulation, Optical Character recognition, barcode assignment, and facing canceling) of existing sortation systems. The portions of these systems used are the singulation, address/barcode assigning/reading/interpretation of the units.

Frame Inserter

The Frame Inserter places individual mail pieces into frames. It is assumed that mail piece frames will come in many different sizes. The inserter or its computing subsystem will choose the proper size of mail frame and insert the mail inside by using, e.g., optical recognition technology, photodiodes, or other known technologies all of which are capable of being implemented by one of skill in the art. In embodiments, the inserter shall be capable of inserting flat and letter mail at the rate of about 35,000 mail pieces per hour. In embodiments, the inserter can be a rotary inserter. By way of example, the rotary inserters include two pinch belts. As the mail passes between the pinch belts, it will be inserted within the frames as they are automatically expanded about a radius of the frame. (The frames open as they revolve around a carousel.) The rotary inserter, in embodiments, has the capability of about 35,000 insertions per hour. In implementation, it is contemplated that there would be one inserter for every DBCS or every two FSM machines.

Frames

The frames are designed to hold mail pieces. Although many different sizes of frames are contemplated by the present invention, two specific sizes of frames can include one full-height (which can contain any size mail piece) and one half-height that shall convey mail pieces smaller than 6 inches tall. Frames are capable of being measured for minimal thickness necessary for diversion. A frame maximum thickness when stacked empty can be less than 0.1 inch. Also, frames containing mail pieces of less than or equal to 0.1 thickness can store the resulting mail pieces on ⅛ inch centers. The frames are also configured and structured to be closed (sealed to prevent mail piece from escaping during sortation and transportation) at the end of insertion operations. In still further embodiments, the frames should be able to be stored in variably spaced storage units (only occupy the thickness of the mail piece). Also, the frames are designed such that they are able to be stored, diverted, retrieved and conveyed during normal truck transportation vibration at full conveyor speed. Also, the frames are conveyed and diverted with only the drive power from the conveyor, e.g., transportation system.

Buffer Subsystem

In certain embodiments, the Buffer Subsystem assures that surges in mail input do not result in overstressing the transport and assures that mail pieces get routed to the proper transport layer.

Transport Subsystem

The Transport Subsystem includes the numerous conveyors that transport the mail frames internally through the system. The transports carry the frames from the inserters throughout the system. In embodiments, the transport can handle about 80,000 mail pieces per hour (or 800,000 per hour for the main trunk). Transports include straight, curved, and ramped conveyors preferably of a lead screw type. The transport, in one embodiment, may be stacked layers.

Storage Subsystem

The Storage Subsystem automatically stores and retrieves mail pieces (in frames). This system can include buffers or storage areas for shuttles, which are designed to hold the frames during transport between different components.

Delivery Container Loader

The Delivery Container Loader packs the mail pieces into Delivery Containers. In embodiments, the loader resembles a conveyor other than the walls are a series of delivery containers. The containers are loaded at the speed of the conveyor. There is a small buffer to allow switching between full and empty containers. In embodiments, the following is noted.

The delivery container loader is configured to not require additional packaging machinery (like lidders/banders) to make the packages ready for delivery. The delivery container loader is configured to automatically load an empty container when a previous container is full. The delivery container loader is configured to at least operate 10 minutes without requiring manual intervention including adding new packages, or removing full packages.

System Management Subsystem

The System Management Subsystem controls and coordinates all system operations and maintains the identity of all mail pieces and/or frames. The system management subsystem is the series of computers that control and schedule all system movements, keep track of all mail piece identification by position, interface with human operators, and that interface all information between subsystems. The system management subsystem can include known algorithms to sort/sequence the mail (in the frames), as well as controls to control the ejection of the mail from the frames, the stacking thereof, etc.

Delivery Container Movement Subsystem

The Delivery Container Movement Subsystem moves the Delivery Containers from the loader to the point of delivery (dock). This system can include specially designed carts that may be nestable as discussed in the instant application.

The system of the present invention should have as small a space footprint as possible. The footprint includes all major components and working areas for personnel associated with the equipment. As such, the components are designed to be located within existing USPS processing and delivery facilities. In addition, it is contemplated that the throughput of the sorting and/or sequencing is significantly increased compared to conventional systems, e.g., upwards of 80,000 frames or more per hour. Additionally, and advantageously, the system is designed to handle all types of mail, simultaneously, while still using some existing sortation equipment such as, for example, letter, flat and parcel input feeders.

Additional Systems and Components

Although not specifically shown, the system can also include additional components and systems such as, for example, an unpackaging subsystem, Dispatch Packaging system, Receipt Packaging system, and Input Multiplexing subsystem. More specifically, the Unpackaging subsystem removes mail pieces from the standard mail packages and puts the resultant mail into tubs or containers, directly into transportation vehicles, or delivery point packaging. The Dispatch Packaging system packages standard mail packages into containers for shipping to the processing facilities without removing the individual mail piece container. The Dispatch Packaging system also packages standard mail packages into shipping containers, rolling stock or directly into transportation vehicles to other processing facilities without removing the individual mail piece container. The Receipt Packaging system unpacks standard mail packages from shipping containers, rolling stock, or directly for transportation vehicles from other processing facilities without removing the individual mail piece container. The Input Multiplexing subsystem takes mail from many different input devices and delivers them to the many modular storage and sortation subsystems, described herein. This subsystem associates a mail unique identification with its position in the system. Multiplexing operations are determined by this association.

System Environment

FIG. 1A shows an exemplary computer system environment 100 for implementing a facility wide mail sorting and/or sequencing system in accordance with the invention. As shown in FIG. 1A , the exemplary computer system environment 100 includes a computer infrastructure 102 that is operable to perform the processes described herein using a computing device 105 . The computer infrastructure 102 can be, for example, one or more servers that are accessible by different computing devices throughout the facility or remotely from the facility.

The computing device 105 includes a processor 107 , a memory 110 , an input/output (I/O) interface 115 , and a bus 120 . The bus 120 provides a communications link between each of the components in the computing device 105 . The communications link may be a wire or wireless link such as, for example, a LAN, WAN, intranet or the Internet. Additionally, the computer system environment 100 includes a storage system 117 , e.g., database. While only a single storage system 117 is shown, it should be understood that the computer infrastructure 102 may include any number of storage systems 117 . Moreover, it should be understood that, in embodiments, the storage system 117 may include one or more local storage systems implemented throughout the facility wide system and/or one or more remote storage systems. For example, the one or more storage systems 117 can be utilized to store information such as, for example, sorting and/or sequencing schemes, allocation plan, mail piece position within the facility, dock management information, control of different subcomponents, frame and mail piece size, identification and other attribute information, frame manifest, system wide functions, maintenance information, etc, as discussed in further detail below.

The processor 107 executes computer program code processes on computer storage media, which may be stored in the memory 110 and/or storage system 117 . The computer storage media may be, for example, a magnetic or optical portable disk, a hard drive, random access memory (RAM), read-only memory (ROM), an erasable programmable read-only memory, etc. to name a few. While executing computer program code, the processor 107 can read and/or write data to/from the memory 110 , storage system 117 , and/or I/O interface 115 . The memory 110 may include, for example, local memory employed during actual execution of program code, bulk storage, and/or cache memories which provide temporary storage of at least some program code to reduce the number of times code must be retrieved from bulk storage during execution.

Further, the computing device 105 is in communication with an external I/O device/resource 112 . The I/O device 112 can interact with the computing device 105 . In embodiments, the external I/O device/resource 112 may be, for example, a keyboard, one or more interfaces, one or more pointing devices, etc.

Thus, for example, as described herein further below, the computer infrastructure 102 may include one or more computing devices, e.g., for each processing and delivery center (P&DC) or for each regional command center. Moreover, in embodiments, the computer infrastructure 102 may be provided for each regional command center, wherein the computer infrastructure 102 of each regional command center is in communication with the other computer infrastructures 102 of the other regional command centers of the system-wide mail sorting and/or sequencing system.

Exemplary Processing Flow

FIG. 1B illustrates an exemplary processing and delivery center (P&DC) mail piece flow 125 for letter and flat mail pieces in accordance with aspects of the present invention. As shown in FIG. 1B , incoming mail pieces M include originating collection mail, incoming mail and originating bulk mail that are received, for example, at a receiving dock. Additionally, subsequent to a sorting and/or sequencing by the facility-wide mail sorting and/or sequencing system 127 , outgoing mail pieces M are output by the system in a sorted and/or sequenced order. However, in some embodiments as shown in FIG. 1B , the outgoing letters and the 5-digit cross dock bundles of originating bulk mail are not processed by the sorting and/or sequencing system 127 , but are collected for dispatch at outgoing mail 141 and destinating mail 146 , respectively.

Further, as shown in FIG. 1B , the exemplary P&DC mail piece flow 125 is divided into a letters flow 132 shown in the upper half of the exemplary processing and delivery center (P&DC) mail piece flow, and a flat mail piece flow 135 shown in the lower half of the exemplary processing and delivery center (P&DC) mail piece flow. However, as can be observed, both the letter mail piece flow 132 and the flat mail piece flow 135 utilize the same facility-wide mail sorting and/or sequencing system 127 in accordance with aspects of the invention.

As shown in FIG. 1B , with the present invention, the processing of originating non-local collection letter mail 137 will follow one of two processing paths, depending on whether the automatic face canceling system (AFCS) is an upgraded system. For example, for a site that does not have an upgraded AFCS, e.g., AFCS-200, facing, canceling and image lift, described further herein below, occurs on the AFCS. Separation of mail into local and outgoing is also performed on the AFCS, but, in embodiments, only for online address recognition results. Both the local and outgoing streams run through a primary sort operation on a delivery bar code sorter input/output subsystem (DIOSS) or combined input/output subsystem (CIOSS), where remote bar code scanning (RBCS) address results are obtained and the Postnet bar code applied. The local mail output of the DIOSS/CIOSS will be fed into the facility-wide mail sorting and/or sequencing system 127 in accordance with aspects of the present invention.

For a site that has an upgraded AFCS, e.g., an AFCS-200, (flow shown with the dashed line), the Postnet bar code is applied by the AFCS-200 for online address recognition results. As shown in FIG. 1B , local mail whose destination address is resolved on an AFCS-200 can be sent directly to the facility-wide mail sorting and/or sequencing system 127 . Moreover, RBCS address results are obtained on a DIOSS/CIOSS with the local mail output being fed into the facility-wide mail sorting and/or sequencing system 127 .

As further shown in FIG. 1B , in accordance with aspects of the invention, flat mail pieces are processed following a different flow 135 . After manual canceling and facing, all flats (local and outgoing) collection mail 140 is inducted directly into the facility-wide mail sorting and/or sequencing system 127 . As discussed further herein below, the facility-wide mail sorting and/or sequencing system 127 performs address recognition, applies ID tags, and separates the mail stream into local (or destinating) and outgoing mail. Both mail streams are processed within the facility-wide mail sorting and/or sequencing system 127 , with local flats being sequenced with letters to form a local (or destinating) mail output 142 and outgoing flats being sorted and made ready for the outgoing dispatches 145 .

Thus, as shown in FIG. 1B , originating and incoming mail 130 for letter and flat mail pieces and originating bulk mail for flats (except for the 5-digit cross dock bundles) is inducted into the sorting and/or sequencing system 127 . Moreover, as shown in FIG. 1B and described further herein below, the present invention will with one pass, sort the mail pieces (including letters and flats) and combine the destinating mail 142 into a single stream and pack it in delivery containers. Thus, as described above, by implementing the present invention, letters and flats mail operations at a P&DC may be greatly simplified.

FIG. 1C shows an exemplary mail processing equipment (MPE) operations flow 147 in accordance with aspects of the invention. As shown in FIG. 1C , incoming mail pieces may include collection mail 148 (or mail pieces collected locally), managed mail 150 (from other P&DCs) and destinating mail 152 (from other P&DCs). With regard to the collection mail 148 , all local letters collection mail 156 from an AFCS (or, in embodiments, a manual facing/canceling) enters the facility-wide mail sorting and/or sequencing system 127 directly. Additionally, all flats collection mail 154 enters the facility-wide mail sorting and/or sequencing system 127 directly, after being cancelled and faced. Further, as discussed above and explained further herein below, flats mail 154 is divided into local flat mail pieces and non-local flat mail pieces, and the local flat mail pieces are sorted and/or sequenced and the non-local flats mail is sorted for dispatch. Moreover, as shown in FIG. 1C , non-local letters collection mail 158 (and FIM mail) are not sent to the facility-wide mail sorting and/or sequencing system 127 . Rather, the non-local letters collection mail 158 (and FIM mail) are sent to the outgoing primary and, in embodiments, secondary operations.

As further shown in FIG. 1C , incoming managed mail 150 (from other P&DCs) is inducted directly into the facility-wide mail sorting and/or sequencing system 127 . However, managed mail 150 for letters that are destined to downstream P&DCs are held out at induction to the facility-wide mail sorting and/or sequencing system 127 and sent for dispatch to another P&DC. Additionally, as shown in FIG. 3 , all incoming destinating mail 152 (or mail destined for local delivery) from other P&DCs is inducted directly into the facility-wide mail sorting and/or sequencing system 127 . Thus, as shown in FIG. 1C , in accordance with aspects of the invention, the facility-wide mail sorting and/or sequencing system 127 of the present invention accomplishes all sorting and/or sequencing internally, requiring only a single induction process per mail piece and a single sort plan to be loaded.

FIG. 1D shows an exemplary illustration of a methodology 160 for sorting and/or sequencing mail in accordance with aspects of the present invention. As shown in FIG. 1D , and explained further herein below, the methodology 160 comprises a presorting operation 162 , a presequence/sorting operation 165 , an initial sequencing operation 167 , a post-sequencing collection operation 170 and a final sequencing operation 172 . Moreover, a container loading operation 175 occurs after the final sequencing operation 172 has completed.

In accordance with aspects of the invention, all mail (contained in frames, which is explained herein further below) enters the presorting operation 162 after induction. The presorting operation 162 looks up the destination of each mail piece in an allocation plan to determine the correct presort accumulator into which to move the frame. In embodiments, each accumulator is a first-in-first-out buffer area. Accumulator volume is monitored and when an accumulator becomes full, the entire group of frames is loaded onto a transport shuttle, as described further herein below. Additionally, a frame manifest is created that identifies the frames contained within the group.

In embodiments, the allocation plan is received from a system management function in the system of the present invention. The allocation plan provides information that is used to partition the presort accumulators by destination. That is, the accumulator allocation plan defines the presort rules for letters and flats destinating mail and flats outgoing mail. In embodiments, the allocation plan identifies the accumulators allocated for:

Destinating mail, defined by groupings of ZIP codes; Flats managed mail, defined by ZIP code breakouts for the downstream P&DCs; Domestic flats outgoing mail, defined by groupings of ADCs; Flats outgoing mail for APO/FPO locations, defined by APO/FPO groupings; Flats international mail, defined by international groupings; and/or If and when required, flats seasonal mail.

In accordance with further aspects of the invention, the pre-sequencing/sorting operation 165 follows the presorting operation 162 . The pre-sequencing/sorting operation 165 is a continuous operation that ends shortly after induction is closed and includes a pre-sequencing operation for local (or destinating) letters and flats mail and a sorting operation for non-local (or outgoing) flats mail. The pre-sequencing operation is performed on shuttles containing letters and flats destinating mail. More specifically, frames are unloaded from shuttles, sorted into groups based on assigned storage unit, and reloaded into a new set of shuttles, as described further herein below. Moreover, the shuttles are sent to a frame transport operation.

On the other hand, a sorting operation is performed on shuttles containing outgoing flats mail. More specifically, frames are unloaded from shuttles, sorted into the required separations per the sort plan, and reloaded into a new set of shuttles. These shuttles are sent directly to the container loading operation 175 for immediate dispatch.

In accordance with further aspects of the invention, the initial sequencing operation 167 follows the pre-sequencing/sorting operation 165 . The initial sequencing operation 167 is performed on groups of mail frames contained in shuttles within a specific storage unit. In embodiments, as described further herein below, the initial sequencing operation 167 creates a “chain” of e.g., 10 sequenced shuttles based on a sequencing plan, which is received from the system management function. Each chain of shuttles is sent on to the post-sequence collection operation 170 . In embodiments, the initial sequencing operation 167 is a continuous operation that completes before the start of dispatch.

The post-sequence collection operation 170 is performed on chains of shuttles within each storage unit. The post-sequence collection operation 170 sequences all mail contained in, e.g., 10 chains to create a “snake” of, e.g., 100 shuttles. In embodiments, the post-sequence collection operation 170 is an ongoing operation that completes before the start of dispatch. Each “snake” is sent to its assigned storage unit and stored until the final sequencing operation 172 begins.

The final sequencing operation 172 is the last sequencing operation, which occurs at the beginning of dispatch. In embodiments, the final sequencing operation 172 receives a trigger from the system management function to begin the dispatch process. In accordance with aspects of the invention, the final sequencing operation 172 sequences all mail contained in the, e.g., 10 snakes located in each storage unit to create a single, sequenced stream of mail. The sequenced stream is sent directly to the container loading operation 175 . The container loading operation 175 builds a container load manifest that lists the frame IDs to be unloaded into every delivery container.

FIG. 1E shows an exemplary mail flow 177 for sorting and/or sequencing in accordance with aspects of the invention. In embodiments, the system of the present invention views mail induction as a random process. That is, the mail may be inducted into the sorting and/or sequencing system of the present invention in a random order. The inducted mail stream may include destinating mail for letters and flats, outgoing mail for flats, managed mail, amongst other mail piece types.

In accordance with aspects of the invention, letters and flats destinating mail is separated from outgoing flats mail at a separation operation 180 . As shown in FIG. 1E , managed mail for letter mail pieces destined to downstream P&DCs is held out to multiple separations. Additionally, redirected letters mail is held out at induction for subsequent processing on a combined input/output subsystem (CIOSS). Local (or destinating) mail enters the presorting operation 162 , where it is separated (e.g., sorted) into equitable (substantially equal) segments of mail and loaded into shuttles. The pre-sequence/sorting operation 165 occurs next, where the mail contained in the shuttles for each system segment is further sorted to the storage unit. It should be understood that no sequencing occurs during the presorting operation 162 or the pre-sequencing/sorting operation 165 .

The initial sequencing operation 167 creates groups of sequenced shuttles called “chains”. In embodiments, each chain contains approximately 10 shuttles or 1,000 mail pieces. The post-sequence collection operation 170 creates a larger group of sequenced shuttles called a “snake”, containing, in embodiments, approximately 10 chains or 10,000 mail pieces. In embodiments, the final sequencing operation 172 occurs at about the time of dispatch when all snakes are combined into a single, sequenced stream of, e.g., 100,000 mail pieces. As explained herein further below, this process occurs within every storage unit in the system, with one stream created per storage unit. In accordance with aspects of the invention, all mail pieces of the sequenced stream are sequenced in delivery point sequence (DPS) order per the sequencing plan (or other sort depth).

As additionally shown in FIG. 1E , outgoing flats mail follows a different flow. That is, the presorting operation 162 loads outgoing flats mail onto shuttles, which are destined to a specific system segment. Additionally, a sort operation 182 creates sort separations as defined in the sort plan. In embodiments, this sort plan defines the separations required for managed mail to downstream P&DCs, ADCs, APO/FPO destinations, international mail, and where and when required, seasonal mail, amongst other separations.

Equipment Interface System

FIG. 1F shows an exemplary illustration of existing equipment 184 interfaced with the sorting and/or sequencing system 127 of the present invention in accordance with aspects of the invention. As should be understood, current mail sorting facilities may have existing equipment 184 , e.g., bar code sorters, facing canceling machines, flat sorting machines, and parcel sorting machines that essentially perform the same input function as the input portion of the facility wide sorting and/or sequencing system 127 , e.g., singulating mail pieces, scanning the mail piece address and/or bar codes, and transporting the mail pieces individually into their individual sorting subsystems. Thus, the invention contemplates that, in order to save money necessary to duplicate this existing capability, in embodiments, the inputs section of existing equipment 184 may be used as the input to the facility-wide mail sorting and/or sequencing system 127 . That is, in embodiments, for example, existing mail processing equipment (MPE) and/or mail handling equipment (MHE) may be “retrofitted” in order to interface with the facility-wide mail piece and/or sequencing system 127 of the present invention. Moreover, the remaining elements of the existing equipment 184 (for example, other elements besides the feeder input section of the existing equipment 184 , e.g., a multiplexer section and/or an output section) may not be used when a feeder input section of the existing equipment 184 is interfaced with the sorting and/or sequencing system 127 .

More specifically, the input to existing equipment 184 (e.g., a flat sorting machine, bar code sorter, facing canceling machine, or parcel sorter) may include a feeder having, e.g., a friction or vacuum feed unit, a scanning device capable of scanning the mail piece identifier (typically a camera or bar code scanner), and a transport consisting of, e.g., pinch belts, that moves the mail into sections of the machine to process the mail. According to aspects of the present invention, if the equipment is separate from the sorting and/or sequencing system 127 of the present invention, e.g., if the equipment is existing equipment 184 (for example, MPE and/or MHE), an existing equipment interface would be necessary to interface the existing equipment 184 with the sorting and/or sequencing system 127 .

FIG. 1G shows an existing equipment interface 186 in accordance with aspects of the invention. In embodiments, the existing equipment interface 186 may include a physical interface 188 , a mail piece synchronization data stream interface 190 , a mail piece attribute data stream interface 192 , a control interface 194 , an emergency stop signal interface 196 and interface logic 198 , amongst other elements.

The physical interface 186 physically receives the mail pieces from the output of the existing equipment 184 feeder. As shown in FIG. 1G , in embodiments, the physical interface 186 may include a section of pinch belt 189 mounted to receive mail pieces from the existing feeder 184 and a sensor or detector 191 to indicate when a mail piece is present.

The mail piece synchronization data stream interface 190 is a data stream interface that connects to the existing equipment 127 and is used to synchronize or otherwise relate the mail piece attribute data with the position of the physical mail piece being delivered from the physical interface 188 . In embodiments, the mail piece synchronization data stream interface 190 may be incorporated into the mail piece attribute data stream interface 192 , described further below. In embodiments, the mail piece synchronization data stream interface 190 data stream may comprise, for example, an ordered list of mail pieces (so mail piece identity is assumed by relative position), a indication of arrival position on the transport (for instance a slot number or conveyor position number of a mail piece), a time stamp that corresponds to the mail piece arrival time, or a message that is delivered that is synchronized to corresponding to the time of delivery of the mail piece itself, amongst other data.

The mail piece attribute data stream interface 192 connects to the existing equipment 184 and is used to transmit data consisting of the mail piece identity and any other attributes (such as, for example, mail piece thickness or image data).

The control interface 194 is operable to provide signals from the facility-wide mail sorting and/or sequencing system 127 to the feeder of the existing equipment 184 . For example, the facility-wide mail sorting and/or sequencing system 127 may provide a control signal to stop the feeder of the existing equipment 184 from feeding mail pieces to the facility-wide mail sorting and/or sequencing system 127 . That is, the control signal transmitted via the control interface 194 may be used, for example, to stop the feeding of mail pieces in case of a jam or another situation that prevents the sequencing of letters. In embodiments, additional control signals may include the following signals: start feeder; pause feeder; message acknowledgement; heartbeat and communication interface monitoring; and/or a command to put feeder into a particular state or diagnostic mode, amongst other signals.

An emergency stop signal interface 196 is operable to route emergency stop signals that remove power from both the feeder of the existing equipment 184 and existing equipment interface 186 . In embodiments, the emergency stop signal interface 196 may be electrical and/or mechanical. According to aspects of the invention, the emergency stop signal interface 196 permits one emergency stop switch to stop both the input feeder of the existing equipment 184 and the existing equipment interface 186 .

Additionally, in embodiments, the existing equipment interface 186 may include interface logic module 198 to simulate the signals and/or commands to/from the now unused sorting section of the existing equipment 184 (e.g., the multiplexer and/or output sections). Since each type and revision of existing equipment 184 may have different data and control signals, in embodiments, the interface logic module 198 may be modular to support interface to multiple feeders of existing equipment 184 (e.g., each existing equipment feeder would have its own interface module). According to aspects of the invention, the interface logic module 198 allows the input section of the feeder to be disconnected from its output sections and reconnected to the facility wide sequencing interface without requiring changes to the interface logic module 198 .

FIG. 1H shows an exemplary flow 100 ′ for processing mail pieces using the existing equipment interface 186 in accordance with aspects of the invention. The steps of FIG. 1H may be implemented in the environment of FIG. 1A , for example, as with all flows described herein. The flow diagrams described herein may equally represent high-level block diagrams of the invention. It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

As shown in FIG. 1H , at step 102 ′, mail piece attribute data is received by the facility-wide mail sorting and/or sequencing system via the mail piece attribute data stream interface. At step 106 ′, the mail piece attribute data is buffered (if necessary) until the mail piece synchronization data is received. Additionally, at step 104 ′, mail piece synchronization data is received by the facility-wide mail sorting and/or sequencing system via the mail piece synchronization data stream interface. At step 108 ′, the mail piece synchronization data is buffered (if necessary) until the mail piece attribute data is received.

At step 110 ′, the facility-wide mail sorting and/or sequencing system uses the mail piece synchronization data to associate the mail piece attribute data with the mail piece. At step 112 ′, the associated mail piece attribute data is stored in a storage system 117 ′, e.g., a database. It should be understood that, in embodiments, the storage system 117 ′ may be the storage system 117 of FIG. 1A . At step 132 ′, a determination is made as to whether there is an additional mail piece for a particular sort and/or sequence plan. If, at step 132 ′, it is determined that there is an additional mail piece for a particular sort plan, the process proceeds to steps 102 ′ and 104 ′. If, at step 132 ′, it is determined that there is not an additional mail piece for a particular sort and/or sequence plan, at step 134 ′, the attribute and synchronization data collection for the particular sort and/or sequence plan ends.

At step 114 ′, a mail piece is received by the existing physical interface of the facility wide mail sorting and/or sequencing system and detected by the mail piece detector of the facility wide mail sorting and/or sequencing system. At step 116 ′, the mail piece attribute data may be looked up and retrieved from the storage system 117 ′. At step 118 ′, a determination is made as to whether the mail piece attribute data exists yet in the storage system 117 ′. That is, there may be a delay between receiving the mail piece and the mail piece attribute information being available in the storage system 117 ′. If, at step 118 ′, it is determined that the mail piece attribute data exists in the storage system 117 ′, the process proceeds to step 120 ′.

At step 120 ′, the facility-wide mail sorting and/or sequencing system updates the record in the storage system 117 ′ to indicate that the mail piece was received by the facility-wide mail sorting and/or sequencing system. At step 122 ′, the mail piece is sorted and/or sequenced by the mail sorting and/or sequencing system. At step 128 ′, a determination is made as to whether there is an additional mail piece for a particular sort plan. If, at step 128 ′, it is determined that there is an additional mail piece for a particular sort plan, the process proceeds to step 114 ′. If, at step 128 ′, it is determined that there is not an additional mail piece for a particular sort and/or sequence plan, the process proceeds to step 130 ′, where mail piece detection for the particular sort plan is ended.

If, at step 118 ′, it is determined that the mail piece attribute data does not yet exist in the storage system 117 ′, at step 124 ′, a determination is made as to whether a predetermined time period has expired. It should be understood that, in embodiments, the predetermined time period is user-configurable. If, at step 124 ′, it is determined that the predetermined time period has not expired, the process continues at step 116 ′. If, at step 124 ′, it is determined that the predetermined time period has expired, the process continues at step 126 ′. At step 126 ′, the mail sorting and/or sequencing system triggers an error signal. That is, as described above, some time may be required for the system to process the mail piece and determine and associate mail piece attribute data to a particular mail piece. However, if this information has not been received in the storage system after expiration of the predetermined time period, there may be some error with respect to that mail piece. Thus, in accordance with aspects of the invention, an alarm signal is issued to indicate that data still does not exist in the storage system for the particular mail piece. Moreover, in embodiments, the particular mail piece may be buffered to wait further processing (e.g., video coding and/or other manual interventions). Subsequent to triggering an alarm signal at step 126 ′, the process proceeds to step 128 ′.

Letter and Flats Facing and Canceling in a Centralized Flat and Letter Facility-Wide Sorting and/or Sequencing System

The present invention provides for the incorporation of automatic culling, facing, and canceling operations into a facility wide flats and letters sorting and/or sequencing system. Although many individual machines currently exist to perform these functions (or a subset of these functions) as a stand alone or independent operation, there is none incorporated into a facility wide flats and letters sortation and/or sequencing system.

The Letter Facer Canceller systems are a series (0 to many) of Letter Facer Canceller systems may be composed of a system that faces the mail, cancels the stamp, an address scanner, a barcode printer, a mechanical interface to convey mail from the output into the facility wide sortation system, and an electrical interface to communicate the associated address information to other components of the facility wide system in accordance with the invention. The Letter Facer Canceller may deliver some mail in a conventional manner (to a single output bin or bins) and some mail to the facility wide mail sorting and/or sequencing system. The Letter Facer Canceller may also communicate other information associated with a mail piece including mail image(s), indicia image(s) or characteristics, dimensions, barcodes, weights, sorter identification, and sortation information in accordance with aspects of the invention to other subsystems of the facility wide mail sorting and/or sequencing system.

Exemplary machines for performing the automatic culling, facing and canceling functions are disclosed in U.S. Patent Publication 2004/0073532, entitled, “Mail Processing Apparatus”, by Shimizu, and assigned to NEC Corporation, and U.S. Pat. No. 7,235,791, entitled “Image Inputting Device”, by Watanabe et al., and also assigned to NEC Corporation. These references are incorporated by reference in their entireties herein. While the current machines may be capable of performing their automatic culling, facing and canceling functions, the current machines perform these functions independently of the other activities occurring in the facility. Accordingly, if there is a malfunction in the current machines or if there is alternatively a malfunction in the other systems within the facility, there is a possibility that the automatic culling, facing and canceling functions could adversely affect the entire operation of the facility by processing too few flats and letters (malfunction in the automatic culling, facing and canceling machinery), or by processing too many flats and letters (malfunction in the other facility systems) resulting in an inconvenient accumulation of canceled products that require storage. For example, if there is a jam in the automatic culling, facing and canceling machinery, the jam could substantially disrupt the throughput of the entire facility.

Referring now to FIG. 2 , a block diagram illustrates the relationship between an automatic culling, facing and canceling (“ACFC”) system 201 , an induction system 202 , and a sequencing system 203 . (The ACFC is also known as an automatic facer canceler system (AFCS).) The ACFC system 201 is at the front end of facility operations and is configured to include:

A unit for culling products that are unsuitable for sequencing; A unit for facing the products, which have not been culled, by determining the existence and location of a valid indicia and by orienting the products; and A unit for canceling the faced products having a valid indicia.

There is an interface between the ACFC system 201 and the sequencing system 203 , and it is implemented as described above in the overview. In embodiments, two or more ACFC systems can be implemented by the present invention. The second or more of the ACFC systems can be redundant back up systems for performing the culling, facing and canceling functions when a monitoring unit indicates that the units are not functioning normally.

Once the incoming mail pieces or products have been culled, faced and canceled by the ACFC system 201 , the mail pieces are sent to the induction system 202 , for inserting into frames as described in another section of the instant application. The canceled mail pieces that are successfully inducted are input to the sequencing system 203 . The sequencing system 203 monitors the throughput of the ACFC system 201 with a monitoring unit 204 . It should be understood by those of skill in the art that the monitoring unit 204 may be a standalone system or incorporated into the sequencing system or any of its subsystems such as, for example, frame inserters, frame extractors, buffers, etc. If there are any malfunctions in the ACFC system 201 , the monitoring unit generates a warning signal and the sequencing system 203 takes appropriate remedial measures. For example, the sequencing system 203 is capable of taking remedial measures such as activating backup ACFC systems 201 or slowing down other facility operations.

Transportable Storage Facilities for Expansion of Facilities without the Need for Additional Building and Easing Transitioning Into a Working Processing & Distribution Center

The present invention is directed to a system which provides transportable storage facilities that allow expansion of facilities into external areas, such as parking lots. The present invention also provides the ability to expand facilities without the need for building additional structures, as well as easing the transition to the sorting and/or sequencing system into a working processing and distribution center.

A facility-wide letters and flats sorting and/or sequencing machine requires mail to be sequenced and stored prior to dispatch. This requires storage space for the mail for an entire day. In a modern Processing and Distribution Center (P & DC), this could mean storage in excess of five million mail pieces. To generate the maximum return on investment, the facility-wide sorting and/or sequencing machine of the present invention is preferably space neutral. In other words, the facility-wide machine as contemplated by the present invention preferably does not take up more space than the current manual and semiautomatic processes current in use by the postal facility or other sorting operations. While it is feasible that a single machine could be designed space neutral, the challenge comes when the new facility-wide machine is delivered, and the existing facility must be converted to the new facility-wide machine.

During the time of the transition, existing facilities should continue to process the mail. This means that there is no tolerance for the facility to be completely emptied of its existing machines and then to have the new facility-wide machine installed on the premises. To accomplish this objective, the present invention provides a mechanism of delivering the mail and still allowing new capability to be added to the processing system. This can be accomplished by providing a storage facility or sorting capability external to the existing facility. Since the storage capability in the facility-wide sequencing is the most floor space consuming operation, it is the most cost effective subsystem to locate external to the building.

In embodiments, the additional capability required during converting or “transitioning” to the facility wide sorting and/or sequencing system of the present invention is added through the use of portable storage and main trunk transport units positioned outside the P&DC structure. These portable storage and main trunk transport units can be provided in the P&DC parking lot and connected together to the existing facility, as disused herein. This gives the capability to convert at lowest cost plus giving the capability to add future additional surge capability to any facility as necessary.

Further, in addition to the actual transition time period and period of surges, this capability to sort and store external to the facility such as, for example, within semi-trailers, or packaging this capability into a shipping container, could be used to reduce or eliminate sorting/sequencing/storage within a P&DC or could easily be located at a delivery unit, such as a post office, or even be used to deliver the mail to a facility. For example, the sorting and storage could occur while in the portable storage and main trunk transport units, e.g., shipping container. This can occur while the shipping container is stationary or while moving or traveling, i.e., “en route”. Shipping containers naturally may be used as a stand alone unit, typically called temporary trailers, or they can be transported by truck, as in a semi-trailer, or even on a train. This allows much functionality as to where mail sorting and storage of mail pieces occur. In embodiments, each portable storage and main trunk transport unit would be totally automatic and would be unmanned. In addition, they would be built to withstand vibration and temperature extremes, so they could perform sorting operations while moving.

In embodiments, the portable storage and main trunk transport units includes several aisles and levels to move mail pieces in frames or clamps. The frames can be transported to different levels and different storage units using lead screws and right angle diverts. In embodiments, each portable storage and main trunk transport unit includes the following features, as discussed throughout the present disclosure.

The system automatically sequences mail pieces (defined as USPS letter mail, flats mail, and/or parcels). The system is located and/or attached and/or is contained within transportation vehicles. The system has a sequencing subsystem that sorts the mail pieces to a predefined sequence. The system has an input port for accepting mail pieces and/or frames. This input port, in embodiments, may be designed to accept shuttles. The system has an output port for retrieving mail pieces (or frames) in a predefined sequence. This port may be the same as the above noted input port. This outport, in embodiments, may be designed to accept shuttles. The system has a port for semi-automatically transferring mail in a predefined sequence from one transportation vehicle to another. This port may be the same as the ports discussed above. The system has storage to automatically store mail pieces before, during and after the sequencing operation. The system has a conveyance system for internally transferring mail pieces from the ports to the storage and the sequencing subsystems or other subsystems. The system has a conveyance system for internally transferring mail pieces from the storage and the sequencing subsystem (or other subsystems) to the output ports.

FIG. 3A shows a portable storage and main trunk transport unit, e.g., shipping container storage unit, in accordance with an aspect of the invention. In embodiments, the shipping container storage unit 300 is positioned outside the P&DC structure, such as in the parking lot, and is linked to the P&DC structure via conveying systems through an input/output port 320 . In embodiments, the system may include a plurality of shipping container storage units 300 , which are linked to each other and linked to the P&DC structure.

The shipping container storage units 300 are all designed to be able to withstand the elements of the outside environment. The elements which prevent vibration may include dampers shown at reference numeral 302 and/or rugged construction that can withstand the vibration during moving, and to sort while transporting. The system may also include encapsulated circuitry to protect the controls from the moisture, vibration, and temperature extremes. This encapsulated circuitry may be embodied in the computing infrastructure of FIG. 1 , and may include the encapsulation as discussed in more detail with reference to the S.M.A.R.T. card of the instant application. In embodiments, the computing infrastructure of FIG. 1A may be remote from the shipping container storage units 300 and communication may be provided over a wireless network such as, for example, WiFi, etc.

The shipping container storage units 300 may include semi-trailers that are configured to be connected to a tractor, a truck, or a train. Accordingly, storing and sorting may occur within the shipping container storage unit 300 while the shipping container storage unit 300 is stationary or while it is moving. Each shipping container storage unit 300 is configured to be completely automatic, e.g., to be operated remotely, is constructed to withstand vibration and withstand temperature extremes (e.g., provided with insulation).

Still referring to FIG. 3A , the shipping container storage unit 300 includes a plurality of parallel storage aisles 305 for sorting and/or sequencing operations as should understood in view of other sections of the instant invention. In embodiments, the mail pieces are conveyed to each of the storage aisles 305 by a conveyor aisle 310 . The conveyor aisle 310 includes a conveyance system, such as lead screws SL and right angle diverts RAD to move the mail pieces between the conveyor aisle 310 and bin locations in each storage aisle 305 . The conveyor aisle 310 can also include compression and/or decompression zones as discussed in the instant application. The storage aisles can be configured to hold the frames in a certain order for sequencing thereof as discussed in the instant invention.

As shown in FIG. 3A , the shipping container storage unit 300 includes one or more input/output port 320 . The input/output port 320 provides access from the exterior to the interior of the shipping container storage unit 300 . Accordingly, the input/output port 320 provides the link or connection between the shipping container storage unit 300 and the P&DC, or the link or connection to another shipping container storage unit 300 . The link or connection may include a conveying device, such as a conveyor belt, lead screws, conveyor belts with cogs, segmented screws, a shuttle docking station or conventional transports. Alternatively, the mail pieces may be moved between the P&DC and the shipping container storage unit 300 manually or via trucks. In such a case, the P&DC and the shipping container storage unit 300 are linked by the manual movement of the mail pieces or by the trucks.

The input/output port 320 is connected to the inside induction system and more specifically to the conveying aisle 310 and/or an elevator 315 . This allows the mail pieces to enter and exit from the shipping container storage unit 300 . In embodiments, the input/output port 320 may be connected between two or more of the shipping container storage units. Accordingly, mail pieces can be manipulated inside the P&DC or another shipping container storage unit and then transported outside to another of the shipping container storage unit and manipulated therein. Also, the mail pieces can be transported back into the P&DC or another shipping container storage unit for remaining operations.

Additionally, as shown in FIG. 3B , the shipping container storage unit 300 includes a plurality of vertically stacked storage aisles 305 . In one contemplated embodiment, an eight foot tall shipping container storage unit 300 will accommodate four layers of storage aisles 305 ; although other amounts of layers are contemplated by the present invention. Further, each layer includes a conveyor aisle 310 that extends in a direction transverse to the storage aisles 305 and along the length of the shipping container storage unit 300 . Mail pieces can be conveyed along the conveyor aisles 310 and stored in the storage aisles 305 on any of the levels. FIG. 3B also shows the elevator 315 that raises and lowers the mail pieces between the layers of storage aisles 305 and conveyor aisles 310 .

It should be recognized by those of skill in the art that the shipping container storage unit 300 should not be limiting to a system for storing and sequencing of mail pieces, but may be implemented for any subsystem of the present invention. For example, it is contemplated that the shipping container storage unit 300 can be used for the induction and/or extraction of mail pieces into frames or any other subsystem as the P&DC facility is being dismantled and reassembled with the sorting and/or sequencing machine of the present invention. Illustratively, in the case that the sequencing and storage system is already installed in the facility, it is possible to have the induction of the mail pieces into frames provided in the shipping container storage unit 300 . Once the frames are filled, they may be sent to the facility for sorting and/or sequencing operations. After the sequencing operations, the frames may be transported to the same or another of the shipping container storage unit 300 for extraction of the mail pieces. Any of the other processes described in the instant application are also contemplated for use in the shipping container storage unit 300 .

Accordingly, the present invention provides a system in which the mail is processed while installing the new system. The system includes portable units including a trailer or a shell located in the parking lot during installation, so as not to be disruptive to the working system. Accordingly, the present invention provides both storage and a working subsystem of the new system, with no significant periods where the mail center is not processing mail. As such, in order to ensure that there is no significant interruption in the mail processing three options can be utilized for transitioning into the system of the present invention: gradual changeover, annex processing, and portable processing as recapped below.

Gradual Changeover

This strategy involves replacing input machines with the capabilities of the system of the present invention and phasing in delivery routes to the present invention until the entire P&DC has implemented the system of the present invention. Although the present system may rely on current sortation machines and storage areas to be replaced with buffers, transport conveyors, and storage units, the system of the present invention is designed to be space neutral. In this way, a partial system can occupy more space than the machine it replaces. Also to phase in output to specific delivery routes to be incorporated into a growing system, additional sortation may be required.

Annex Processing

Annex processing is used in addition to the gradual changeover. This strategy uses an Annex area that is temporarily built (or leased) to maintain a base of system capability to allow enough capability to gradually replace current P&DC processing machines. The Annex may either be a temporary of permanent facility for processing the mail pieces during a change over.

Portable Processing

This concept is again in addition to gradual changeover. In this case, additional capability is added through the use of portable storage and transport units positioned outside the P&DC structure (e.g., P&DC parking lot) and connected together. This gives the capability to transition at lowest cost plus giving the capability to add future additional surge capability to any plant as necessary.

Remote Access and Control of a Facility Wide Mail Piece Sorting and/or Sequencing System

Conventionally, the network architecture in a USPS processing and distribution center is segmented into two networks: (1) the Facility network (which is tied to the Postal wide area network (WAN)) to which everyone in the postal service accesses; and (2) the Mail Processing Equipment (MPE) local area network (MPE LAN), which maintenance employees may access, e.g., maintain a MPE. This segmentation is done to accomplish two goals: (1) to prevent normal users on the Postal WAN from attaching to and controlling a MPE and (2) to prevent someone maintaining MPE from accessing the Postal WAN. In this way, the USPS carefully controls who has access to the MPE LAN, for example, typically only providing modem access for remote access to a MPE for troubleshooting purposes.

With a facility-wide mail sorting and/or sequencing system in accordance with the present invention, there are many large subsystems that should communicate simultaneously on a network. For example, a single sequencer may need to process five million mail pieces per day, through twenty feeding stations, and many different sequencing, storage, insertion, extraction and transportation systems. Additionally, each feeder provides high resolution images of each mail piece to subsystem in order to perform address recognition tasks. Also, the transportation, storage, sequencing, insertion and extraction systems use frame identifiers, e.g., bar code, in order to correlate to the mail piece therein and the sequencing plan. Each of these subsystem add to the network congestion. Thus, all motion, data collection, etc. should be coordinated by a system management function; however, such coordination communication also creates much network traffic.

According to an aspect of the invention, to facilitate communication, a discrete communication network or local LAN may be established between some of the individual subsystems for exchanging, for example, high-use data between the individual subsystems. Moreover, a plurality of these discrete networks or local LANs may be established for different groups of the individual subsystems. That is, the system may provide a number of discrete networks between a plurality of subsystems that, for example, share a large amount of data, to prevent too much communication data for a single network, which connects all of the subsystems. This allows for islands of isolation to be created within the facility-wide system to minimize dependence upon, for example, other subsystems or components, and to reduce network congestion on the network that connects all of the subsystems. That is, as discussed further below, in addition to the discrete networks or local LANs, all of the subsystems are connected to one another and the system management subsystem via another network or system management LAN. However, by providing the discrete networks, network traffic on the system management LAN connecting all of the subsystems and the system management subsystem can be reduced.

In embodiments, the above-described discrete networks or local LANs, also allow a remote user access to the system (or many different subsystems), e.g., for troubleshooting or maintenance. That is, according to a further aspect of the invention, in addition to above-described discrete networks or local LANs, a system management network is provided to facilitate communication between all the subsystems and also to allow a remote user to access the system, including all the subsystems, for, e.g., troubleshooting.

FIG. 4 shows a system management subsystem 405 . The system management subsystem 405 is a centralized server on a centralized network which communicates with all subsystems 415 in a network via a system management LAN 420 (indicated by the solid line) for the purpose of controlling and remote monitoring of all the subsystems. The system management subsystem 405 may be implemented on the computing infrastructure shown in FIG. 1 , for example. The LAN may be a wired or wireless communication link, known to those of skill in the art. The overall system management and control are sent on the separate system management LAN 420 , which is also used to allow an authorized and authenticated user to access any other computer (or subsystem) on the network. For example, once a remote user attaches to the system management subsystem 405 via the modem access 410 , the user can use any of the utilities, e.g., remote desktop, to access any other subsystem on the network.

Moreover, according to an aspect of the invention, high-use data is routed on the local LANs 425 (indicated by the dashed lines) that are specifically set up between high-use subsystems (for example, those subsystems for address recognition). Thus, as shown in FIG. 4 , for example, a local LAN 425 is provided between subsystem 1 and subsystem 2 and another local LAN 425 is provided between subsystem 3 and subsystem 4 . The local LANs provide communication paths between the high-use subsystems, thereby alleviating network congestion on other communication paths, e.g., the system management LAN 420 .

Thus, for example, using the above-described system management LAN and local LAN arrangement, one subsystem, e.g., an optical character recognition (OCR) scanner, may be on a separate local LAN 425 with a series of recognition subsystems. This allows the OCR scanner and other recognition subsystems to communicate between each other on the local LAN 425 . Additionally, the subsystem, e.g., the OCR scanner, may provide status information on the mail, e.g., mail piece dimensions, to the central system, e.g., the system management subsystem 405 , to determine, e.g., an appropriate frame size for the mail piece via the system management LAN 420 .

Moreover, as shown in FIG. 4 , the control and communication of the system and the subsystems of the present invention may be arranged in a hierarchical fashion, wherein a top tier level (e.g., the system management subsystem 410 ) forwards commands to lower tiers (e.g., the subsystems 415 ). Additionally, the routing and control is provided within the system itself.

Centralized Address Recognition System and Method for a Facility-Wide Sorting and/or Sequencing Machine

The invention relates to a system and method for providing centralized address recognition in a facility-wide mail sorting and/or sequencing system. The invention also provides a system and method for associating video coding returns with mail pieces and frame and/or clamp identification in a facility-wide mail sorting and/or sequencing system. In embodiments, the centralized address recognition system utilizes a centralized address recognition sub-system which communicates and/or interfaces with each of a facing canceling sub-system, a mail piece feeding sub-system, a flats feeding sub-system, and a parcel feeding sub-system.

The ability to recognize addresses is important to all mail sorting and sequencing operations. In typical mail processing systems, video coding is performed such that addresses are read by photographing a face of the mail piece (i.e., the face of the envelop) at one or more machines and locations. For example, addresses can be read at an:

Automatic Facer Canceller Machine, a barcode reader with an input to perform address recognition, i.e., DIOSS (Delivery Barcode Sorter Input/Output Subsystem), DBCS/ISS (Delivery Bar-Code Sorter/Information System Services), (if it is not accomplished at presort and translated into a barcode), or a dedicated subsystem such as, for example, a MLOCR (Multi Line Optical Character Reader).

Once the photograph is taken, it is forwarded to an “on-board” mail piece recognition system to determine the address or the ZIP code.

An onboard “recognition” engine will resolve a high percentage of addresses (e.g., around 90%); however, about 10% of addresses which are not resolved need to be forwarded to a bank of video terminals that allow operators to resolve the addresses. This is done by a laborious process of keying addresses after viewing the photographs. Since operators along with the required queuing of information and awaiting results takes a considerable amount of time (typically more than the buffer of any current sorting machine), the mail pieces that require address recognition are typically identified with a bar code. In subsequent sorting operations (e.g., performed after the video coding takes place), the bar code can be looked up in a table and the results then placed on the mail pieces.

In a facility wide sequencing system, mail pieces that are not recognized with “on-board” recognition can also be forwarded to manual video coding stations. But in a facility wide system, sorting occurs typically with very little delay and therefore the mail pieces may need to be assigned to a buffer. There are costs associated with having mail pieces stacked up in a buffer, however. As a result, it can be cost effective to put in another layer of machine recognition at the full system level in an attempt to recognize the addresses. This can be accomplished by use of known algorithms for system level recognition.

Presently, some address recognition algorithms are not present on individual machines or sub systems due to their proprietary nature, especially for the recognition engines in the input feeder subsystems (which are very expensive to update). Furthermore, keeping all input feeders and other sub systems (each with different architectures and interfaces) up to date with the same recognition algorithms and ensuring the availability of the input processing power necessary to simultaneously perform multiple algorithms on an individual feeder and other sub systems can be costly. As a result, it is advantageous to have a centralized recognition capability as a subsystem to the facility wide sorting system, itself.

In implementations, using current sorting approaches, identification codes are placed on individual mail pieces. Subsequent sorting operations, which usually take place on different sorting machines and/or subassemblies, read the barcode and look up the address assignment by the barcode on the mail piece, if necessary. However, with a facility wide sortation system, the mail piece is not always available to scan and, therefore, a barcode will identify the individual frames and/or clamps that contain the mail piece. The mail piece can then be sorted and sequenced by associating the bar code with the mail piece address. When video encoding is required, the mail piece information can be updated by updating the information about the mail piece. Of course, the mail piece information is associated with the frames and/or clamps identifier to be effective. Thus, the ability to associate mail piece information with the frames and/or clamps identification (ID) and to use a mail piece recognized result is an advantage of the invention.

FIG. 5 shows a system and method for providing centralized address recognition in a facility wide sorting and/or sequencing system with multiple layers of “onboard recognition” in accordance with aspects of the invention. More specifically, FIG. 5 shows a system 500 that includes several subsystems 501 , 502 , 503 , 504 , each with the capability to read address information and provide such information to a respective address recognition system. In embodiments, the subsystems 501 , 502 , 503 , 504 provide the address information to a centralized system address recognition sub-system 505 in order to resolve the address information. The centralized system address recognition sub-system 505 can be implemented in the computing infrastructure of FIG. 1A and is capable of reconciling address information with the frame and/or clamp identification and associated mail piece in order to sort and/or sequence the mail pieces. Advantageously, each subsystem 501 , 502 , 503 , 504 can take a picture of the address at different locations and at different sub system levels within the sorting and/or sequencing system, and provide this information to an onboard recognition engine. The onboard recognition engine of each subsystem can then be provided to the centralized address recognition subsystem 505 . As such, there are several opportunities to photograph and resolve the address information throughout the system thereby potentially eliminating the need for operator assistance and intervention.

In particular, the system 500 includes one or more facing canceling sub-systems 501 . The one or more facing canceling sub-systems 501 each include a camera system and an address recognition engine. The one or more facing canceling sub-systems 501 can be of a conventionally known facing canceling sub-system or specifically configured for use with a facility-wide mail pieces sorting and/or sequencing system disclosed in the instant application.

The system 500 also includes one or more letter feeding sub-systems 502 . The one or more letter feeding sub-systems 502 each include a camera system and an address recognition engine. The one or letter feeding sub-systems 502 can be of a conventionally known mail piece feeding sub-system or specifically configured for use with a facility-wide mail pieces sequencing system disclosed in the instant application.

The system 500 additionally includes one or more flats feeding sub-systems 503 . The one or more flats feeding sub-systems 503 each include a camera system and an address recognition engine. The one or more flats feeding sub-systems 503 can be a conventionally known type or specifically configured for use with a facility-wide mail pieces mail sequencing system disclosed in the instant application.

The system 500 further includes one or more parcel feeding sub-systems 504 . The one or more parcel feeding sub-systems 504 each include a camera system and an address recognition engine. The one or more parcel feeding sub-systems 504 can be a conventionally known type or specifically configured for use with a facility-wide mail pieces sequencing system of the type disclosed in the instant application. Those of skill in the art will appreciate the distinction between letters, flats and parcels and, as such, further explanation is not required herein. The use of mail piece(s), though, should be understood to encompass all types of mail and/or product, regardless of the size and shape of the mail and/or product.

FIG. 5 also shows a centralized system address recognition sub-system 505 . This centralized system address recognition sub-system 505 receives information, i.e., photographs of addresses, from the address recognition engines of the sub-systems 501 , 502 , 503 and 504 via a communications link such as a wireless or wired link known to those of skill in the art. The centralized system address recognition sub-system 505 can utilize one or more known algorithms to resolve the addresses. If the addresses are resolved, the mail pieces can be sent to a buffer system 506 . Non-limiting examples of the buffer system 506 include the system described herein with reference to FIG. 21 . This is facilitated by a communication link between the buffer system 506 and centralized system address recognition sub-system 505 .

If the addresses are not resolved by the centralized system address recognition sub-system 505 , the mail pieces can be sent to one or more banks of centralized video coding 507 . The one or more banks of centralized video coding 507 can be of a conventionally known type or of specifically configured for use with a facility-wide mail pieces sorting and/or sequencing system disclosed in the instant application.

Facility Management and Inter-Facility Letter and Flat Mail Scheduling

The invention is directed generally to mail handling and processing and, more particularly, to a method and system for facility management and inter-facility letter and mail scheduling. In embodiments, a system management server is provided that receives data from a number of sources that are both internal and external to a mail processing and distribution center (P&DC). Based upon the data, the system management server generates assignments for handling all of the mail within the P&DC, in real time. The assignments may be related to, for example, dock receipt of the mail, scheduled movement of mail within the P&DC, storage of mail at locations in the P&DC, processing of the mail in a facility wide sorting and/or sequencing system, and dispatch of the mail from the P&DC. By continuously updating the various handling assignments as new data is received, the system management server provides a dynamic material management system for a P&DC.

In a typical processing and distribution center (P&DC), mail arrives all day long. However, because of the method in which the mail is sorted, most mail processing occurs in the late evening or early morning. This conventional mail processing profile is not caused by the truck arrival schedule, but by the underlying sorting algorithm. This is due to the fact that in conventional P&DC sort methodologies, a local mail piece is sorted approximately three times (e.g., goes through three passes) to sort to the delivery point sequence, DPS (e.g., delivery address). In such multi-pass systems, the entire first pass is completed before the second pass begins. Since the first pass is typically not completed until late evening, most of the processing occurs in the late evening and early morning. This creates the need for many more machines and operators than would be necessary if mail was more evenly processed all day long.

Moreover, in a conventional P&DC, there is a large amount of manual movement of objects throughout the sorting process. For example, as depicted in FIG. 6A , mail objects arrive at a conventional P&DC 605 at a dock receipt 607 (e.g., loading dock). The mail objects may include letters, flats, parcels, etc., and typically arrive in bulk, such as, for example, on pallets, in bundles, etc. From the dock receipt 607 , the mail objects are manually moved via material movement 608 to a staging area 609 . The material movement 608 may be a forklift that moves a pallet of mail, and the staging area 609 typically comprises an assigned space where the pallet is temporarily stored before it is processed.

Still referring to the conventional P&DC 605 in FIG. 6A , mail objects are moved from the staging area 609 to one of many different types of processing machines for sorting the mail. For example, parcels may be delivered to an Automated Package Processing System (APPS) 611 , flats to a Flats Sorting Sequencer (FSS) 613 , as are known such that further explanation is not believed necessary. Other mail may be delivered to a preparation area 617 where, for example, strapping and shrink wrap are removed. From the preparation area, bundles of mail are manually moved (e.g., via bundle movement 618 ) to other mail handling equipment (MHE), mail processing equipment (MPE), or to the FSS 613 . After sorting of the different types of mail on the different machines, different types of that could not be sorted are hand-cased and output from the P&DC 605 at dock dispatch 620 . Included in the conventional sorting arrangement shown in FIG. 6A are numerous manual movements of mail (e.g., material movements 608 and bundle movements 618 ).

In contrast to the conventional sorting arrangement shown in FIG. 6A , the facility wide sorting and/or sequencing system of the present invention uses a different sorting algorithm and a different sorting paradigm as described in the instant application. In embodiments, due to the different paradigm the facility-wide sorting and/or sequencing system comprises a comprehensive system that accepts different types of mail (e.g., letters, flats, etc.), sequences the different types of mail together, and outputs a single stream of sequenced mail. In this manner, much of the manual handling of mail (e.g., bundle movement and hand casing described above with respect to FIG. 6A ) is eliminated.

More specifically, in accordance with aspects of the invention, mail arrives at a P&DC all day long and may be temporarily stored or input into a facility-wide sorting and/or sequencing system as it arrives. In embodiments, the facility-wide sorting and/or sequencing system sorts the mail and stores it until it is discharged at dispatch, which allows more judicious use of resources and eliminates the need for many feeders and operators. The facility wide sorting and/or sequencing system has different types of feeders to input the various types of mail (e.g., letters and flats). Additionally, the facility-wide sorting and/or sequencing system includes plural ones of the different types of feeders for capacity and redundancy. In implementations, the facility-wide sorting and/or sequencing system typically operates twenty hours a day and stores all the mail internally until the time of dispatch. In this manner, the facility-wide sorting and/or sequencing system is an automated machine that automatically processes and sequences the mail internally to the machine, whereby the sequencing algorithm is independent of when the mail arrives. This allows mail to be input into the facility-wide sorting and/or sequencing system anytime within the service window, and eliminates the need to complete a first pass before beginning a second pass, as with the conventional multi-pass systems.

As the inventive facility-wide sorting and/or sequencing system is highly automated, scheduling functions within the system allow a supervisor to schedule input of mail into feeders based on the availability of the feeders and personnel to operate the feeders, which allows mail to be more evenly processed all day long. Due to such automation, implementations of the facility-wide sorting and/or sequencing system typically utilize less operators and feeders, resulting in less peak mail processing power than a conventional P&DC. Thus, in the facility-wide sorting and/or sequencing system, there is an increased emphasis on forecasting the arrival of mail at the P&DC, efficiently and precisely handling the mail within the P&DC prior to induction into the feeders, and scheduling the input of mail into the feeders.

Accordingly, in embodiments of the invention, there is provided a material management system that operates to, among other things, obtain data from sources external to the P&DC, obtain data from sources internal to the P&DC, and generate material receipt, storage, movement, and dispatch schedules for material in the P&DC in real time. The material management system may include features of the Dock Management System (DMS) disclosed in U.S. Patent Application Publication Number 2006/0271234, published Nov. 30, 2006, the disclosure of which is hereby incorporated by reference in its entirety.

The material management system is a system and method that integrates various systems to provide an overview of existing containerized mail including but not limited to pallets, trays, tubs, and rolling stock, expected containerized mail, and sortation equipment capacity and predicted throughput in a facility such as a P&DC. The material management system comprises a server that utilizes existing databases to efficiently identify staging area assignments, schedule internal material deliveries, automatically calculate internal plant routing of materials, notify when internal delivery commitments cannot be met, and incorporate internal delivery verification. This information can then be used to perform numerous tasks such as, for example, storing, tracking, and managing pallets on the dock and throughout the sortation process, predicting workload, generating and monitoring sortation schedules. Additionally, the material management system automatically provides staging assignments for incoming pallets, provides staging areas within the existing facility footprint, schedules and tracks pallets from the dock to the point of consumption, assists in scheduling and tracking of sorting operations, alerts personnel when priorities and schedules cannot be met, and generates alternate processing recommendations in the event of exception conditions such as sortation system failures and pallet cancellation.

In further embodiments, the material management system also takes into account data from external sources such as, for example, global positioning system (GPS) and data from other facilities, while applying the methodology to a facility-wide sorting and/or sequencing system. For example, as depicted in FIG. 6B , a P&DC 623 utilizes the facility-wide sorting and/or sequencing system comprises a system management server (SMS) 625 . The system management server 625 may be the same as the system manager described in other parts of the instant application. In embodiments, the system management server 625 may be implemented in the computer infrastructure shown in FIG. 1A . In further embodiments, the system management server 625 comprises appropriate programming to provide some or all of the functions of a DMS server (referred to as element “10” in U.S. Pub. No. 2006/0271234), or may be communicatively connected to a DMS server, to perform the processes described herein. For example, the system management server 625 may be programmed with logic and business rules that provide handling assignments (e.g., receipt, movement, storage, processing, and dispatch) for all of the mail in the P&DC 623 in real time based upon data from sources internal and external to the P&DC 623 .

According to aspects of the invention, the system management server 625 receives or obtains data regarding incoming mail from at least one external data source including, but not limited to: incoming trucks 627 , a surface visibility database 629 , another P&DC 631 , and a presort house, warehouse or other facility 633 . The system management server 625 also receives updates from sources internal to the P&DC 623 , including, but not limited to: available pallet storage space within the facility, anticipated future incoming pallets, characteristics of the pallet, time needed to process the pallet, schedules of other pallets, deadline for processing the pallet, operational status of components of the facility-wide sorting and/or sequencing system machines (e.g., input feeders) needed to process the pallet, sort plan of the facility-wide sorting and/or sequencing system, etc.

Based upon the data from both the internal and the external source(s), the system management server 625 generates assignments and schedules for handling mail within the P&DC 623 . For example, the system management server 625 may generate handling assignments including, but not limited to: where and when to receive mail (e.g., pallets) at dock receipt 635 , where and when to move pallets to the staging area 637 , where and when to move pallets to the preparation area 639 , where and when to move pallets to the facility-wide sorting and/or sequencing system 641 , where and when to dispatch sequenced mail from the facility-wide sorting and/or sequencing system 641 to dock dispatch 642 , and what personnel will be utilized to perform such tasks.

As will be apparent to one of ordinary skill in the art, the system management server 625 dynamically updates the handling assignments for all of the mail within the P&DC 623 based upon updates received from the internal and/or external data sources. For example, the act of assigning a pallet to a particular storage location may affect the management and handling of other pallets of the facility. Put another way, when the system management server 625 assigns a pallet to a location, then that location is no longer available for other pallets. This new data (e.g., one less storage location) may affect the results of subsequent operations of staging assignment, scheduling assignment. As another example, if a pallet is moved from location “A” in the staging area 637 to location “B” in a preparation area 639 , then the system management server 625 can ascertain that there is now an open storage location at area “A” and may determine that an anticipated incoming pallet may be placed in this location upon receipt of that incoming pallet at the dock 635 .

As an example of data received from an external source, a presort house 633 may transmit data to the system management server 625 that a shipment of eight thousand periodicals will be delivered to the P&DC 623 at noon on the next working day. With this data, and based upon already known data of what loading docks will be in use at the expected delivery time, the system management server 625 may generate an assignment to receive the shipment at a particular loading dock, at a particular time, and with particular personnel assigned to the task. Additionally, based upon other data parameters (e.g., due date of the periodicals, availability of storage space within the P&DC 623 , availability of input feeders of the facility wide sorting system, etc.), the system management server 625 may generate a movement schedule for the periodicals throughout the P&DC 623 . This schedule may include, for example, the schedule to place the periodicals in frames by use of frame inserters, etc.

In another example of external data, the system management server 625 may receive data from another P&DC 631 , which is sending mail to the P&DC 623 . Particularly, a centralized processor in a facility wide sorting and/or sequencing system at the other P&DC 631 records information of every mail piece in its facility wide sorting and/or sequencing system. The information may include, for example: address information, size weight, and even position in the system. This information is stored in internal databases, reported to postal mail tracking applications, and is available to other authorized systems and users in accordance with the invention. At the other P&DC 631 , outgoing mail is input into the system and subsequently output to waiting trucks. As soon as the mail is processed, the information may be recorded to databases. The estimated time of arrival from the other P&DC 631 to the receiving P&DC 623 may be calculated from the daily truck arrival schedule and historical transportation data. This information, amongst other information such as, for example, the type of mail, the sort depth of the mail, etc., is then forwarded to the system management server 625 of the receiving P&DC 623 , which may use this information to update its own handling assignments (e.g., receipt, movement, storage, processing, and dispatch) of mail within the P&DC 623 .

In another example, GPS data associated with incoming trucks 627 may be utilized by the system management server 625 . Particularly, when the system management server 625 receives or obtains data from any one of a surface visibility database 629 , another P&DC 631 , and a presort house 633 , the data may include an indication of a shipment of incoming mail on an incoming truck 627 . More specifically, the data may include, but is not limited to: a unique identifier of the incoming truck 627 , pallet characteristics (e.g., type of mail, class of mail, due dates, sort depth of the mail, etc.), and expected delivery date and time. Furthermore, the incoming truck 627 may be equipped with a GPS system that gives a real-time location of the truck. The system management server 625 may receive the GPS data, transmitted from either the truck 627 or the GPS service provider. By monitoring the GPS-based location of the incoming truck 627 in real time, the system management server 625 may periodically refine its estimation of when the incoming truck 627 will arrive at the loading dock. Accordingly, the system management server 625 may use this updated arrival time (e.g., based upon the GPS data) to update its handling assignments (e.g., receipt, movement, storage, processing, and dispatch) for all of the mail in the P&DC 623 in real time.

As another example, based upon real-time updated data (from both internal and external sources), the system management server 625 may verify that a previously assigned receiving dock at dock receipt 635 is available for an incoming truck 627 , or may assign a different receiving dock to the incoming truck 627 . The updated receiving dock assignment may be transmitted to the incoming truck 627 (or the driver told when the incoming truck 627 arrives). Additionally, based upon the totality of the data, the system management server 625 may schedule dock personnel to unload the incoming truck 627 , and notify the scheduled personnel via computer 643 and/or PDA 645 .

Moreover, data from external sources (e.g., GPS data from an incoming truck 627 or an outgoing truck 655 ) may be used by the system management server 625 in scheduling the processing of mail in the facility-wide sorting and/or sequencing system and dispatch of mail from the facility-wide sorting and/or sequencing system. For example, based upon data that loading dock space is not available at dock dispatch 642 , or if outgoing trucks 655 are not available to receive dispatched mail, the system management server 625 may instruct the facility-wide sorting and/or sequencing system 641 to delay dispatching mail from the facility-wide sorting and/or sequencing system until such dock dispatch 642 and outgoing trucks 655 are available. As mail can be temporarily stored in the facility-wide sorting and/or sequencing system, the system management server 625 may be programmed to delay dispatch until just before dock dispatch 642 and outgoing trucks 655 are available.

In another example, the system management server 625 may delay dispatch from the facility-wide sorting and/or sequencing system 641 to await inclusion of mail that is inbound on an incoming truck 627 . In embodiments, the facility-wide sorting and/or sequencing system 641 performs one dispatch per day. Also, as a general rule, first class mail is processed by a P&DC on the day it is received. The system management server 625 may be programmed to delay dispatch by a predefined amount of time if GPS data associated with an inbound truck 627 carrying first class mail indicates that the first class mail will arrive within a predetermined acceptable amount of time. The system management server 625 may also be provided with logic that determines (e.g., based upon GPS data of an inbound truck 627 ), that the first class mail on incoming truck 627 will arrive too late for inclusion in the current sequencing of the facility-wide sorting and/or sequencing system 641 . Accordingly, the system management server 625 would allow the dispatch to occur at the scheduled time, and alert a supervisor that the incoming first class mail needs special handling upon arrival.

In an even further example, the system management server 625 updates handling assignments for mail within the P&DC 623 based upon operation status of the processing machinery. For example, if the system management server 625 ascertains from internal data that a first input feeder of the facility-wide sorting and/or sequencing system 641 is operating at maximum capacity or even behind schedule by a certain amount of time, then the system management server 625 may dictate that no more pallets be moved to that first input feeder until the backlog is cleared, or that pallets be routed to other input feeders that can handle the workload.

Thus, according to aspects of the invention, information from internal and external sources is received by the system management server 625 at the local P&DC 623 and is used to update material handling operations in the P&DC 623 and the planning for processing within the facility wide sequencing machine. In embodiments, the system management server 625 updates the handling assignments (e.g., receipt, movement, storage, processing, and dispatch) for all of the mail in the P&DC 623 in real time when updated data is received. Although particular data may be associated with a subset of mail, the data may have an effect on the handling assignments (e.g., receipt, movement, storage, processing, and dispatch) for potentially all of the mail within the P&DC 623 . In this manner, the system management server 625 provides a comprehensive material management system for facilities that utilize a facility wide sorting and/or sequencing system.

In addition to coordination input (receipt) operations from other P&DCs, dispatch operations can be coordinated with incoming trucks delivering mail to local delivery unit (post offices). For example, if trucks arrive late and the mail is dispatched from the system, the result is a need for a staging area until the truck does arrive and the need to transport the mail from the staging area to the actual dock. This extra effort could be reduced by having truck arrivals automatically estimated by GPS. Therefore the mail could remain in the system until right before the truck arrives. If any manual processing is required due to trucks arriving late, this labor can be automatically scheduled and coordinated through the system. The system also can communicate directly with the delivery unit to help with individual scheduling.

FIG. 6C shows an exemplary interface 660 displaying data from the system management server 625 . The interface 660 may comprise, for example, a graphic user interface displayed on the computer 643 and/or PDA 645 . As discussed above with respect to FIG. 6B , personnel may utilize a computer 643 and/or PDA 645 to view handling assignments generated by the system management server 625 .

In the example shown in FIG. 6C , the interface 660 shows detailed tracking information for a tray in the P&DC 623 . For example, when an operator inputs the tray ID number 662 using a PDA 645 , the PDA 645 transmits the tray ID to the system management server 625 , which accesses stored data associated with the tray ID. The system management server 625 transmits the stored data to the PDA, where the data is displayed via interface 660 .

More specifically, the interface 660 shows details of the particular tray, such as: tray ID number 662 ; date and time the tray was input into the system 664 ; origination of the mail in the tray 666 ; type of mail 668 ; weight of mail in the tray 670 ; type of tray 672 ; quantity of mail pieces in the tray 674 ; current location of tray in the facility 676 ; and history of locations in the facility 678 . The information shown in interface 660 is merely exemplary, and any suitable information may be displayed in accordance with aspects of the invention.

In addition to coordinating facility operations, inter-facility communication can also facilitate mail processing. In conventional system, the first time a mail piece is input into the system a bar code is assigned to the mail piece. It takes far fewer resources to recognize a barcode than to recognize a written address. Therefore, even today, address information (e.g., the ZIP code) is shared between facilities so an address recognized at one facility can be looked up by barcode at another facility. However, a facility wide sorting machine assigns individual mail pieces to individual containers (e.g., folders, frames, etc.). In the individual containers, the mail piece bar code may not be present. Therefore the individual containers have identifiers associated with them. Because of the individual container identifiers, it may not be necessary to track mail pieces by a “sprayed” on barcode on the letter itself. Instead, the mail piece may be tracked through its association with the container, and such information may be shared between respective system management server 625 at respective facilities for planning purposes.

Modular Partitioning and Expansion of a Facility-Wide Sorting and/or Sequencing System and the Use of Redundancy of Parallel Independent Segments, Subsystems, and Components to Improve Reliability of a Facility-Wide Sorting and/or Sequencing Machine

Modular Partitioning and Expansion of a

Facility-Wide Mail Sorting and/or Sequencing System

The present invention relates to a modular partitioning and expansion system. More specifically, the invention relates to a mail processing system that has a modular design. In this regard, the modular design allows the mail processing system to easily conform to the size of a particular mail processing facility. That is, the system of the invention is modular in nature, so that it may be sized appropriately for the unique mail handling capacity requirements, and size limitations of a particular facility. Sizing for a facility starts with a base module, and adds additional expansion modules to meet the capacity requirements and size limitations.

In embodiments, the modular design may include a base module and one or more expansion module(s). The base module, as well as any of the expansion modules, can include subsystems of the sorting and/or sequencing system discussed in the instant application. These subsystems can be, for example, feeders, sorters, sequencers, conveying or transporting mechanisms such as lead screw modules, storage systems, buffers, induction units, frame inserters, frame extractors, etc. The expansion modules can include any combination of these subsystems in order to increase efficiency of the unique facility. For example, the addition of an expansion module serves to increase a quantity of mail that the system can process daily. It can include all capacity-limited subsystems and functions (such as sequencing and storage), but without the need for the management systems, as this is provided with the base module.

In one illustrative example, the expansion module might increase daily mail handling capacity by 500,000 mail pieces. Therefore, the capacity of a system of the present invention with one base module and one expansion module would be 1 million mail pieces. Similarly, the capacity of the system with one base module and three expansion modules would be 2 million mail pieces. Many expansion modules can be added to a base model, depending on the required scaling.

FIGS. 7A-7C illustratively show additional systems of the present invention, which may be included in the base module and/or the expansion module. These figures also representatively shows mail pieces being routed through different systems and subsystems in accordance with aspects of the invention. More specifically, FIG. 7A shows a base module and expansion module in accordance with aspects of the invention. In particular, the base module is shown at reference numeral 700 a and the expansion module is shown at reference numeral 700 n . In one illustrative example, the base module 700 a is capable of handling a daily capacity of, e.g., 500,000 mail pieces, and the expansion module 700 n can handle the same amount, thereby doubling the mail processing capacity of the entire system. Of course, the expansion module 700 n can be designed to have a mail processing capacity similar to that of the base module 700 a or other capacities, depending on the particular application of the system. Thus, it should be appreciated that the base module 700 a and expansion module(s) 700 n can have varying mail processing capacities without departing from the scope of the invention.

The base module 700 a and expansion module(s) 700 n are physically very similar, and designed to be easily integrated together to function as a single system. Therefore the system of the present invention is an easily scalable system. Sizing the system of the present invention to a particular facility requires very little design work. Also, after initial installation, capacity of the system of the present invention could be increased (or decreased) with relative ease (through the addition or removal of expansion modules) by a plug and play system.

The base module 700 a and expansion module 700 n may include any and all of the subsystems of the present invention which are required to process mail. These systems may include, for example, feeders, cancellers, frame inserters and mail extractors, transport mechanism, buffers, accumulators, split mail induction devices, split pathway induction unit, docking stations, storage areas, compression and decompression zones, etc. The feeder may include devices such as scanners, sensors, OCRs, printers, BCRs, photo eyes, cameras, and thickness detection mechanisms to identify, monitor, track, and assist in directing mail pieces. However, although possible, it is not necessary that the expansion module(s) 700 n include all of the subsystems of the base module 700 a.

The base module 700 a may also include a system manager SMGR, which can be implemented in the computing infrastructure shown in FIG. 1A . Also, the base module 700 a may include a frame management FMGT and shuttle (e.g., any suitable type of cart for managing transportation of frames) management SMGT. The frame management FMGT and shuttle management SMGT may be implemented in the computing infrastructure of FIG. 1A . In embodiments, the frame management FMGT and shuttle management SMGT will manage the movement of the frames and shuttles throughout the entire system, knowing the location of the frames and shuttles with respect to other systems and other frames and shuttles. This can be accomplished by use of RFID sensors, photodiodes or other known sensors, for example, placed throughout the system. For the frames, this can also be accomplished by use of encoders placed on the transport systems, which would maintain track and control of the frames as they are sorted, sequenced and/or stored, for example. As the base module 700 a includes the frame management FMGT and shuttle management SMGT, it may not be necessary to provide such systems on the expansion module(s) 700 n . Additionally, frame inspectors may be provided in the base module 700 a and expansion modules 700 n to inspect frames for signs of degradation in order to remove frames from the system prior to failure. This may be implemented as a camera system (which detects fatigue cracks), vibration sensors (which detects vibrations above a threshold that may be indicative of a crack or other degradation of the frame), etc.

Further, the base module 700 a may include a storage manager which may be implemented with the system manager SMGR or as a separate unit. The storage manager manages the storage of mail pieces contained in frames that are awaiting final sorting/sequencing and dispatch. In this regard, it is possible to provide the storage manager in both the base module 700 a and expansion module(s) 700 n ; although as this function is preferably implemented in the computing infrastructure it is contemplated that only the base module 700 a would require this feature. As such, when an expansion module 700 n is plugged into the base module 700 a , the functionality of the storage manager can automatically detect the base module 700 n and provide its functionality to the base module 700 n.

In embodiments, the expansion module(s) 700 n may be designed for a plug-and-play operation. For example, adding an expansion module(s) 700 n to the base module 700 a may be automated such that the system manager SMGR automatically (and immediately) recognizes when an expansion module(s) has been plugged in and added to the system. Thus, the system manager SMGR provided with the base module 700 a would be fully capable of managing the systems of the newly-added expansion module(s) 700 n (similar to the FMGT and SMGT).

Additionally, as shown in FIGS. 7A-7C , each of the base module 700 a and the expansion module(s) 700 n may include an input segment ISGT for introducing mail pieces into the mail processing system, a processing segment PSGT for processing the mail pieces, and an output segment OSGT which receives processed mail from the processing segment PSGT. In this regard, the input segment ISGT may include, e.g., an induction feeder IFDR, mail induction MI, and frame inserter FITR subsystems, as well as a presort accumulator PACC which may serve as a buffer for mail entering a processing segment PSGT. The processing segment PSGT may include, e.g., a sequencer subsystem SQ which sequences the mail. The output segment OSGT may include, e.g., storage segments STSUB for storing the mail pieces.

In further detail, the presort accumulators PACC of the base module 700 a and expansion module(s) 700 n may also perform an initial separation of mail pieces contained in frames and load the frames into shuttles for transport. Similarly, the sequencers of the base module 700 a and expansion module(s) 700 n may perform several sorting and/or sequencing steps including (but not limited to) sorting/pre-sequencing, initial sequencing, and post sequencing.

Additionally, each of the base module 700 a and expansion module(s) 700 n may include a container loader that extracts mail pieces from frames and loads containers for dispatch. Further, both the base module 700 a and expansion module(s) 700 n may include a container dispatcher that transports containers filled with sorted/sequenced mail pieces within the mail center.

Further, the base module 700 a and/or expansion module(s) 700 n may include a transport subsystem TSUB (e.g., a multiplexer or transport controller) to transport mail pieces between different subsystems of the base module and expansion module(s), as well as transport mail pieces to other expansion module(s). Additionally, the base module 700 a and/or expansion modules 700 n may also include a container dispatch for receiving sorted and sequenced mail. The base module 700 a and expansion module(s) 700 n may be interconnected by a transport subsystem TSUB. Additionally, multiplexing may be accomplished by the transport subsystem TSUB. In this regard, mail intended for a particular destination (e.g., ZIP code) may be transported to a corresponding area (e.g., branch) of the mail processing system.

Facility-wide processing of mail in a single system has not previously been accomplished. This solution for facility-wide mail processing is better than a single standardized system design because it allows sizing of the system to the unique space constraints and mail processing capacity requirements of each postal facility. This solution is better than designing a customized system for each facility in that it requires minimal unique design work on a site-by-site basis. Also, it has the additional advantage of being easily scalable after initial installation. This allows flexibility in the event of changing mail flow trends.

Also, the base module 700 a and expansion module(s) 700 n of the modular subsystem of the present invention may include any number of the subsystems, in any desirable combination. It is also easy to integrate the modules together as they are plug and play compatible. Therefore the system can be easily scaled to a wide range of capacities e.g., 500,000 to millions of mail pieces. The addition of an expansion module also includes all capacity-limited subsystems and functions (such as sequencing and storage), but does not require functions that do not have a capacity limit. (These functions are already included in the base module, so the base module will perform these functions for the entire system.)

Redundancy of Parallel Independent Segments, Subsystems, and Components to Improve Reliability

The invention relates to a system and method of improving the overall reliability and availability of a large, facility-wide machine that sorts and sequences letters and flats mail. This improvement is accomplished by configuring the facility-wide mail processing system as a network of parallel, independent branches, at multiple levels. A parallel configuration has at least two significant advantages. Firstly, when configured in independent, parallel branches, a single point failure in one branch will not affect the other branches. Secondly, being configured in parallel allows the addition of extra parallel branches. For example, if 10 parallel branches are required to be operating at any given time, it is possible to include an 11 th branch in the design. Therefore it is possible to have any one of the 11 branches offline, and still have the required 10 branches operating. This allows for a cyclic rotation. For example, with the example of 11 parallel branches, operational wear would be evenly distributed across all 11 branches by rotating out one of the branches (for maintenance) during processing. Furthermore, this allows for earlier detection of a fault in any one branch than might occur if a redundant branch were left idle for days or weeks. These advantages of parallel systems can be used to increase the overall availability of the system and can be integrated into the modular design of the present invention.

FIG. 7D shows the mail processing system being arranged in independent parallel branches to process mail in accordance with aspects of the invention. More specifically, FIG. 7D illustratively shows mail pieces being re-routed around an inoperative segment, subsystem or component of a branch of the mail processing system in accordance with aspects of the invention. FIG. 7C also shows parallel processing with the addition of subsystems, segments and components discussed above. As such, it should be understood that the present invention can easily be implemented with the subsystems, segments and components of FIG. 7C and/or the subsystems, segments and components as described throughout the instant application.

For example, as shown in FIG. 7D , each branch BR of the mail processing system (i.e., the branches of the base and expansion module(s)) may include components from a base module and expansion module arranged in parallel with components of other branches. Accordingly, if any one of the parallel components of the branches BR are not in operation (e.g., due to maintenance) the other branches BR may continue to operate and take over the processing capabilities for the inoperable component. In this regard, the overall availability of a large, facility-wide machine that sorts and sequences letters and flats mail is improved. In particular, the improvement may be accomplished by configuring the facility-wide mail processing system as a network of parallel, independent branches BR, at multiple levels.

As an illustrative example, a segment level SL may include arranging the same type of components (segments) of the base module or the expansion module in parallel. For example, in the segment level SL, three input segments, processing segments and/or output segments can be arranged in parallel. In this configuration, if any of these segments fail in a branch, another of the segments of a different branch can compensate for such inoperability; that is, a parallel branch BR of the mail processing system having an inoperable segment will not significantly affect operation of the other segments and processing of the mail pieces. In fact, when more than the required segments are provided, an inoperable segment will have no affect on the throughput of the system, as this inoperable segment can simply be cycled out for maintenance. This, of course, increases the availability and efficiency of the overall system. It should be understood by those of skill in the art that more or less than three segments and types of segments can be provided in the segment level, and that these segments should not be considered a limiting feature of the present invention.

In another example, similar in concept to above, a subsystem level SUBL may include arranging subsystems (e.g., the mail induction systems) in parallel. In this illustrative example, each subsystem level SUBL includes two subsystems such as, for example, a buffer or presort accumulator that can be arranged in parallel. In this configuration, if any of these subsystems fail in a branch, another of the subsystems of a different branch can compensate for such inoperability; that is, a parallel branch BR of the mail processing system having an inoperable subsystem will not significantly affect operation of the other subsystems and processing of the mail pieces. In fact, when more than the required subsystems are provided, an inoperable subsystem will have no affect on the throughput of the system, as this inoperable subsystem can simply be cycled out for maintenance. This, of course, increases the reliability and efficiency of the overall system. It should be understood by those of skill in the art that more than two subsystems can be provided in the subsystem level SUBL, and that these subsystems should not be considered a limiting feature of the present invention.

Still referring to FIG. 7D , a component level CL may include arranging components such as transporting systems, e.g., lead screws (for conveying mail pieces) in parallel. In this illustrative example, each component level CL includes three components such as, for example, a sensor, OCR, lead screw, etc. that be arranged in parallel. As shown in FIG. 7C , for example, the components may be a container induction station CIS, that allows empty containers and container labels to be received into the mail processing system. In this configuration, if any of these components fail in a branch, another of the components of a different branch can compensate for such inoperability; that is, a parallel branch BR of the mail processing system having an inoperable component will not significantly affect operation of the other components and processing of the mail pieces. In fact, when more than the required components are provided, an inoperable component will have no affect on the throughput of the system, as this inoperable component can simply be cycled out for maintenance. This, of course, increases the availability and efficiency of the overall system. It should be understood by those of skill in the art that more or less than three components can be provided in the component level CL, and that these components should not be considered a limiting feature of the present invention.

In this regard, a parallel configuration has many significant advantages. Firstly, the parallel branches BR of the present invention are configured to process mail independently of each other. For example, if (for any reason) a presort accumulator PACC provided in one path of the mail processing system is inoperable (e.g., due to mechanical breakage or routine downtime of one of the branches), the other branches BR are still fully capable of processing mail. That is, as the mail processing system can be arranged in parallel it is possible to provide a plurality of independently operational branches BR. In regard to the mail processing system of the present invention being arranged in parallel at the component level CL, by way of non-limiting example, the components of the container induction station CIS, that allows empty containers and container labels to be received into the mail processing system, may also be arranged in parallel and independent of each other.

Secondly, arranging the branches BRs in parallel allows that addition of parallel branches BRs, e.g., in order to increase the mail processing capacity of the mail processing system. For example, if a particular mail processing facility requires ten parallel branches BRs in operation at any given time (i.e., in order to meet the particular mail processing facility mail processing requirement), an additional parallel branch BR (i.e., eleven parallel branches in total) may be included in the mail processing system design. Therefore, it is possible to have any one of a number of the branches BRs off-line and still meet mail processing requirements of a particular facility. Thus, one of ordinary skill in the art would appreciate that each additional branch BR added to the mail processing system increases the reliability and availability of the mail processing system.

Thirdly, the mail processing system of the present invention allows for all of the parallel branches BRs to be rotated in and out of service at any particular time. For example, routine maintenance may be performed on any number of the parallel branches BRs while the remaining parallel branches BRs process mail. Additionally, in order to prevent unnecessary and uneven wear on the mail processing system, branches BRs can be rotated routinely from in-service and out-of-service states while still meeting the mail processing requirements of a particular facility. In other words, operational wear can be evenly distributed across all of the parallel branches BRs of the mail processing system.

Further, it should be appreciated, that any of the subsystems not specifically mentioned in this portion of the detailed description, may also form part of the modular design of the mail processing system and be arranged in parallel. That is, so that independent branches are capable or operating when other branches BRs of the mail processing system are not in service.

Regional and Nationwide System Visibility for a Network of Centralized Flat and Letter Facility-Wide Sorting and/or Sequencing System

The invention provides a central management system to monitor facility-wide mail processing machines. In current processing and distribution centers (P&DCs), the United States Postal Service (USPS) mandates the use of a proprietary interface. However, this proprietary interface creates several problems. For example, there are several problems with the architecture including: (1) the underlying transport of the USPS specification does not easily permit sharing of information between facilities (especially, for example, facilities on disparate networks and behind firewalls); (2) the proprietary interface does not easily permit forwarding, aggregating, and/or processing of information in a hierarchical fashion; (3) there is no smart translator on the mail processing equipment (MPE) or mail handling equipment (MHE) that can be updated to extract new data from existing data streams and databases (and thus, vendor equipment should be updated with each new request for data); (4) the proprietary interface does not address system and network management (currently there are a number of commercial products cobbled together to perform these tasks); and (5) the proprietary interface does not address system wide configuration and update of MPE.

Moreover, these problems are compounded when being used with a facility-wide machine that has many subsystems and components that store information in a hierarchal nature. That is, for example, data may be stored in a hierarchal nature where it makes most sense, depending on, for example, where the data is generated and where (and how often) the data is used. With a current approach, for example, all mail piece information is forwarded to a data warehouse when the data itself may be infrequently queried.

Thus, according to an aspect of the present invention, another interface may be used, which is much more extensible than the proprietary USPS interface. In embodiments, the interface uses web services and a service oriented architecture as a basis, which can utilize commercial off-the-shelf (COTS) based business rules engines in hierarchical control and data aggregation centers and COTS based interface modules that reside on the MPE. According to an aspect of the invention, this infrastructure allows for the centralized control and management of one or more of remote and system management functions and equipment specific processing functions, from disparate mail processing machines (e.g., different devices from, e.g., different manufacturers). The infrastructure, e.g., interface, can be implemented in the computer infrastructure of FIG. 1A . Moreover, the present invention allows for data to be stored once, aggregated, where necessary, and queried in the most efficient manner. Additionally, implementing the present invention reduces network bandwidth while maintaining the ability to make fast queries to the data. Also a facility-wide sortation and or sequencing machine may easily obtain data from other sites for scheduling purposes.

Remote and System Management

The remote and system management functions may include:

Access security and auditing; Property management and inventory; Software inventory, distribution and configuration management; Remote hardware/network/software diagnostics; Event and status notification, and escalation; Data archiving, backup, purging and management; Remote access to MPE/MHE and facility wide mail sorting and/or sequencing subsystems and components; and/or Remote restart monitoring, amongst other remote and system management functions.

Equipment Specific Processing

Equipment specific processing functions may include:

Remote configuration of individual MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components; Configuration file of MPE/MHEs and/or facility wide mail sorting and/or sequencing subsystems and components; Staged storage of images and data; Interpreting and reporting MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components performance data; Remote viewing of MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components images; Searching, displaying, and managing configuration files and executables over a distributed network; Interfacing to existing MPE/MHE units and/or facility wide mail sorting and/or sequencing subsystems and components; Update of MPE/MHE libraries; Operator performance measurement and efficiency reporting; Escalation of detected threats; Operator/Supervisor communication; Linking of operator training certification between different operator stations; Linking other MPE/MHE scans of a specific mail pieces; and/or Mail image distribution prior to video coding terminal identification, amongst other equipment specific processing functions.

According to an aspect of the invention, the centralized system uses as its backbone a Service Oriented Architecture. Service-Oriented Architecture (SOA) is a software architecture where functionality is grouped around business processes and packaged as interoperable services. SOA also describes IT infrastructure which allows different applications to exchange data with one another as they participate in business processes. The aim is a loose coupling of services with operating systems, programming languages and other technologies which underlie applications. SOA separates functions into distinct units, or services, which are made accessible over a network in order that they can be combined and reused in the production of business applications. These services communicate with each other by passing data from one service to another, or by coordinating an activity between two or more services. SOA concepts are often seen as built upon, and evolving from older concepts of distributed computing and modular programming. In accordance with aspects of the invention, the SOA architecture may be provided in the computer infrastructure of FIG. 1A .

In embodiments, a Service Oriented Architecture (SOA) of the present invention has the following characteristics:

Uses XML; Uses web services; Internet transport (other transports such as e-mail also applicable); Has capability for automatic discovery; Through-the-firewall messaging; Capable of two way communications (either through true asynchronous communication or polling scheme); Use of hypertext transfer protocol over secure socket layer (HTTPS) or web services (WS)-security to secure message routing and authentication; Can use “open source” business engines and scripting to implement routing, tracking, authentication, message delivery and associated business logic rules. This allows new/updated capabilities to be added with a change of script; Allows additional MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components to be added to the system by only adding a “plug-in” interface module. In embodiments, this interface module can take the form of a separately programmed application, an agent that resides on the MPE/MHE itself, or a plug in dynamically linked library (DLL) module that plugs into a generic interface module. According to an aspect of the invention, existing MPE/MHE currently communicating in the USPS interoperability format could be seamlessly added to the SOA architecture by the use of a single common communication module; Additional capabilities can be added to the server by adding MPE/MHE functionality as generic modules and changes to the “open source” business engine script; and/or Allows the partitioning of a system into tiers (for example, the presentation tier containing all graphical user interfaces, a business tier containing business rules, and/or a database tier containing the data layer). The partitioning of the system into tiers prevents software coupling, and therefore increases reuse and decreases costs of software upgrades and modifications.

Furthermore, XML tags of a service oriented architecture facilitate easy grouping, searching, and/or aggregation of data of the raw data stream (e.g., permitting easy aggregation, filtering, and/or forwarding of data for a hierarchical management structure) and easy storage to databases.

In addition, this same interface could be used for mail piece image and data dissemination for video coding purposes. For example, using either SOAP Message Transmission Optimization Mechanism (MTOM), Direct Internet Message Encapsulation (DIME), or Multipurpose Internet Mail Extensions (MIME) or another method of encapsulating binary data into a SOAP message, mail piece images may be routed on the same hierarchy. According to an aspect of the invention, this would allow video coders (personnel that manually key in address information from a mail piece, typically because the address could not be recognized by an automatic recognition software program) to be positioned anywhere that has a network connection, e.g., a high speed connection to the Internet. Moreover, web services can forward any video or results through firewalls, and be encrypted to even use the Internet as a network, which is facilitated by the easy encryption offered for SOAP messages. These encryption possibilities include, for example, HTTPS (the same encryption offered to a secure internet site) or WS-Security, amongst other encryption methods.

FIG. 8A shows an exemplary central management structure 800 implemented in a hierarchical structure in accordance with aspects of the present invention. As shown in FIG. 8A , multiple MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components 810 (labeled as MPE and referred hereinafter as MPE) are monitored, the data aggregated, and controlled in multiple P&DCs 808 at a regional command center (or regional center) 804 . The status of each P&DC 808 and aggregated status of all MPE 810 within each P&DC 808 can be monitored and data stored at regional centers 804 . In embodiments, these regional centers 804 may include regional data marts and/or data warehouses. Additionally, the regional centers 804 may be manned to allow an intermediate level of command and control. Likewise, the status of any regional command center 804 and aggregated status of all MPE 810 can be monitored at other regional centers 804 in a hierarchical situation. Thus, according to an aspect of the invention, the present system is able to stage information where it makes sense, either on the MPE 810 itself, centrally within a P&DC 808 , elsewhere in a regional data center 804 , e.g., a data mart, or in a enterprise wide data warehouse (not shown). A national command center (or national center) 802 may be positioned anywhere with network communication and may also provide all functionality of any P&DC 808 . (A hierarchal command center structure is the subject of patent publication US 2005/0251397 which is incorporated herein by reference in its entirety.)

FIG. 8B shows a logical view 800 ′ of the hierarchical relationships shown in FIG. 8A . As shown in FIG. 8B , a national center 802 communicates with and, for example, executes command and control over a plurality of regional centers 804 . In embodiments, the regional centers 804 may include data marts. Furthermore, the plurality of regional centers 804 communicate with and, for example, execute command and control over one or more P&DCs 808 . Furthermore, the P&DCs 808 communicate with and, for example, execute command and control over one or more MPE 810 . Additionally, as shown in FIG. 8B , in embodiments, a regional center 804 may also communicate with and, for example, execute command and control over mail processing equipment at an associate office 812 .

FIG. 8C shows an exemplary illustration of a service oriented interface 811 including an MPE interface module 812 in accordance with aspects of the present invention. This interface 811 allows a common piece of software to control system access security and message routing. New functionality can easily be added to the interface 811 through plug-in modules. Additionally, the interface 811 can be rapidly configured with changes in script to handle new or modified MPE 810 or changes in monitoring requirements. Moreover, these changes in scripts can be accomplished without a software release to the underlying software. In addition, since the interface 811 uses XML web services as its implementation, messaging readily passes through firewalls 824 .

In addition to a centralized reporting system, each facility-wide MPE 810 includes an MPE interface module 812 assigned to it (multiple MPE may be serviced by one MPE interface module 812 ). The MPE interface module 812 is responsible for the communications, security, connectivity, and control of the messages. The actual implementation of the MPE interface module 812 includes a business rule engine 822 that is operable to control the routing of messages to internal plug-in modules. In embodiments, these plug-in modules may be implemented in a dynamic link library (DLL). In this exemplary implementation, requests may be received from a control center 804 and routed to the business rule engine 822 . In embodiments, the business rule engine 822 may be implemented, for example, in custom software or with a COTS Business Rule Engine with scripting to control individual message routing. COTS Business Rule Engines typically also include the communication and security functions to communicate over a web service interface (shown in the SOA communication module 820 in FIG. 8C ).

As shown in FIG. 8C , the business rule engine 822 routes the message to the appropriate internal software module. Since the standard USPS MPE interface is the P&DC Interoperability Specification interface (based on ISO 9506 and IEC 61850 international standards), one of the interface module types would facilitate this standard USPS MPE interface which, in embodiments, would communicate to all legacy systems. However, as discussed above, the current USPS interoperability standard is unsatisfactory for inter-facility communication, especially through firewalls and in a hierarchical architecture.

The MPE 810 also has subsystems which would also communicate with the control center 804 over the same architecture. That is, communication may occur using the same software modules hosted on the control center 804 and subsystem controllers. In embodiments, these software modules, for example, may be implemented in Service Oriented Architecture themselves and be based on web services, or they may be software (e.g., agents, plug in DLLs, applications, services, Demons, routines, etc.) that run on the actual MPE, on other computers for the purpose of interfacing between disparate threat scanning machine, and a centralized command and control center 804 . Additionally, in embodiments, these interface module functionalities could also be hard-coded within the MPE interface modules 812 themselves.

In embodiments, there are two types of interface software modules: a translator module 816 and a functional module 814 . The translator module 816 is responsible for interfacing translating data from the control center 804 to a source of data within the MPE 810 . In embodiments, the translator module 816 may include interfaces to:

MPE specific messages and data buses (even those messages that are not in the interoperability interface); MPE (or associate) databases 818 ; and/or MPE file system, system registries, event logs, XML data sources, system resource usage and allocations, and/or system authentication data stores.

The functional module 814 is responsible for capturing, transmitting, commanding, or otherwise communicating to the MPE 810 (through an MPE interface module 812 ) in relation to a task or a group of tasks. Examples of responsibilities of the functional modules 814 include:

Property management and inventory; Software inventory, distribution, and configuration management; Remote hardware/network/software diagnostics; Error, warning event and status notification, and escalation; Data archiving, backup, purging and management; Remote access to MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components and command center assets; User and system authentication setup; Auditing of all actions taken; Auditing of all messages received; Routing of command signals; Remote configuration of individual MPE/MHEs and/or facility wide mail sorting and/or sequencing subsystems and components; Scoring the accuracy of MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components operators; Staged storage of images and data; Interpreting and reporting MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components performance data; Remote viewing of MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components images; Searching, displaying, and managing threat data over a distributed network; Update of MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components threat libraries; Operator performance measurement and efficiency reporting; Escalation of detected threats; Operator/Supervisor communication; Linking of identification information between remote databases; Linking other MPE/MHE scans of specific mail pieces; Scheduling update or software/download of files; Remote control of operator/user functions; Gathering of computer/system/user diagnostic data; Remote training of users; Storing and queuing of information; Configuration of the scanning machine; Report generation; Remote desktop sharing; and/or Remote restart monitoring.

The Control Center

FIG. 8D shows an exemplary high level control center architecture in accordance with aspects of the invention. It should be understood that, in embodiments, the control center 804 may be an enterprise or national control center, a regional control center, a data mart, a data warehouse or a central video coding center.

According to an aspect of the invention, control center geographic location is not important as long as there is an Internet connection 844 to the network (or a connection to a Wide Area Network 842 ) due to the ability for the Service Oriented Architecture to pass messages to the individual MPE interfaces 811 . This Service Oriented Architecture allows the system to be dynamically configurable. For example, if an MPE is not able to process the load or for any reason fails, another control center 804 (or another MPE) can be configured to pick up the load.

In embodiments, messages to and from the MPE 810 and control centers 804 may be composed of XML and composed of Simple Object Access Protocol (SOAP) format messages. Before encryption, these messages are human readable and self-descriptive, thus providing messages that are easy to troubleshoot. Moreover, these messages do not have message translation problems between different operating systems and memory storage formats (as is the case with many binary messaging implementations). Furthermore, the XML tags and available Document Object Model (DOM) processing algorithms allow easy filtering and aggregation of message data.

The architecture of the present invention incorporates XML web services to communicate to and from the MPE 810 . These messages may use hypertext transfer protocol (HTTP) to communicate, although the invention contemplates that other transport methods, for example, e-mail or HTTPS may be used with the present invention. This protocol can be routed through firewalls 824 . This allows encrypted information to be routed to and from any site with Internet access. Thus, near real-time two-way communications between MPE/MHE 810 and the control center 804 may be achieved, for example, through the use of polling and/or true asynchronous communication.

According to a further aspect of the invention, a Service Oriented Architecture allows commercial off-the-shelf (COTS) software business engines to implement the basic message routing, tracking, authentication, message delivery, and associated business rules, e.g., allowing developers to concentrate on the business object logic. Business engines also use open source scripting languages and web service objects, allowing multiple sourcing. According to an aspect of the invention, new functionality can easily be added later as stand-alone objects with just simple changes to the scripting. Moreover, system administrators may distribute only the new business objects and scripts, thus eliminating the expensive re-compile and re-release cycle of an entire application, traditionally associated with custom software. In addition, new services can be discovered with Universal Description, Discovery and Integration (UDDI) and integrated without human configuration.

As shown in FIG. 8D , the control center architecture consists of a business logic rules and SOA messaging module 846 and includes a number of software modules. In embodiments, the software modules include an address recognition image logic module 830 for transmitting address recognition images, an MPE status and control module 832 , and a maintenance server module 834 . Additionally, the business logic rules and SOA messaging 846 communicates with local and/or remote databases such as data marts and data warehouses 836 . In embodiments, the data warehouses 836 may be implemented in the storage system 120 (shown in FIG. 1 ).

FIG. 8E shows an address recognition image logic module 830 in accordance with aspects of the invention. More specifically, the address recognition image logic module 830 is operable to schedule and manage the workflow of the address recognition systems of the present invention. In embodiments, these address recognition systems include the central address recognition nodes 856 , which are operable to automatically detect an address, e.g., via an optical character recognition (OCR) device, and the local video coding interface 858 , which interfaces with local video coding machines that allow, e.g., an operator to manually determine an address, for example, when the central address recognition nodes are not able to determine the address.

As shown in FIG. 8E , the address recognition image logic module architecture 830 includes a scheduler 850 in communication with a workflow manager 852 . The workflow manager 852 is additionally in communication with a local video coding interface 858 and central address recognition nodes 856 . The scheduler 850 and the workflow manager 852 are operable to schedule and manage the workflow for address recognition operations. For example, the workflow manager 852 may be aware of which central address recognition nodes 856 have spare capacity and may, e.g., assign a mail piece to a particular address recognition node for address recognition. Moreover, the workflow manager 852 may provide particular address recognition node with, e.g., fifty-five seconds to determine the address of the mail piece. If the fifty-five seconds expire without the particular address recognition node determining an address for the mail piece, the workflow manager 852 is operable to reassign the mail piece address recognition task to a local video coding machine via the local video coding interface 858 .

Further, as shown in FIG. 8E , the local video coding interface 858 and central address recognition nodes 856 are both in communication with an address database 860 . In embodiments, the address database 860 contains, for example, every mailing address in the United States. Additionally, in embodiments, the address database 860 may be a single database or a plurality of databases. Moreover, the address database 860 may be local to, e.g., MPE, or may be a remotely located database. Further, in embodiments, the address database 860 may be implemented in the storage system 120 (shown in FIG. 1 ).

The workflow manager 852 is also in communication with an interface control logic module 854 . Moreover, the interface and control logic module 854 is in communication with the address database 860 and the business rules and SOA messaging module 846 . The business rules and SOA messaging module 846 is operable to control where messages are routed. For example, the business rules and SOA messaging module 846 is operable to route a message, e.g., a request for resolution message, to the address recognition images module 830 . Additionally, the interface and control logic module is operable to interface the business rules and SOA messaging module 846 with elements of the address recognition images module 830 .

Additionally, according to aspects of the invention, address recognition image communication allows images that are not detected locally (for example, at local video coding machines connected via the local video coding interface 858 ) to be communicated elsewhere for, e.g., manual video coding. Since these messages are already in Internet-ready format, the messages can be forwarded to, for example, many distributed video coders (making their efforts virtually independent of location). Thus, it is possible to take advantage of video coders in disparate places, such as, for example, within many different USPS facilities, distributed locations (such as video coders operating from their homes) or even the ability to take advantage of cheaper labor from foreign labor pools. The images themselves can be encoded within SOAP messages through use of binary extension such as, for example, Message Transmission Optimization Mechanism (MTOM), Direct Internet Message Encapsulation (DIME), or Multipurpose Internet Mail Extensions (MIME).

FIG. 8F shows a control center MPE status and control logic module 832 in accordance with aspects of the invention. As shown in FIG. 8F , the control center MPE status and control logic module 832 includes a switch logic module 862 in communication with an instruction logic module 864 and a data management logic module 870 . As discussed above, the business rules and SOA messaging module 846 is operable to route a message, e.g., a status message, to the MPE status and control logic module 832 . In embodiments, the switch logic module 862 is operable to route the message to either the instruction logic module 864 or the data management logic module 870 , as discussed further below.

As further shown in FIG. 8F , the instruction logic module 864 is in communication with existing local equipment 868 via an interface and control logic module 866 . That is, existing local equipment 868 may not be capable of SOA communications (indicated by the dashed lines), for example, using Web-based communication protocols, e.g., extensible markup language (XML). As such, the interface and control logic module 866 is operable to interface with existing local equipment 868 such that SOA communications may be utilized. It should be understood that while the existing local equipment is shown as a single element in FIG. 8F , the existing local equipment 868 can be any number of existing local equipment. Moreover, the invention contemplates that local equipment may be operable to interface with the instruction logic module 864 without the interface and control logic module 866 . That is, the invention contemplates that local equipment may be capable of SOA communications. Thus, in embodiments, some local equipment (not shown) may be directly in communication with the instruction logic module 864 .

Additionally, as shown in FIG. 8F , the data management logic module 870 is in communication with command logic 872 , the data mart or data warehouse 836 and a report generation and viewer module 874 . The command logic 872 is operable to provide, for example, separate controls for some commands, which, e.g., cannot be routed through existing equipment. For example, the command logic 872 may provide a power-down command.

In embodiments, the data mart or data warehouse 836 is a database (or a plurality of databases) containing, for example, data from multiple MPE/MHE and/or facility wide mail sorting and/or sequencing subsystems and components (hereinafter referred to as MPE in the instant section) from multiple locations. That is, a particular MPE may process a number of mail pieces. Upon processing these mail pieces (or during processing, e.g., in real-time), the MPE may send a record of the processing to the data mart or data warehouse 836 . Thus, the data mart or data warehouse 836 contains records of the status of the MPE. However, the invention contemplates that some data may be stored locally to the MPE, and thus, in embodiments, this data may not be sent to the data mart or data warehouse 836 . In embodiments, the data warehouses 836 may be implemented in the storage system 120 (shown in FIG. 1A ).

The report generation and viewer module 874 is operable to generate reports. For example, at the end of a mail piece processing run, e.g., an operator may want to know how many of each type of mail pieces (e.g., flats, letters, etc.) were processed. According to aspects of the invention, the report generation and viewer module 874 , is operable to access, e.g., the data mart or data warehouse 836 or MPE, and determine how many of each type of mail pieces (e.g., flats, letters, etc.) were processed. Moreover, the report generation and viewer module 874 is operable to output a report 876 .

The MPE status and control logic module architecture controls the data transmitted to and from the MPE. In embodiments, this data may include:

Mail piece messages detailing the mail piece ZIP and bar code information; MPE state; Data point (snap shot of key state and data variables on the MPE); Mail piece location information (path and container information); End-Of-Run, Start-Of-Run; Command interface; Sort plan information; Operator information; Throughput information; Fault information; Communication network heartbeat status; and/or End-of-run summary information, amongst other data.

Additionally, remote management includes the functionality to remotely manage the hardware platform the system is running on.

FIG. 8G shows a control center maintenance server software module 834 in accordance with aspects of the invention. Generally, the maintenance server software module 834 is operable to perform remote and/or local configuration of MPE, software loading, maintenance and network troubleshooting, amongst other operations. As shown in FIG. 8G , the maintenance server software module 834 includes a switch logic module 862 in communication with an instruction logic module 864 ′, a configuration updater module 880 and a data management logic module 870 ′. As discussed above, the business rules and SOA messaging module 846 is operable to route a message, e.g., a maintenance message, to the maintenance server software module 834 . In embodiments, the switch logic module 862 ′ is operable to route the message to the instruction logic module 864 ′, the configuration updater module 880 or the data management logic module 870 ′, as discussed further below.

As further shown in FIG. 8G , the instruction logic module 864 ′ is in communication with existing local equipment 868 via an interface and control logic module 866 ′. That is, as discussed above, existing local equipment 868 may not be capable of SOA communications (indicated by the dashed lines), for example, using Web-based communication protocols, e.g., extensible markup language (XML). As such, the interface and control logic module 866 ′ is operable to interface with existing local equipment 868 such that SOA communications may be utilized. It should be understood that while the existing local equipment is shown as a single element in FIG. 8G , the existing local equipment 868 can be any number of existing local equipment. Moreover, the invention contemplates that local equipment may be operable to interface with the instruction logic module 864 ′ without the interface and control logic module 866 ′. That is, the invention contemplates that local equipment may be capable of SOA communications. Thus, in embodiments, some local equipment (not shown) may be directly in communication with the instruction logic module 864 ′.

As shown in FIG. 8G , the configuration updater module 880 is in communication with a configuration data database 882 . In accordance with aspects of the invention, the configuration updater module 880 is operable to configure, for example, local MPE. Moreover, the configuration updater module 880 is operable to access the configuration data database 882 to, e.g., retrieve configuration data for configuring MPE and store the configuration data for MPE.

Furthermore, as shown in FIG. 8G , the data management logic module 870 ′ communicates with the data mart or data warehouse 836 ′, a system administration updater 890 , a scheduler 884 and a report generation and viewer module 886 . The scheduler 884 is operable to schedule, e.g., maintenance, remote configuration, software loading, etc. For example, consider a task of updating configuration data for a number, e.g., five hundred, servers. If all of these servers attempted to access, e.g., the configuration data database 882 , at the same time, network traffic could be adversely affected. Thus, the scheduler 884 is operable to schedule the updates of configuration data so to prevent, for example, network traffic congestion. In embodiments, the data mart or data warehouse 836 may contain, for example, a current configuration version for each MPE. That is, as an MPE is updated with, e.g., a new configuration, this may be stored in the data mart or data warehouse 836 ′. In embodiments, the data mart or data warehouse 836 ′ may be implemented in the storage system 120 (shown in FIG. 1 ).

The system administration updater 890 is operable to provide system administration update. For example, the system administration updater 890 may be used to change users of a system and/or configure an operating system, amongst other operations.

The report generation and viewer module 886 is operable to produce reports 888 . For example, consider a situation where a software configuration is to be performed on a particular type of existing local equipment, e.g., updating to version 6.0. The report generation and viewer module 886 is operable to access, e.g., the data mart or data warehouse 836 ′, and determine, for example, which local equipment is already running version 6.0 (and thus, does not need to be updated) and which local equipment is running an older version (and thus, should be updated).

In embodiments, the maintenance server software modules 834 are operable to perform the following tasks:

System time sync; Reboot MPE machinery; Gather and report machine status (MPE machines); Support of backup and recovery, for example, both at the control center and MPE; Provide system administration (including system user IDs and passwords); Provide ability to schedule tasks; Log all actions taken; Ability to view all systems log files; Ability to connect to (send & receive data to/from) “Parent” and “Child” control center; Receive files (updated signature & code) and send the to the MPE for installation/update; Provide configuration management (CM) of data deployed or schedule for deployment; Provide ability to schedule distribution; View download schedule; View versions deployed; and/or View configuration management of stored files.

Thus, as described above, the present invention provides the following functions and advantages, amongst other functions and advantages:

1. A system that monitors status and collects information for disparate Mail Processing/Handling Equipment (e.g., machines from different manufacturers) from one of more processing centers using a Service Oriented Architecture (e.g., SOAP messages) to implement the communications between the control center and MPE. In embodiments, the system is composed of three parts:

Software modules that are local (for example, either on threat scanning machines themselves or on machines that have network access to threat scanning machines); A network interface between the MPE and central control centers; and Central control centers, which perform centralized management of the MPE.

2. A system in which the centralized management functions include separately or in combination:

Property management and inventory; Software inventory, distribution and configuration management; and/or Remote hardware/network/software diagnostics.

Additionally, the present invention is operable to perform the following tasks:

Alarm, error, warning event and status notification, and escalation; Data archiving, backup, purging and management; Remote access to MPE and/or command center assets; User and system authentication setup; Auditing of all actions taken; Auditing of all messages received; Routing of command signals; Remote configuration of individual MPE; Scoring the accuracy of MPE operators; Staged storage of images and data; Interpreting and reporting MPE performance data; Remote viewing of MPE images; Searching, displaying, and managing threat data over a distributed network; Update of MPE libraries/software; Operator performance measurement and efficiency reporting; Operator/Supervisor communication; Linking of identification information (e.g., mail piece and frame identification) between a remote database and an MPE; Linking other MPE scans of to specific mail pieces; Scheduling update or software/download of files; Remote control of operator/user functions; Command and control of MPE machine; Gathering of computer/system/user diagnostic data; Remote training of users; Storing and queuing of information; Configuration of the scanning machine; Report generation; Remote desktop sharing; Report MPE utilization; Report machine performance; Communication of data, image, training, configuration, audit, database registry to a central control center for centralized management, archiving, and/or temporary storage; Capturing and reporting of technical performance measurement (TPM) operator keystroke information; Remote restart monitoring; Operator user tracking and time keeping; Identification information gathering, comparing to existing databases of MPE and correlating to mail pieces; and/or Security encryption of data stream.

3. Additionally, the present invention allows for centralized collection of mail processing status information and control of MPE including:

Mail piece messages detailing the mail piece ZIP and bar code information; MPE statuses; Data point (snap shot of key state and data variables on the MPE); Mail piece location information (e.g., path and frame information); End-of-run and/or start-of-run information; Command interface information; Sort plan information; Operator information; Throughput information; Fault information; Communication network heartbeat status; and/or End-of-run summary information.

4. Additionally, the present invention allows the decentralized processing (e.g., automatic address recognition and/or manual video coding) through the use of a Service Oriented Architecture (for example, SOAP messages) to implement the communications between the mail processing equipment and decentralized equipment and operators that recognize the addresses.

Transportation and Conveying of Containerized Mailpieces

The present invention is directed to a conveyance or transport system designed and structured to transport frames in a sorting and/or sequencing system. The frames can be filled with mail pieces of different sizes, shapes and types, such as, for example, flats and letters. The present invention is also directed to a method of controlling and coordinating the movement of a high volume of mail pieces held within individual frames through the system for efficient sorting and/or sequencing. The present invention also provides related mechanisms to sense, monitor, and control, e.g., divert, high volumes of individual frames independently of other frames along a given conveyance path within the conveyance system. The system of the present invention provides advantages over known systems in that it is now possible to sort and/or sequence different types of object types or mail pieces, i.e., letters, flats, parcels, etc. effectively and efficiently in a single facility-wide letters/flats mail sorting and/or sequencing system.

In embodiments, conveyance mechanisms are configured to transport the frames through the system at a canted angle of about 45 degrees (with relation to the stream of travel) and in a front-to-back orientation (as compared to a lengthwise orientation). This orientation allows for a dense and efficient way to transport the frames in volume, and allows the frames to efficiently be diverted along different paths, e.g., at right angles, without slowing the speed of transport. Also, as the mail pieces are in a front-to-back orientation, more mail pieces can be carried on the conveyance mechanism in less amount of floor space, in a faster manner than conventional lengthwise conveyances. That is, angling the frames at 45 degrees allows for more efficient transporting and diverting of the frames in less space from one conveyance path to another. The conveyance mechanisms may be, but are not limited to, lead screw mechanisms, tooth belt mechanisms, pinch belt mechanisms, individual roller mechanisms, chain mechanisms or any combination of the different conveyance mechanisms.

In various embodiments, as described below, mail pieces in frames are sorted and sequenced using right angle diverts (RADs), merges, compression zones, decompression zones, and shuttles. For example, RADs split a stream of frames into different streams, e.g., at right angles, by diverting individual frames. Due to the 45 degree angle orientation of the frames through the system, RADs can divert the frames without stopping either stream by sliding them from between adjacent frames. Merges merge two streams of frames into a single stream, again using RADS. Again, due to the 45 degree orientation angle, two streams of frames can be merged without stoppage. Compression zones remove gaps from between frames within a stream and decompression zones insert gaps between frames within a stream. When individual handling of frames is not required, frames are moved as batches contained in shuttles. After mail pieces have been sorted and sequenced, they are extracted from the frames and inserted into trays for delivery. The process of extracting mail pieces from frames is referred to as “extraction”.

In embodiments, the conveyance mechanisms transport the frames forward, backward, up, down, or divert the frames from one conveyance path to another provided throughout the sorting and/or sequencing system. In an aspect of the present invention, the conveyance mechanisms also allow the frames to be compressed or decompressed for more efficient movement of sorted (and/or sequenced) frames through the sorting and sequencing system. More specifically, e.g., the compression zone mechanisms are structured to compress frames closer together as they move throughout the system, thereby increasing overall usable space on the conveyance mechanisms.

In embodiments, movement (e.g., diversion and compression) of the frames is controlled by a control unit (i.e., also known as a Frame Routing Agent) which coordinates the movements of individual frames using real-time location notifications from a plurality of sensors communicating with the control unit. In other words, best-path routing of the frames through the sorting and sequencing system is determined by a series of request and response messages between the plurality of sensors and the control unit monitoring each individual frame as discussed in the instant invention.

Based on the foregoing, the present invention provides a conveyance system for efficiently and reliably transporting a high volume of individual frames carrying mail pieces through a sorting and/or sequencing system in less space. It is also contemplated that the present invention may be implemented in any type of postal service or company mail center that needs to presort, sort or sequence mail pieces.

Right Angle Diverts

In sorting millions of mail pieces a day, mail pieces are conveyed at high rates from many inputs (e.g., a conveyance path) and may be selectively diverted to one of many outputs (e.g., branched conveyance paths). Effective diversion (i.e., re-routing) of an individual frame (carrying a mail piece) from one conveyance path to another, as provided by the present invention, does not affect the position or velocity of a neighboring frame on either conveyance path, does not require space on the path (in addition to its own dimensions), and does not require either conveyance path to slow or stop the frames to accomplish the diversion.

In this regard, FIG. 9A-FIG . 9 C generally show various right angle diverts along the conveyance system in accordance with aspects of the present invention. For example, as shown in FIGS. 9A and 9C , initially frames having a leading edge and a trailing edge are conveyed along the (linear) conveyance path “A” at a 45 degree angle with respect to direction of travel. In the example of FIG. 9B , the initial conveyance path is conveyance path “B”. Referring specifically to FIG. 9A , at a point of diversion (where the input conveyance path “A” converges with conveyance path “B”, e.g., at a location where the frame intersect with an output conveyance path “B”), the frame's forward motion is redirected at a right angle down the output conveyance path “B” starting at its trailing edge.

In the example of FIG. 9B , interestingly, the frames can be diverted from conveyance path “B” to either of conveyance path “A” or “C”, depending on the sorting scheme. In the example of FIG. 9C , interestingly, the frames can be diverted from conveyance path “A” to either of conveyance path “B” or “C”, depending on the sorting scheme. In both of the examples of FIGS. 9B and 9C , the frames will remain in a 45 degree angle when transported to a conveyance path that is at a right angle; whereas, the frames will be reoriented onto the output conveyance paths when they are not at a right angle. However, in any scenario, the frames will remain in a front-to-back orientation. That is, the frames (and their respective mail pieces) are oriented such that the front of one mail piece is laterally stacked (at the 45 degree angle) next to the back of a neighboring mail piece, thereby enabling mail pieces to easily move from one conveyance path to another.

In any of the embodiments shown in FIGS. 9A-9C , the frame transitions from the input conveyance path to the output conveyance path without slowing conveyance path speed and without disturbing any adjacent frames. That is, the frames can be merged into streams and removed from streams at full transport speed, without interruption to the processing. In embodiments to accomplish this advantage, forward motion of the leading edge of the frame stops at the point of diversion and the trailing edge of the frame initiates the diversion to the output conveyance path (i.e., the trailing edge becomes the leading edge down the diversion pathway).

Additionally, the following is contemplated by the present invention:

The conveyance paths operate at a fixed speed; A diversion operation performs at a set input speed of the input conveyance path; Since all conveyance paths operate at the fixed speed, it is possible to reduce the number of required conveyance motors, thus eliminating the need for each frame or mail piece (slot) to have an independent motor (such as implemented in some existing diversion technologies); Since mail pieces are stacked front-to-back, throughput limitations of conveying mail pieces end-to-end is eliminated; Divert mechanisms may act like filters. That is, divert mechanisms may be controlled to intentionally divert certain mail pieces on to a path based on a sorting or sequencing algorithm; Although up to three divert paths are shown in FIG. 9A-9C , more divert paths at other angles are also contemplated by the present invention; Mail pieces do not need to originate on a path that has them at 90 degrees to the output conveyance path (see e.g., FIG. 9A ). An example of this is shown in FIG. 9B and FIG. 9C ; and The diversion operations may be reversed. That is, as long as there is an opening for a frame available, multiple paths can be combined into a single stream.

Diverts may be implemented in a variety of machines within the mail sorting and/or sequencing system. For example, diverts may form the basis for a mail stream multiplexer as shown in FIG. 9D . In particular, the multiplexer is located between sections of large sorting and/or sequencing machines which are capable of routing mail pieces (frames) from one of many input conveyance paths to one of many output conveyance paths. The multiplexer may, for example, route mail pieces to paths that will process, store, package, unpackage, and deliver the mail pieces to their appropriate destinations within the mail sorting and/or sequencing system.

By way of further example, diverts may also be implemented in a mail sorter and/or sequencer, itself. As shown in FIG. 9E , frames can be streamed through an input conveyance path in an un-sequenced order and divided into a plurality of divert paths (or “sections”) corresponding to the number of diverts associated with the sequencer (e.g., nine diverts). As the frames are streamed to the different divert sections, a sorting process can begin. For example, in the example of FIG. 9E , each frame is designated with a number from 1 to 9, as there are nine different diverts. Numbers 1-9 also represent the order of each mail piece in the group of nine. These incoming unsequenced mail pieces are diverted into the sorting “aisles” based on that sequence number. The sequence number only refers to the position within that group of 9 (and does not have any relation to the position of letters in other groups). In this example, all mail frames designated with “1” will be diverted to the first divert, all mail pieces designated with a “2” will be diverted to a second divert, and so on. In this way, each divert will handle a certain designated mail frame. As the frames are diverted to the outgoing transport, they are placed in a numerical order, e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9. This numerical order can be a first sorting of the mail pieces. In this way, the frames (mail pieces) can begin the process in a random order and end a first segment of the process in a numerical order indicative of a first level type sort. The sequence itself, as should be understood by those of skill in the art, may be a configurable algorithm that corresponds to a mail piece destination, a delivery sequence, a mail carrier preference, or other criteria. It should be noted that the numbers in FIG. 9E show a mail sequence of mail pieces relative to other mail pieces in the same “section’ for illustrative purposes. For example, a number 5 mail piece in one “section” of mail has no relationship to the sequence of a number 5 mail piece in another “section” of mail.

It should further be noted that each mail piece includes a designated sequencing number and each frame transport “FT” includes a frame transport number. As shown, as each individual mail piece arrives at its designated frame transport “FT”, the RAD diverts the mail piece into the designated frame transport “FT”.

As further shown in FIG. 9E , the mail pieces travel along their respective frame transports “FT” (also referred to as frame transport tubes) are merged via a respective RAD (not labeled) onto the outgoing path or main branch. Moreover, as can be observed in FIG. 9E , upon being diverted to the main branch, the mail pieces are in a sequenced order with relation to one another. This may be considered a first stage of sorting and/or sequencing. For example, mail pieces are numbered 1-9, which is representative of nine diverts (frame transports FT). In embodiments, these numbers do not represent mail addresses, ZIP codes, etc. but are numbers relating to the number of transports FT. Each respective numbered mail piece will be diverted to its respective frame transport FT, e.g., mail pieces numbered 1 will be transported to a transport 1, etc. As the mail pieces exit each of the frame transports FT, they will be placed in a sequence, e.g., 1-9 for further processing. So, in the example shown in FIG. 9E there are a plurality of groups of mail pieces in a sequence 1-9.

Similarly, diverts may further be implemented in cascading sections of a mail sorting and/or sequencing system. FIG. 9F illustrates how smaller batches of mail pieces which are themselves in relative sequenced order may be grouped together to form larger batches of sequenced mail pieces, in accordance with aspects of the present invention. In this exemplary embodiment, upon being merged, the mail pieces are within groups of nine, as there were nine frame transport tubes in the first stage of sequencing.

As further shown in FIG. 9F , the output of the first stage is cascaded to a second stage. In the second stage of the sequencing/sorting, the mail pieces are diverted via RADs (not labeled) into respective frame transports. It should be noted that the numbers on the mail pieces in the second stage reflect the second stage group ordering. Additionally, it should be noted that with this exemplary embodiment, upon being merged, the mail pieces are within groups of ninety, as there were nine frame transports in the first stage of sequencing and ten frame transport tubes in the second stage of sequencing. It should be appreciated that the output of the second stage can be cascaded to a third stage, etc. As such, additional stages and frame transports may be added to sequence any size group of mail pieces. Thus, with this exemplary embodiment, the third stage can be an intermediate or a final stage. Moreover, in embodiments, as each frame transport in sequenced order in a final stage the output may be retrieved at full conveyor speed.

More particularly, FIG. 9F shows frames being diverted from a main branch MB into different divert sections DS. From these divert sections, the frames can then be further diverted into a second main branch MB 2 and thereafter into additional divert sections DS 2 . Although only two main branches and divert sections are shown, those of skill in the art will realize that more than two cascading sections are contemplated by the present invention. In this example, the main branch MB includes some frames that may have been sequenced to a certain depth with relation to other mail pieces in the group. The frames are diverted to the diverts DS and, depending on the sorting algorithm, are diverted in a certain order to the main branch MB 2 . Positions on an output conveyance path, e.g., main branch MB 2 , that mail pieces will occupy after sequencing are shown with dashed lines. Thereafter, the frames are diverted into the diverts DS 2 in a certain order based on the sorting algorithm. This cascading process can continue until all of the mail pieces with a frame are sorted to a certain depth or sequenced. As such, the bottom of the figure representatively shows a snapshot of on-going sequencing operations.

As should be recognized, the input stream brings in a continual stream of mail pieces. For the sortation to work, the conveyor does not have to slow down or stop but just continually sort the mail. For this sortation, it does not matter about the sequence of future or past mail pieces; just the mail pieces in the group. Therefore, there is no need to know the destination of every mail piece before sorting can begin (as with current “n-pass” sorting used by the USPS). All the sorting requires knowing is the order within the group. However, it should be recognized that using the ZIP code, it is possible to use a sort scheme or plan to always determine the order of a group of mail pieces. Second, all mail pieces are sequenced in relation to all other mail pieces. So another sorting stage is introduced with reference to FIG. 9F , for example. In this stage the sequence groups are each diverted to a separate tray. For illustration purposes, 10 sort trays are used for this sorter. As should be understood, mail pieces are diverted out in sequence, e.g., groups of 90 mail pieces in sequence order. Additional stages can be added to have any group size.

FIG. 9G shows a non-limiting example of a perspective view of a sorting and/or sequencing module 900 that may be implemented within a sorting and sequencing system. The module 900 includes a plurality of conveyance paths 901 , at right angles to one another. These conveyance paths 901 may be representative of the conveyance paths shown in, for example, any one of FIGS. 9A-9E . The sequencing module also includes docking stations 903 a and 903 b , designed to dock with shuttles. The docking stations 903 a and 903 b can be an input docking station and an output docking station, respectively. That is, the docking station 903 a can be provided for shuttles to input frames into the module and the docking station 903 b can be provided for shuttles to receive frames from the module.

It should also be understood by those of skill in the art that the module 900 is configurable; that is, the modules are designed in such a way that the two or more modules can be interconnected to one another at the docking stations, for example, or at any of the conveyance paths 901 . This makes the system flexible for enlarging or minimizing the processing capabilities of the system by simply adding or subtracting modules from the system. Also, it should be understood by those of skill in the art that any of the conveyance paths may also be eliminated or added, depending on the particular application. For example, the middle conveyance path can be eliminated or an additional middle conveyance path can be added to the system. As such, it is contemplated that the module provided in FIG. 9G may be reconfigured to accomplish any necessary filtering of mail pieces required by being expanded, multiplied, reduced, or otherwise reconfigured so as to accommodate the various needs of a given sorting and/or sequencing system. The module 900 also forms the basis for various machines including, but not limited to, multiplexers, sequencers, induction units, and presort accumulators.

More particularly, FIG. 9H shows various conveyance paths and diversion options of a frame conveyed through the module of FIG. 9G , from an entrance to an exit. In embodiments, at the point of any diversion, the trailing edge of the frame (in the input conveyance path) will direct the frame to the divert direction. That is, the frame will be diverted into an alternative path by its trailing edge. In an active divert area, frames may either be diverted or they may bypass the point of diversion to continue along the input conveyance path to some subsequent output conveyance path (depending on the specified algorithm controlling movement of the frames). Frames may also be merged with other frames as they are diverted.

By way of illustration, at induction, the frame can perform an active left angle divert or a passive left angle divert. More specifically, the frame can be actively diverted leftward at divert area DA 1 . This is an active divert because the frame has the option of traveling in a straight path. Alternatively, the frame can be passively diverted leftward at divert area DA 2 . This is a passive divert, as the frame must be diverted at this position.

Taking the flow path from the active divert area DA 1 , the frame can travel to either divert area DA 3 or divert area DA 6 . At divert area DA 3 , the frame can be actively diverted rightward and then passively diverted left at divert area DA 4 . At this left angle divert, the frames are merged in the conveyance path with frames that were passively diverted at divert area DA 2 . In a merge, the input conveyance path runs into an output conveyance path carrying a plurality of frames and extending in perpendicular to the direction of the input conveyance path. Again, there is an active divert because the frame has the option of traveling in a straight path. The frames from divert area DA 2 and divert area DA 4 would then merge at divert area DA 5 with frames passively diverted at DA 6 to the exit.

Taking the flow path from divert area DA 3 , the frame can be passively diverted through right angle divert at divert area DA 6 to the exit. Similar to the diverting process at divert area DA 4 , the frames are merged in the conveyance path with frames that were passively diverted at divert area DA 2 .

As thus described, utilizing diverts allows mail to be continuously processed to various locations throughout the mail sorting and/or sequencing system without compromising the speed of the conveyance system. Diverting of the mail pieces improves sorting, sequencing, and storing mail pieces for delivery to predetermined destinations. Processing of mail pieces is further enhanced because slot spaces for frames need not be fixed (e.g., during a merge) for a given diverted mail piece. That is, since the overall system knows the thickness and monitors the position of the mail pieces at all times, only the space necessary for the mail piece may be reserved for increased efficiency during conveyance. Using the diverts in this manner is also an improvement over existing mail systems in that waiting for all the mail to arrive to start processing is eliminated, as is having to manually run the mail through many different passes to properly sort, sequence, store, and deliver the mail.

Divert Mechanisms and Related Conveyances

The right angle divert advantageously achieves a high throughput of frames (i.e., frames per second) at low transport speeds (i.e., inches per second). Achieving the high throughput is accomplished by orienting the frames in the front-to-back stacked manner as discussed above such that the distance between frames (or “pitch”) is as small as possible. In embodiments, each frame is provided with at least one pin (e.g., at a top end of the frame) or other mechanism in order to effectuate diversion. Also, in embodiments, the distance between pins of stacked frames will be the same as the distance between the frames, respectively. Therefore, since the distance between frames should be small, the distance between pins should also be minimized.

Active diverts are accomplished by a divert mechanism. The divert mechanism selectively diverts any, all, or none of the frames that cross its path. Thus, the divert mechanism is capable of acting on each individual pin such that the divert mechanism may switch from the input conveyance path to the diverted output conveyance path and back to the input conveyance path between each approaching pin (i.e., frame). This requires fast switching times to accommodate the high throughput and small frame pitch. Alternatively, the divert mechanism may allow a plurality of frames to be diverted before switching back to the input conveyance path to allow other frames to bypass the divert. Thus, the present invention contemplates a variety of divert mechanisms used in conjunction with the various conveyance mechanisms to efficiently move mail pieces throughout the mail sorting and sequencing system.

Rotating Cam Divert Mechanism and Lead Screw Conveyance

FIG. 9I (A) shows a perspective view of the non-limiting embodiment of the conveyance module of FIG. 9G without support frames of the module in accordance with aspects of the invention. More specifically, FIG. 9 I(A) shows a perspective view of the module 900 as discussed above without the support framing to show a four lead screw conveyance system 902 which conveys frames F within the module 900 . In embodiments, diverts in a lead screw conveyance system may be accomplished by a rotating cam divert mechanism, as discussed further below. As shown in FIG. 9 I(A), the circled area labeled (A) depicts the area of an active right angle divert. That is, a rotating cam divert mechanism 906 interacts with a given frame F (or plurality of frames) to divert the frames F from an input conveyance path 908 to an output conveyance path 910 , e.g., divert the frame at a right angle.

FIG. 9 I(B) shows the four lead screw conveyance system as further described with respect to FIG. 9W and FIG. 9X . The four lead screw conveyance system includes a set of at least four lead screws 902 a (two provided at a lower portion of the conveyance path and two provided at an upper portion of the conveyance path). The upper lead screws 902 a are parallel to each other in a width direction and parallel to the lower pair in the height direction as both ends extend along the length of the main conveyance path. The lead screws 902 a are designed and structured to support the frames F at upper and lower edge ends thereof. The lead screws 902 a also rotate parallel to each other.

Threads of the lead screws 902 a have a pitch such that the frames F are angled at 45 degrees to the direction of travel of the lead screws 902 a and are transported along the lead screws 902 a to readily and easily engage various divert sections and compression zones without compromising the conveying speed of the system. In this regard, and referring to FIGS. 9 I(B) and 9 X, the lead screws 902 a may be powered by an independent motor 994 . More specifically, lead screw drive shafts 989 are driven by the motor 994 (which in turn drives the lead screws 902 a ) and may include at least one, one-to-one right angle gear box 995 to provide uniform synchronized rotation of the lead screws 902 a during operation based upon the output of the motor 994 . The right angle gear box 995 is provided so as not to limit the configuration of the system, and may be utilized in an unlimited number of possible configurations for the motor 994 , drive shafts 989 , and lead screws 987 depending on spacing constraints, etc.

Using the one-to-one gear ratio, it is ensured that all of the lead screws in a given conveyance system rotate at the same speed. This includes main conveyance paths, as well as any divert sections or compression zones the main conveyance path may encounter. As such, the uniform rotation speed of the lead screws 902 a ensures, e.g., that during a divert bypass, even though the frame F contacts lead screws 902 a of the diverted conveyance path, the contact will not impede the forward progress (or constant speed) of the frame along the main conveyance path. However, during a divert, the speed of the diverted frame F is also not affected because of the 45 degree orientation the frame F has with respect to the a direction of travel. That is, the frame F has a natural tendency to move in the direction of the divert and transition of the trailing edge does not impede the speed of the diverted frame F, or does it slow subsequent frames traveling down the main conveyance path.

Referring to FIGS. 9 I(B), 9 W and 9 X, the lead screws 902 a are supported at a lower surface thereof by a plurality of roller cam brackets 993 . The roller cam brackets 993 also maintain the lead screws 902 a level with a floor surface. In alternative embodiments, the roller cam brackets 993 may also provide the driving force to rotate the lead screws 902 a , in lieu of, or in conjunction with the motor 994 . The present invention further contemplates that the motor 994 may be set to rotate the lead screw shafts 989 at about 110 rpm and tolerances may allow for about a 10% variance in performance.

FIG. 9J shows perspective views of the rotating cam divert mechanism 906 and related components. In particular, FIG. 9J shows a plurality of support members 902 b that form conveyance paths such as, for example, conveyance path 908 and conveyance path 910 . In embodiments, conveyance path 908 is at a right angle with respect to conveyance path 910 . The support members 902 b are also structured to support components such as, for example, the lead screws 902 a , roller cam brackets 993 ( FIG. 9X ), one-to-one right angle gear box 995 ( FIG. 9X ), motor 918 ( FIG. 9L ), rotating cam 920 ( FIG. 9L ), in addition to sensors and other components that require mounting and support.

As further shown in FIG. 9J , frames F are conveyed along the conveyance path 908 and conveyance path 910 (via the lead screws). In embodiments, the frames F include a plurality of projections 912 that engage the lead screws. As the lead screws are at the same pitch and at the same speed, the lead screws in the conveyance path 910 will not interfere with the movement of the frames F as they are being transported along the conveyance path 908 , past the intersection of the conveyance path 910 . However, when the frames F are to be diverted, the lead screws of the conveyance path 910 will engage the frames F to divert them to the conveyance path 910 , by use of the rotating cam divert mechanism 906 .

As shown in the exploded views of FIG. 9J , the rotating cam divert mechanism 906 includes a motor 918 and a rotating cam 920 for diverting the frame F. The rotating cam divert mechanism 906 is provided adjacent the intersection of the conveyance path 908 and the conveyance path 910 , and is preferably mounted to a support member 902 b located outside and below an upper lead screw (not shown) of the conveyance path 908 . This ensures that the rotating cam divert mechanism 906 will not interfere with the movement of a bypassing frame F.

In operation, the rotating cam 920 may rotate (or switch) between a bypass setting (as seen in FIG. 9M ) and a divert setting (as seen in FIG. 9N ). By activating the motor, the rotating cam 920 will rotate such that the pin 914 will engage a channel or slot 926 of the rotating cam 920 , and be diverted into an angled groove 930 of the support member thereby directing the frame F to the conveyance path 910 . In a deactivated position (i.e., a bypass setting), the rotating cam 920 will block the pin 914 from entering into the angled groove 930 such that the frame F will continue along its original path.

In embodiments, the rotating cam 920 should not commence a switching action until the previous pin 914 is clear of the rotating cam 920 . However, if several adjacent frames are to be diverted, the rotating cam 920 can remain in divert setting so that multiple frames can be diverted to the conveyance path 910 . This would minimize the need to constantly rotate the rotating cam 920 . Also, due to the high throughput and small pitch of the frames F, the length of the rotating cam 920 should be longer than the pitch between pins 914 . Therefore, one or more pins 914 can enter the rotating cam 920 prior to the switching event, and start down the path of the previous pin 914 .

In the process of switching to the divert setting, the rotating cam 920 may have to push the pin(s) 914 within the rotating cam 920 back to the conveyance path 908 . The pushing of pins 914 should be minimized, though. To minimize the pushing of pins 914 (without reducing throughput or increasing pin pitch) the point of cam rotation 920 can be extended. By extending the point of cam rotation, the channel length of the rotating cam 920 may be shortened. Therefore, only one of the pins will enter the inlet of the rotating cam 920 prior to the switching action. This reduces the torque required of the rotating cam 920 , and the frictional wear on the frames F.

FIG. 9K shows the module of FIG. 9G from a top view without the support frames to show the active right angle divert described above. More specifically, it is shown in FIG. 9K that frames can either pass through the intersection of the conveyance paths 908 and 910 , or be diverted from the conveyance path 908 to the conveyance path 910 .

FIG. 9L shows an exploded view of the circled area of FIG. 9K . More Specifically, FIG. 9L shows a frame F in the act of being diverted from the conveyance path 908 to the conveyance path 910 . As seen, the frame F (via the pin 914 not shown) has entered into the channel 926 of the rotating cam 920 and engaged with the angled groove 930 as it is diverted to the conveyance path 910 . A subsequent frame F is also shown; however, the rotating cam 920 is in its bypass position and thus, the subsequent frame F will not follow the preceding frame F. Rather as the angled groove 930 is blocked by the rotating cam 920 , the subsequent frame F will continue down the conveyance path 908 .

Thus, in operation, as the frame F travels down the input conveyance path 908 , the pin 914 extending from the upper end projection 912 passes into the channel 926 of the rotating cam 920 . At the point of insertion into the channel 926 a sensor, e.g., photodiode or encoder, communicates with a computing infrastructure or with the rotating cam divert mechanism 906 to actuate the motor 918 to rotate (or switch) the rotating cam 920 . This will divert the frame F down the output conveyance path 910 . In embodiments, the sensors can determine the particular frames that need to be diverted using the sorting methodologies as discussed in the instant application. At this time, the pin 914 is guided through the angled groove 930 , and the projection 912 engages the upper lead screw 902 a of the conveyance path 910 to complete the diversion of the frame F.

In this regard and as shown in FIGS. 9M and 9N , the rotating cam 920 includes a front wall 922 and an outwardly tapered back wall 924 which defines the channel 926 . As noted above, the channel 926 accommodates pins 914 either bypassing the conveyance path 910 or being diverted to the conveyance path 910 . The front wall 922 is generally flat such that it is parallel to the support member 902 b when in the bypass setting. The tapered back wall 924 is angled at a receiving end of the channel 926 (i.e., the point of cam rotation). The tapered back wall 924 may be angled, for example, at 22 degrees, so that in the divert setting it allows pins 914 to continually be fed into the angled groove 930 and hence towards the conveyance path 910 . This will eliminate the need for the rotating cam 920 to be switched back and forth even though successive, adjacent, frames F are to be diverted to the same conveyance path. Thus, many successive frames F can be efficiently diverted into the angled groove 930 and hence to a right angle transport lane, e.g., conveyance path 910 , by only turning the rotating cam 920 one time. In other words, the tapered back wall 924 allows the rotating cam divert mechanism 906 to quickly divert frames F, while reducing wear on components and minimizing pin pushing. In embodiments, the rotating cam 920 will rotate about 22 degrees, in the divert setting such that the tapered back wall 924 will be flush or substantially flush with a surface of the frame, e.g., does not extend beyond the support member 902 b , in the divert setting.

Pinch Belt Divert Mechanism and Tooth Belt Conveyances

In embodiments, diverts in a tooth belt conveyance system may be accomplished by a pinch belt divert mechanism. To this end, FIG. 9O shows perspective view of a pinch belt divert mechanism in accordance with aspects of the invention. FIG. 9P shows an exploded view of FIG. 9O showing lift mechanisms in accordance with aspects of the invention.

Referring to FIGS. 9O and 9P , a non-limiting example of a tooth belt conveyance system 932 includes an input conveyance path 934 and an intersecting output conveyance path 936 . The tooth belt conveyance system 932 includes a plurality of teeth 938 at spaced intervals extending along at least two outer sides 940 of the conveyance path such that frames F are supported at upper edge ends by the teeth 938 . The frames F include projections 944 at lower surfaces of the upper edge ends so as to engage spaces in between the teeth 936 , and thus allow the frames F to be suspended (i.e., to hang) as they are transported along the conveyance path. The frames F also include upward projecting pins 946 provided at a center portion of a top end of the frame F for use during a diversion.

The tooth belt conveyance system 932 further includes a pinch belt conveyance system 948 provided for diversion of the frames F to conveyance path 936 . The pinch belt conveyance system 948 is provided at the intersection of the conveyance systems 934 , 936 . In embodiments, the pinch belt conveyance system 948 is positioned above the input and output conveyance systems 934 , 936 to provide clearance for frames F (and upward projecting pins 946 ). This also prevents interference during a bypass operation (i.e., when the frames F are not diverted to the output conveyance path 936 ). The pinch belt conveyance system 948 includes at least two parallel horizontal belts 950 continuously running in a loop. The horizontal belts 950 provide a guide path 952 therebetween such that the upward projecting pins 946 may be engaged between the two horizontal belts 950 . In engagement, the horizontal belts 950 carry the frames F from the input conveyance path 934 down the output conveyance path 936 .

Lifting mechanisms 954 having vertically disposed belts 956 are provided along the tooth belt conveyance system 932 . The vertically disposed belts 956 include horizontal indexes 958 . At the point of diversion, the lifting mechanisms 952 may engage the frames F and push them upward (disengaging the frames F from the input conveyance path 936 ). That is, the horizontal indexes 958 engage upper edge ends of the frames F and push the upward projecting pins 946 into the pinch belt conveyance system 948 . In this regard, the upward projecting pins 946 are securely inserted into the guide path 952 between the horizontal belts 950 . The horizontal belts 950 may then carry the diverted frames F to the conveyance path 936 , from conveyance path 934 .

The horizontal belts 950 may also carry the diverted frames F until they clear the input conveyance path 934 . More particularly, after the frames F clear the input conveyance path 936 , the frames F may be placed on another tooth belt conveyance system until diversion or other action is required. It is contemplated that several different belts in series may be provided along the tooth belt conveyance system 932 such that frame F may be compressed or decompressed for more efficient sorting and sequencing of the mail pieces.

In operation, the frames F (suspended by the projections 944 at either side of the upper edge ends of the frames F along the tooth belt conveyance system 932 ) are driven down the input conveyance path 934 . At the point of diversion (intersection of the input and output paths), a timing sensor detects the approaching frames F to determine whether or not the at least two lifting mechanisms 954 are activated for diverting a given frame F. During a diversion, the frames F are vertically lifted such that the upward projecting pin 946 becomes wedged between the two horizontal belts 950 . The horizontal belts 950 divert the frames F from the input conveyance path 934 by capturing the pin 946 in the guide path 952 . As this happens, the frame F disconnects from the teeth 938 of the input conveyance path 934 and the trailing edge of the frame F becomes a new leading edge of the frame F. The new leading edge of the frame F may engage a guide channel (not shown) to keep the frame on track. At an end of the pinch belt conveyance system 948 , the leading edge of the frame F (more specifically at the projection 944 ) engages teeth on another tooth belt conveyance path and the tooth belt conveyance path drives the leading edge of the frame F down the output conveyance path 936 . As the frame F begins to engage the other tooth belt conveyance system, the upward projecting pin 946 disengages the pinch belt conveyance system 948 allowing the new tooth belt conveyance system to continue the progress of the frame F through the module 900 .

Vertical Divert Mechanism

In embodiments, diverts may also be accomplished with a vertical divert mechanism. Specifically, referring to FIG. 9Q-FIG . 9 T vertical diverts may be implemented, e.g., when facility space is limited. The vertical divert mechanism allows selected frames F to vertically divert and serves as a bridge to guide bypassing frames F (i.e., frames not diverted) across a gap 962 at an intersection of an input conveyance path 964 and an output conveyance path 966 (i.e., a point of diversion). The conveyance paths 964 , 966 move the frames F via timing belts 968 . The timing belts 968 engage the frames F by pins 970 extending at upper edge ends of the frames F and move the frames F along the conveyance path. The pins 970 support the weight of the frames F.

In embodiments and as shown in FIGS. 9Q and 9R , a slotted cam 971 is provided at the point of diversion. FIG. 9Q shows the vertical divert mechanism in a bypass setting (i.e., the frame F is not diverted). Here, the pin 970 of the approaching frame F passes through a slot 972 in the slotted cam 971 . In a divert setting (shown in FIG. 9R ), the slotted cam 971 rotates so as to direct the pin 970 (and the frame F) down the diverted output conveyance path 966 . In operation, as the frame F approaches the slotted cam 971 , a sensor detects the frame such that system controls and frame tracking software indicate whether the frame F should be diverted or not. If the frame F is to be diverted, the slotted cam 971 will actuate (i.e., rotate) so as to allow the frame F to engage the vertical timing belts 968 . If consecutive frames F are to be diverted, the slotted cam 971 will remain actuated open until such time a frame F is detected that should travel across the gap 962 and remain on the input conveyance path 964 . An advantage of this cam-style actuation is that fewer actuations will be needed for a batch of frames F that need to travel in any given direction. The mechanism only needs to actuate open or closed once for a large batch of frames F to pass either along the input conveyance path 964 or down the output conveyance path 966 instead of having to continually rotate for each individual frame 960 .

The vertical divert mechanism also includes a guide 973 to bridge the gap for the frames F bypassing the divert from the slotted cam 971 . The guide 973 can be integral to the vertical divert mechanism itself, or a separate boom that extends from the slotted cam 971 to the next area of horizontal support.

In embodiments and as shown in FIG. 9S and FIG. 9T , the vertical divert mechanism may alternatively include a latch or gate 974 (pivotally attached to guide 973 ) that is actuated to divert the frames F down a vertical descent (or up a vertical ascent) of the diverted timing belt 968 . In a bypass setting (as shown in FIG. 9S ), the gate 974 is closed and the frames F travel across a top end of the gate 974 past the guide 973 to continue along the input conveyance path 964 . In a divert setting (as shown in FIG. 9T ), the gate 974 is open such that the frame F is directly transferred from the input conveyance path timing belt 968 to the output conveyance path timing belt 968 .

In embodiments, gravity assists in pulling the frames F downward; however indexes may be used if necessary to maintain separation or orientation of the frames. Using gravity to propel frames reduces complexity of the vertical divert mechanism (e.g., reduces the dependency on motors, belts, pulleys, chains, rollers, etc.). Frames may also simply slide on rails to their next destination. At the bottom of the timing belt 968 , frames F may be gated for merging into a subsequent conveyance path, which may travel in any direction.

Rotatable Slotted Cam Device

In yet another embodiment, diverts may be accomplished in a roller conveyance system. Referring to FIG. 9U , the roller conveyance system 976 includes adjacent threaded rollers 980 that transport frames F along an input conveyance path 978 and selectively divert the frames F to a diverted path or output conveyance path 979 that intersects input conveyance path 978 . The frames are oriented at 45 degrees to both paths 978 , 979 as they are carried along the plurality of adjacent threaded rollers 980 .

In embodiments, the frames have horizontal tabs 981 at top corners thereof. The bottoms of these tabs are “knife-edged.” The tabs 981 hang from tops of the threaded rollers 980 . Thus, the weight of the frames F is carried by the threaded rollers 980 , and the frames F can be moved and positioned by controlled rotation of the threaded rollers 980 . The frames F also include vertical pins 982 in at least the upper edge end of the trailing edge of the frame F. The vertical pin 982 controls whether the frame F travels down the input conveyance path 978 or the output conveyance path 979 . In this regard, the pin 982 passes through a rotatable slotted cam device 983 , similar to that described with respect to the rotating cam divert mechanism 906 discussed above. However, the rotatable slotted cam device 983 is positioned above a support member and the pin 982 passes through a lower portion of the slotted cam. The present invention contemplates either orientation for both embodiments.

The rotatable slotted cam device 983 rotates to engage and direct the pin 982 (and the frame F) either along the input conveyance path 978 or down the output conveyance path 979 . If the pin 982 is diverted to the output conveyance path 979 , e.g., by turning the slotted cam device 983 towards the output conveyance path 979 , the frame F will travel around a smooth, e.g., 90 degree curve and be diverted to the output conveyance path 979 (this is similar to the concept of providing an angled groove as discussed with regard to the rotating cam divert mechanism). In this manner, a single stream of frames F may be smoothly separated into a diverted stream and the original stream, with both streams moving at constant speed.

45 Degree Divert Mechanism

Diverts in a tooth belt conveyance system (as discussed above) may also be accomplished with a 45 degree divert mechanism. Referring to FIG. 9V , the 45 degree divert mechanism 984 provides a tooth belt conveyance system 932 a , a pinch belt conveyance system 948 , and a slotted flat drive belt conveyance system 932 a . The conveyance systems are provided above a top plate to transport the frames “F, which are provided below the top plate. In this regard, the operation of the 45 degree divert will be described. The frames F have movable pins 944 a at upper edge ends thereof and a center pin 946 a provided at a center top end. The movable pins 944 a and the center pin 946 a are engaged in the tooth belt conveyance system 932 a , i.e., the input conveyance path. The movable pins 944 a are in a home position (positioned downward) while traveling along the tooth belt conveyance system 932 a.

The frames F approach a point of diversion, and the movable pins 944 a activate up (from the home position) so as to engage slotted flat drive belts (at 932 a ) to drive the frames into a 45 degree divert. Simultaneously, the center pin 946 a is engaged to the pinch belt conveyance system 948 which also pulls the frame F at a 45 degree angle away from the initial tooth belt conveyance path (at 932 a ).

At an approximate midway point of the 45 degree divert (also termed the “transition area”) one of the slotted flat drive belts 932 a will disengage one of the movable pins 944 a of the frame F, which will drop down and return to the home position on the frame F so as not to interfere with movement of the frame F along the divert path. That is, at the transition area the frame F is driven via two contact points, the center pin 946 a (engaged with the pinch belt conveyance system 948 ) and the other movable pin 944 a (engaged to the slotted flat drive belt 932 a ). At an end of the transition area, the frame F engages a center top drive belt 948 a to further transition the frame F onto another tooth belt conveyance path (not shown) for continued movement through the mail sorting and sequencing system.

Removing Gaps Between Containers Containing Mail Pieces

Compression Zones

In the course of conveying millions of mail pieces through the conveyance systems of a mail sorting and sequencing system, it is oftentimes necessary to be able to adjust gaps between the frames that carry the mail pieces. Reasons for adjusting the gap between frames may include, but are not limited to, reducing the required amount of conveyance space being used, machine availability, facility space restrictions, machine efficiency, or utilization of storage space. Additionally, it is contemplated that adjusting the gaps may also aid in more efficiently and reliably merging various conveyance paths, or aid in positioning the frames in such a way as to match work station spacing.

Adjusting the gaps may be defined as compressing the gaps or decompressing the gaps. Compressing of the gaps includes reducing the spacing between frames traveling through the conveyance system. Decompressing of the gaps includes adjusting the frames to provide additional spacing between frames. Compressing and decompressing may be done independently, or simultaneously, depending on the desired throughput configuration of the frames through the conveyance system.

It is further contemplated that adjusting gaps between frames in a conveyance system can be accomplished using a compression zone. The compression zone may be provided at a segregated section of the conveyance path, and includes an independent drive system. The compression zone, while it may include similar conveying structures as the conveyance system leading to it, may alternatively include different structures to accomplish the task of adjusting the gaps. The compression zone may include, but is certainly not limited to, belts, power rollers, wheels, ball screws, lead screws, linear motors or even robotic arms to adjust the gaps between frames.

Sensors at the compression zone monitor the flow of frames approaching from the conveyance path and the compression zone is configured to receive the frames such that subsequent approaching frames can be held back, slowed down, backed up, or sped up as needed for purposes of spacing the frames to be transitioned to additional locations in the mail sorting and sequencing system. The output result of the frames that are sent through the compression zone may include, but is not limited to, frames that are evenly spaced, frames that contact one another, frames grouped by quantity or characteristic (e.g., thickness, state, city, ZIP code, street, dimension), or gapped in any specific desired configuration for transitioning to other locations throughout the mail sorting and/or sequencing system.

The compression zone operates efficiently such that it does not slow down the overall mail system for sorting, transporting and conveying mail pieces. In embodiments, the mail sorting and/or sequencing system may process five million mail pieces in a twenty four hour period, compared to current systems in operation that process approximately one million mail pieces in a given 24 hour period. It is also contemplated that even without a compression zone, the present mail sorting and/or sequencing system including the main conveyance paths are capable of conveying up to 80,000 mail pieces per hour, double the current handling ability of existing conveyance systems. To accomplish this end, the compression zone works fluidly, integrally, and reliably with main conveyance paths leading to the compression zone such that frames (and mail pieces) are conveyed to their appropriate destinations within a specified time period.

Inset Compression Screws

FIG. 9W shows a perspective view of a non-limiting example of an inset compression zone in accordance with aspects of the invention. FIG. 9X shows a top view of the outset compression zone of FIG. 9W in accordance with aspects of the invention. In embodiments, a compression zone 985 is positioned within, e.g., a four lead screw conveyance system as shown in FIG. 9W and FIG. 9X . However, it is contemplated that the compression zone may be integral with a variety of alternative conveying systems such as, but not limited to, a pulley belt system, chain driven system, and a tooth belt system.

In the embodiment of FIG. 9W and FIG. 9X , the compression zone includes a set of at least four compression screws 986 (two provided at a lower portion of the conveyance path and two provided at an upper portion of the conveyance path) inset from main conveyance lead screws 987 . That is, the compression screws 986 are positioned between the main conveyance lead screws 987 in a parallel relationship along the length of the main conveyance path. The lead screws 987 and compression screws 986 also rotate parallel to each other.

At a point of compression, compression screws 986 engaging the leading edge of the frames F are positioned parallel to the main conveyance lead screws 987 such that an end portion of the main conveyance lead screws 987 extends along side receiving ends of the compression screws 986 . This provides a smooth transition between the lead screws 987 and the compression screws 986 . Compression screws 986 engaging the trailing ends of the frames F are positioned such that a gap is created between the end portion of the main conveyance lead screws 987 and the receiving end of the compression screws 986 . This ensures that the lead screws 987 do not interfere with the compression operation. Additionally, the compression screws 986 are offset from each other to accommodate approaching frames F angled at 45 degree to the direction of the conveyance path.

The lead screws 987 and the compression screws 986 are positioned along parallel lead screw drive shafts 989 and compression drive shafts 990 , respectively. Because the compression zone 985 is provided at a segregated section of the conveyance path, break points 992 separate the lead screws 987 from the compression screws 986 . At the break points 992 , no lead screw portion is provided along the lead screw drive shaft 989 . Instead, only the lead screw drive shaft 989 continues to extend along the conveyance path such that the lead screws 987 do not interfere with the frames F making the transition between the lead screws 987 and the compression screws 986 during a compression operation.

The lead screws 987 and the compression screws 986 are supported at a lower surface thereof by a plurality of roller cam brackets 993 . The roller cam brackets 993 maintain the lead screws and compression screws level with a floor surface. In an alternative embodiment, these roller cam brackets may also provide the driving force to rotate the compression screws 986 and the lead screws 987 .

The lead screw drive shafts 989 are driven by a single motor 994 and may include at least one, one-to-one right angle gear box 995 to provide uniform synchronized rotation of the lead screws 987 during operation based upon the output of the motor 994 . The right angle gear box 995 is provided so as not to limit the configuration of the system, and may be utilized in an unlimited number of possible configurations for the motor 994 , drive shafts 989 , and lead screws 987 depending on spacing constraints, etc. In embodiments, the compression screw drive shafts 990 are driven by an independent motor 996 and also include one-to-one right angle gear boxes 997 for at least the same reasons as provided for above in the description of the lead screw drive shafts 989 . The motor 994 rotating the lead screw shafts 989 may be set to operate at about 110 rpm and tolerances allow for about a 10% variance in performance.

The compression screws 986 of the compression zone 985 adjust gaps between frames being sorted/sequenced through the mail sorting and sequencing system. In this regard, the compression screws 986 can either compress the gaps between a predetermined number of frames F having varying or uniform thickness, or decompress the gaps, and create larger gaps between adjacent frames F. It is contemplated that the lead screws 987 have the capability of compressing from about 11 frames a second (i.e. about 2 inches a second) up to about 22 frames a second (i.e., about 4 inches of mail a second). To achieve this end, the compression screw threads are preferably designed having a pitch range (distance between frames F on the compression screws 986 ) from about 0.177 inches to about 0.25 inches in the direction of the rotation. Tolerances for the pitch characteristic of the compression screws 986 allow for about a 10% acceptable variance range.

The compression screws 986 also easily and readily accept frames F from the lead screws 987 . In this regard, it is contemplated that the compression screws 986 are beveled at 60 degrees at ends interfacing with ends of the lead screws 987 (i.e., at the break point 992 ). The bevel allows frames F to easily transition from the lead screws 987 to the compression screws 986 (and vice versa) without interrupting the flow or speed of approaching or departing frames F.

In operation, the frames F are transported along the lead screws 987 at a 45 degree angle. As the frames F approach the compression zone 985 , a sensor monitors and detects the position of individual frames F (and information logged in the control unit about the individual piece of mail attached thereto, e.g. thickness) on the lead screws 987 . The sensor communicates with the compression screw motor 996 to begin rotation of the compression screws 986 such that the entire frame 988 (including the mail piece) is positioned in the compression zone 985 . Once the frame 988 is securely positioned on the compression screws 986 at the desired position, the compression screw motor 996 is shut-off and rotation of the compression screws 986 stop. The frame 988 is suspended from movement along the conveyance path. The sensors continue to monitor the lead screws 987 for new approaching frames F containing mail pieces. When a new frame 988 reaches the compression zone 985 , the sensors communicate with the compression screw motor 996 such that additional frames F are either compressed or spaced according to a predetermined configuration with the frame already provided in the compression zone 985 . When a predetermined number of frames F are compressed or spaced, the compression screws 986 rotate until the compressed/spaced load is transitioned back online to the lead screws 987 to continue through the conveyance system. The sensors used for compressing may include, but are not limited to, laser sensors, optical sensors, diffuse lasers, magnetic proximity sensors, or encoders.

Outlying Compression Screws

In embodiments, the compression screws 986 may be positioned along the conveyance path outside the lead screws 987 in the parallel relationship similar to that discussed above with respect to the inset compression screws. That is, the lead screws 987 are positioned between the compression screws 986 . The lead screws 987 and the compression screws 986 rotate parallel to each other such that the frames F of individualized mail pieces can be transported along the same for purposes of compression or decompression, and for continued efficient conveyance through the mail sorting and sequencing system.

Inline Compression Screws

FIG. 9Y shows a perspective view of a non-limiting example of an inline compression zone in accordance with aspects of the invention. FIG. 9Z shows an exploded top view of the inline compression zone of FIG. 9Y .

As shown in FIGS. 9Y and 9Z , in embodiments, the compression zone 985 is in-line with the lead screws 987 . In-line compression screws 986 a are provided along the same path (as opposed to a parallel path) with lead screws 987 . More particularly, at the break point 992 of the lead screws 987 where the compression zone 985 initiates operation, the compression screws 986 a and lead screws 987 extend along the same horizontal axis.

In embodiments, the lead screws 987 are hollow outer casings having a thread profile at an outer surface. The hollow outer casing also serves as the drive shaft for rotation of the lead screws 987 . An inner surface of the hollow casing includes a plurality of ball bearings (or alternatively spur gears) to support compression drive shafts 990 extending from the compressions screws 986 a through the inner surface of the lead screws 987 . An independent servo motor (as discussed above) drives the hollow casing. The ball bearings also allow the lead screws 987 to rotate independently of the compression screws 986 a which are rotated by the compression drive shafts 990 driven from another independent motor (not shown). Thus, the compression screws 986 a rotate at a different rate than the lead screws 987 along the same axis to aid in compressing or decompressing frames F depending on the desired operation.

The ends of the lead screws 987 leading to the break point before the point of compression cooperate with a cutback thread mechanism located on the compression screws 986 a at the break point 992 . The cutback thread mechanism includes an end thread design configured such that every other thread is machined back. That is, the cutback thread mechanism includes a full thread, followed by a cut back thread, followed by a full thread, etc. The full thread engages the frames F from the ends of the lead screws 987 . Thus, the compression screws 986 a may accept a frame F from the lead screws 987 to increase the spaced intervals between frames F or to reduce spaced intervals between frames. The spacing created is dependent on the competing rotation speeds of the screws 986 a , 987 , respectively.

It is noted that the last thread of the lead screws 987 may be beveled at, e.g., 60 degrees. The bevel profile does not impede the cutback thread mechanism as it accepts frames from the lead screws 987 at the break point 992 .

The lead screws 987 and the compression screws are supported by roller cam brackets 993 . The roller cam bracket may also be a mesh profile gear that mates the screw threads with the gear teeth such that the gear teeth drive the screws. In embodiments, the roller cam brackets may function as the independent servo motors to start and stop the rotation of the screws based on input received from the sensors at the break point 992 of the lead screws 987 for the approaching frame F.

Thus, the present invention provides a conveyance system for efficiently and reliably transporting a high volume of individual frames carrying mail pieces through a sorting and sequencing system using a variety of conveyance mechanisms. The conveyance mechanisms may include divert mechanisms and compression zone mechanisms to deliver frames from one conveyance path to another without compromising speed of the conveyance path and enhancing the efficiency of the sorting and sequencing system.

Extraction of Mail Pieces from Individually Containerized Mail Pieces

The present invention relates to extraction of mail pieces, such as letters and flats, from individually containerized frames, particularly with regard to such mail pieces being part of a facility-wide automated mail processing system. In addition to mail pieces, the invention encompasses the transportation and processing of other articles, such as, but not limited to, sheets of paper, metal, wood, plastics, etc., as well as CD's, DVD's, and/or their jewel cases, books, photographs, etc. More specifically, the present invention is directed to the extraction of individual mail pieces, such as letters, flats and small parcels, from their individualized frames, particularly with regard to such mail pieces being part of a facility-wide automated mail processing system.

Described elsewhere herein are various types of mail extraction methods and apparatus which generally rely upon a force initiated adjacent, but outside the processing stream of frames and mail pieces. As described in greater detail below, mail piece extraction can alternatively be accomplished by an apparatus, in the form of so-called “extractor frames,” which move along the processing stream itself and which act upon the individually containerized mail pieces via right-angle-diverts (RADS).

As a brief summary before describing details and particular embodiments of the extractor-frame extraction of mail pieces, a facility-wide mail processing system according to the invention relates to individualized frames for mail pieces, such as letters and flats, for use in moving such mail pieces in a facility-wide mail sorting and/or sequencing system. Such frames are herein referred to as a “frame,” a “folder,” or a “frame/folder.” Each frame is constructed for the purpose of containing a single mail piece as the mail piece is sorted and sequenced with other such containerized mail pieces, or as they are stored for subsequent processing. Each mail piece is inserted into a frame when inducted into the system, and extracted from its frame during preparation for dispatch.

Within a given system, frames of different types can be utilized to accommodate letters and flats, e.g., which can vary in size and shape. However, the frames within a system have a standard shape-factor, which makes automated handling easier; although different shapes are also contemplated by the present invention.

A frame, occasionally referred to as a “frame/folder,” includes (1) a frame portion that is transported along a processing path by a driving mechanism, such as lead screws, e.g., which driving mechanism drives a plurality of successive frames within the mail processing system, and (2) a folder portion having at least one portion movably connected to the frame portion, the folder portion having at least a portion movable or deformable relative to the frame between a first position for facilitating selective insertion and extraction of a single mail piece within the container, and a second position, wherein the folder portion is empty of any mail piece.

According to a particular aspect, the engageable portions of the frame are positioned to orient the frame during travel within the mail processing system other than in a direction along the length of the frame. In this manner, a stack of successive frames occupies a minimal length along the travel direction relative to known systems. More particularly according to that aspect of the invention, the aforementioned orientation of the frame is an angle of 45° with respect to the direction of travel.

According to various embodiments according to the invention, in the first position of the folder, insertion and extraction of the mail piece is facilitated. In the second position of the folder, no mail piece is contained in the folder and the folder has a minimized width. In embodiments, the folder can additionally include other positions such as, for example, an intermediate or partially open state to accommodate different sizes of mail pieces.

The frame part of the frame/folder, or “frame,” is rigid, whereas the movable portion of the folder is movable/deformable away from the rigid frame to the first position. The frame is generally rectangular. In the particular embodiments described below, extraction of mail pieces is accomplished through a side opening of the frame.

Mail pieces in frames are sorted and sequenced using Right Angle Diverts (RADs), merges, compression zones, decompression zones, and shuttles. RADs split a stream of frames into two streams, moving at an equal speed, by diverting individual frames. Because of the 45° orientation of the frames, RADs can divert frames without stopping either stream by sliding frames out from between adjacent frames. This results in a sliding or shearing relative motion between adjacent frames.

Merges, or merge areas, merge two streams of frames into a single stream. Again, because of the 45° orientation, such merging is accomplished without requiring the streams to stop. A merge also results in a sliding or shearing movement between adjacent frames.

Compression zones remove gaps from between frames within a stream. Decompression zones insert gaps between frames within a stream. When individual handling of frames is not required, frames are moved as batches contained in shuttles. After mail pieces have been sorted and sequenced, they are extracted from the frames and inserted into trays for delivery.

As described elsewhere herein, mail pieces are individually contained in a frame/folder, generally referred to as a “frame,” as the mail pieces are sorted, sequenced, and otherwise processed in the mail processing system. While it may be possible to leave the mail pieces in their respective frames for delivery to the customer, the additional weight and package size, in addition to potential waste/recycling cost or reuse of the individual frame would be generally prohibitive. Therefore, the better approach is to utilize the individual containers, or frames, for sorting and transport within the mail processing system and to remove the mail pieces from their frames prior to placement into a delivery container.

The present invention, therefore, relates to the removal, or extraction, of flat articles from the individual frames for placement into delivery containers. The invention is applicable to any system that transports flat or mail piece-like articles, including single or multi-sheet documents in individual frames, and requires the removal of such articles from their individually containerized containers, or frames, prior to further processing internally within the system, or externally thereof.

To these and other ends, the invention relates to apparatus and methods of extracting individually containerized flat articles from respective frames during transport of a succession of such containerized mail pieces along a transport path. Extraction of mail pieces can be accomplished by any of a variety of apparatus and methods. For example, an end effecter, such as a vacuum extractor which operates with a perforated belt can engage and extract the mail piece from its frame, while another device, such as a driven friction wheel, withdraws or diverts the emptied container from the transport path.

In an alternative embodiment, end effecters in the form of articulating pushers engage mail pieces by sliding into their respective opened frames to move the mail pieces toward respective grippers for extraction and subsequent handling of the mail pieces. In accordance with alternative embodiments, extraction is accomplished by mechanisms integrated within the mail piece frames, such as a pinch-belt extractor or a slider-in-folder extractor. In other alternative embodiments, the extraction is accomplished by gravity.

In alternative embodiments of methods and apparatus for extracting mail pieces, the mail pieces are extracted from frames being transported via lead screws through the utilization of an extractor frame (or pusher-frame) in conjunction with RADs, merges, compression zones, and decompression zones.

The extractor frame is similar to the mail frame in that it engages lead screws and it can function with RADs, merges, compression zones, and decompression zones. It is diverted into a decompressed stream of frames. This results in a sliding motion between it and the adjacent frames. A particular mechanism (described further below) of the extractor frame engages the mail frame, and uses the sliding motion to slide the mail piece out of the frame. In one embodiment, the mechanism is a “pop-up pusher” that engages the frame and the mail piece via a slot in the side of the frame. The extractor frames are then diverted out of the stream of mail frames, for subsequent reuse.

FIG. 10A schematically shows a mail piece extraction apparatus in accordance with the invention. More particularly, FIG. 10A illustrates a top view of an apparatus that includes a vacuum extractor 1002 which is shown at a point of extraction of mail pieces 1001 from their respective frames F. As shown in the drawing, a stack of successive frames F are conveyed along a direction of travel toward the extractor 1002 , each carrying a single mail piece 1001 . As described elsewhere herein, the frames F can be driven toward the extractor by a plurality of lead screws or other means of conveyance including, but not limited to conveyor belts, chains, ball screw drives, paddles, or other conveyance apparatus, such as magnetic propulsion, cables and hooks, air drive, pneumatic or hydraulic rams, etc.

The vacuum extractor includes a stationary vacuum chamber 1004 positioned within the course of a perforated endless belt 1003 , the belt being driven by at least one of the cylindrical drums 1005 , 1006 . More particularly, a vacuum is pulled through the perforated belt as the containerized mail pieces approach.

The frame F can take the form of the frame/folder described elsewhere herein and shown in, for example, FIG. 11J , whereby the folder maintains the mail piece 1001 between a pair of membranes, one of which includes a C-shaped cutout on the side facing the vacuum extractor 1002 . The cut-out exposes a portion of the mail piece for engagement by the vacuum.

As each containerized mail piece, i.e., mail piece 1001 within a frame F, approaches the vacuum extractor 1002 , the mail piece itself is acquired by the negative pressure of the vacuum chamber 1004 . While so acquired, the perforated belt drives the mail piece through a side opening of the frame (i.e., in the direction of the opening of the “C” of the C-shaped cutout of the folder), thereby extracting the mail piece 1001 from its frame F. As the mail piece is extracted from its frame, or after such extraction, it is engaged by another transport mechanism, such as a pair of pinch-belts 1009 for further processing into a delivery container.

While the mail piece 1001 is being extracted by means of the vacuum extractor, the emptied frame F is driven in a direction opposite of the direction of the extraction of the mail piece by a friction contact wheel 1008 for example, as shown in FIG. 10A . Such emptied frames can thereafter be driven by means of the aforementioned lead screws or other means of conveyance to a frame inserter for insertion of another mail piece.

The extraction apparatus of the embodiment shown in FIG. 10A allows for the vacuum chamber to be as large as necessary to be able to acquire mail pieces accurately within the individual frame and remain in a fixed location. Instead of moving the vacuum head in and out between the individual frames and thereby increasing the gap needed between successive frames, the frames are moved laterally allowing each one to be presented to the vacuum chamber. This eases the mechanical design by not requiring vacuum lines to move with the chamber and sizing the chamber for weight and space constraints between containers. In addition, moving the individual frames is achieved more quickly and consistently because they are of a common form factor. Additionally, mail pieces may be moved directly into a pinch belt transport allowing for a multiplicity of further operations to be performed upon the mail piece including, but not limited to, detection and validation of mail piece extraction, mail piece dimensional characteristic measurements, mail piece orientation correction, mail piece reorientation, hazardous material detection, optical recognition of external markings and identifiers, including indicia marks, addresses, ZIP codes, or other of the like as discussed in the instant application.

FIGS. 10B , 10 C, and 10 D show an alternative arrangement for extracting mail pieces M from their respective frames F. More particularly, FIGS. 10B-10D show mail piece extraction via gravity utilizing a rotatable shuttle 1011 .

The apparatus of FIGS. 10B-10D , under command of the computing infrastructure shown in FIG. 1 , operates in the following manner.

The shuttle 1011 is rotated by 90° by means of a “shuttle flipper” mechanism which is, in exemplary embodiments, provided by way of a gear system structured to rotate the shuttle. More particularly, such a mechanism is configured to capture the shuttle and rotate it 90° and then release it. For example, it could capture the shuttle via a pin-in-hole arrangement, traction belts, gripper paddles, or by design of the shape, such as, but not limited to a 90° angle iron type shape that allows the shuttle to be driven onto it at an orientation of 0° and then rotated 90° and then driven off. To accommodate operating while on its side, the apparatus requires a shuttle structured and arranged to include, for example, a mechanism such as a clamp used with the shuttle described elsewhere herein, for holding the shuttles or frames on the shuttle while the shuttle is rotated.

The rotated shuttle 1011 docks with lead screws 1012 , which to convey the frames F along the processing path at the 45° angle, as shown. Frames F are extracted, with expanded pitch, from the rotated shuttle 1011 onto the rotated lead screws 1012 .

The mail pieces are extracted via gravity force through the bottom of the frames. More specifically, the mail pieces drop via gravity into available spaces between a plurality of separation paddles 1015 . Separation paddles 1015 are positionable relative to the frames F, to ensure the mail pieces are released directly over respective spaces between separation paddles 1015 . This position can be accomplished by the movement of the frames F versus the movement of the available spaces between separation paddles 1015 . Additionally, a sensor or an array of sensing apparatus such as, for example, a photodiode, weight sensor, etc., can be used to verify that each mail piece is collected within the available spaces between separation paddles.

The separation paddles 1015 reorient from a less than 90° to 90° (perpendicular) to the bottom reference edge or deck. The slots are to be oriented at, or approximately at, 45° to accommodate the angle of the mail piece while it is falling out of the frames. According to a particular embodiment, a requirement can be made for the slots/paddles to be able to rotate/change angles. The paddles can either rotate individually or rotate together.

The separation paddles 1015 can withdraw by means of various possible arrangements of linear or radial movement via a solenoid or other driving mechanism known to those skilled in the art. The separation paddles 1015 are to move in a direction that will not lose the edge reference of the mail pieces. Thus, if the edge reference is the bottom right corner of the mail pieces, then the separation paddles 1015 are to be moved in a direction that would not lose the edge reference, i.e., a downward or a rightward, or a down and rightward movement would be optimal. Separation paddles 1015 may withdraw simultaneously or slightly out of time from each other to aid in the reduction of adhesion of mail pieces to the separation paddles.

A final compression of mail pieces is made via compression paddles 1016 a and 1016 b . The compression paddles 1016 a and 1016 b move toward one another to close up gaps created when the separation paddles 1015 are withdrawn, and to create a tighter mail stack that can be moved or conveyed or dropped into a transportable container. Compression paddles can move by means of various possible arrangements, e.g., via a solenoid or other driving mechanism known to those skilled in the art.

In an alternative embodiment, a self-sweeping frame can be utilized for extraction. For example, based upon the need for a mechanical assist to the force of gravity, it is contemplated within the scope of the invention to use rotation of one frame side, or an accordion-like folding side, to sweep against the other frame side and extract the contents. Hinges are integral components of the frame, allowing the frame to fold and recover during an extraction cycle. Clips or latches are incorporated in a frame with symmetrical sides, allowing one side to detach, rotate 180 degrees and reattach the next side after sweeping, as discussed with reference to the frames.

Alternative arrangements for extracting mail pieces from their respective frames are described elsewhere herein in connection with a description of particular embodiments of frames. For example, the embodiment shown in FIGS. 11 Ea- 11 Ec, which provides for a gravity extraction of a mail piece as the movable part 11045 of the frame/folder moves away from the static part 11046 , thereby releasing mail piece which had been gripped therebetween.

Similarly, the embodiment shown in FIGS. 11 Fa- 11 Fd also provides for a gravity extraction of the mail piece as the bottom ledge 11074 , supporting the mail piece, is pulled toward the frame, thereby eliminating the support for the mail piece and allowing the mail piece to be extracted from the bottom of the frame.

Arrangements for extracting mail pieces, other than via gravity extraction, have been described in connection with the description of frames. For example, the embodiment shown in FIG. 11I allows simultaneous extraction from a batch of frames by means of rotatable rods that extend through the folders and move the mail pieces out a side opening of the respective frame/folders. Likewise, the embodiment shown in FIGS. 11 Ka- 11 Kd of a pinch-belt folder and the embodiment shown in FIGS. 11 La- 11 Ld of a slider-in-folder enable mail piece extraction by means of mechanisms integrated within the folder for extracting mail pieces from their respective frame/folders.

FIGS. 10E , 10 F, and 10 G show another alternative arrangement for extracting mail pieces from their respective frames. More particularly, FIGS. 10E-10G show mail piece extraction via a robotic pusher and gripper arrangement.

The apparatus of FIGS. 10E-10G , under command of the computing infrastructure shown in FIG. 1 , operates in the following manner. As shown in FIG. 10E , articulating pushers 1021 slide into opened frame F to begin moving mail pieces toward waiting articulating robotic grippers 1023 a and/or 1023 b.

As shown in FIG. 10F , the articulating pushers 1021 continue to move until an appropriate amount of each of the respective mail pieces is exposed on the opposing side of the frame for the awaiting articulating robotic grippers 1023 a and/or 1023 b can acquire the mail pieces. A sensor such as, for example, a photodiode, may be used to determine the position of the mail piece as it is exposed from the frame.

The articulating pushers 1021 may be purely linear on a rotational head or may be independently articulatable via various joints allowing 360 degrees of freedom of movement in X, Y, and Z axes, moveable by a solenoid as would be known by those skilled in the art. The articulating pushers 1021 may be controlled independently for mail pieces or articles of various lengths but may also be unitarily controlled for mail pieces or articles of like lengths. The articulating pushers may act internal to the frame by slipping completely inside and pushing the mail piece via an end effecter, or it may act external to the frame with an appendage of the end effecter acting internal to the frame via pressure, force, or direct contact through an assortment of possible openings in the folder's surface.

As shown in FIG. 10G , articulating robotic grippers 1023 a and/or 1023 b acquire the mail pieces and move them off to a staging area for preparation in the next process of automation, i.e., transportable container loading. The articulating grippers may be a large plurality of small sized grippers 1023 a capable of acquiring a large quantity of common or less thicknesses of mail pieces. The articulating grippers may also have a smaller plurality of large sized grippers 1023 b staged that may intercede and replace a quantity of small sized grippers 1023 a for acquiring mail pieces of a greater than common thickness of mail pieces.

In the extraction arrangement and method depicted in FIG. 10H , movement along various processing streams is unidirectional and, more particularly, such movement is along the arrows shown therein. As shown, a shuttle 1031 carrying mail-loaded frames M/F is docked at a docking port of the processing stream that moves from left to right in the figure. The frames F are unloaded from the shuttle 1031 and decompressed as they are taken-up by the processing stream.

An endless belt conveyor 1032 drives a plurality of extractor frames EF along the processing streams in the counter-clockwise direction as indicated in the figure. Movements of the extractor frames EF and the processing streams are synchronized such that, as the extractor frames EF, driven by the lead screws LS described elsewhere herein, approach Merge 1 , they merge with the succession of mail-loaded frames.

In a particular embodiment, the extractor frames EF are driven by the lead screws, the conveyor 1032 not providing motive force for driving the extractor frames ER. In such embodiment; the belt itself is powered by the lead screws.

In an alternative embodiment, the extractor frames EF are driven by the conveyor 1032 , and do not engage the lead screws, with the conveyor and the lead screws being synchronized such that the frames F and extractor frames EF can accurately merge and divert.

In succession, each such extractor frame EF of the series of frames associated with the conveyor belt 1032 engages the mail piece m within a respective one of the frames F. As such movement continues (rightward in FIG. 10H ), each extractor frame EF pushes its respective mail piece m out the side of the frame F. When a sufficient extent of the mail piece is exposed as a result of the pushing of the extractor frame, the mail piece is acquired by a gripper or a vacuum head, e.g., (exemplarily illustrated as 1033 , 1034 , respectively, although typically one or the other mechanism would likely (although not necessarily) be used in a given implementation), as the mail piece becomes separated from its respective frame F.

The grippers/vacuum head may or may not be moving along the processing line. Both are fast-acting, as compared to the speed of the frames F moving in the lead screws.

After extraction of mail pieces from the frames, the objective is to stack the mail pieces in a tray. The tray full of mail is then transported to a post office, and taken by the mail carrier on his/her delivery route.

This advantage can be accomplished in a variety of ways within the scope of the invention. Accomplishing this objective would include the following: stacking the mail, and placing it in a tray (and any intermediate transport between steps). It could be accomplished using some combination of the following technologies: Pinch belts, rollers, bottom belts, stackers, linear-actuated paddles, pick-and-place robotics. The vacuum head and gripper are described herein in further detail.

As the empty frames F and extractor frames EF continue their movement (left-to-right in FIG. 10H ), they reach RAD 1 , where their respective directions of movement diverge. The extractor frames EF continue their movement along the endless path defined by the conveyor 1032 and the mail frames F are accumulated in a shuttle, stored, and redeployed as necessary. For example, during a successive day of processing, new mail pieces are inserted into the frames, and the mail processing cycle is then repeated.

The unidirectional alternative shown in FIG. 10I replaces the endless belt for recirculating the extractor frames EF with shuttles, which can be moved from an extractor frame receiving point “a” to an extractor frame feeding point “b” in the direction shown by the arrows at the top of the figure. In other respects, the operation of the unidirectional extraction embodiment of FIG. 10I is much like that of FIG. 10H . Accordingly, as the extractor frames EF approach Merge 2 , they merge with the succession of mail-loaded frames M/F being unloaded and fed from the shuttle 1035 . In succession, each such frame EF of the series of frames engages the mail piece M within a respective one of the frames F. As such movement continues (rightward in FIG. 10I ), each extractor frame EF pushes its respective mail piece M out the side of the frame. When a sufficient extent of the mail piece is exposed as a result of the pushing of the extractor frame, the mail piece is acquired by a gripper, a vacuum head, or other mechanism.

As the empty frames F and extractor frames EF continue their movement (left-to-right in FIG. 10I ), they reach RAD 2 , where their respective directions of movement diverge. The extractor frames EF continue their movement to the shuttle 1036 at point “a” and the mail frames F continue their movement to the shuttle 1037 and are redeployed as necessary.

The embodiment for mail extraction shown in FIGS. 10J and 10K represents an alternative to the unidirectional extraction arrangements of FIGS. 10H and 10I . More specifically, the embodiments of FIGS. 10J and 10K provide a bi-directional extractor arrangement, which eliminates the aforementioned need to recirculate extractor frames.

With initial reference to FIG. 10J , a plurality of extractor frames EF is shown in a buffer storage area 1038 . Another plurality of extractor frames EF is shown in a buffer storage area 1039 . A shuttle 1040 carrying mail-loaded frames M/F is docked at a docking port, where the frames F are unloaded and decompressed as they are then driven toward Merge 3 . Additional docking ports, such as docking port 1041 , could be added, as needed or desired.

As the extractor frames EF approach Merge 3 , they merge with the succession of mail-loaded frames being unloaded and fed from the shuttle 1040 . In succession, each such frame EF of the series of frames engages the mail piece within a respective one of the frames F. As such movement continues (leftward in FIG. 10J ), each extractor frame EF pushes its respective mail piece out the side of the frame. When a sufficient extent of the mail piece is exposed as a result of the pushing of the extractor frame, the mail piece is acquired by a gripper, a vacuum head, or other mechanism.

As the empty frames F and extractor frames EF continue their movement (right-to-left in FIG. 10J ), they reach RAD 3 , where their respective directions of movement diverge. The extractor frames EF continue their movement to the buffer storage 1039 and the mail frames F continue their movement to the shuttle 1042 and are redeployed as necessary. If desired or needed, an additional discharge path 1043 can be utilized.

FIG. 10K illustrates the bi-directional extractor arrangement operating in a reverse mode, with respect to FIG. 10J , thereby eliminating a need to recirculate extractor frames. More specifically, after extractor frames EF accumulate in the buffer storage 1039 during processing in the direction shown in FIG. 10J , the apparatus can be reversed, so that the extractor frames travel from left to right, as shown in FIG. 10K , accumulating in buffer storage 1038 . The shuttle 1044 carrying mail-loaded frames M/F is docked at the indicated docking port, where the frames F are unloaded and decompressed as they are then driven toward Merge 4 .

As the mail-loaded frames are transported to Merge 4 , the mail pieces are extracted, as shown, and the empty frames F and extractor frames EF continue their movement (left-to-right in FIG. 10K ), they reach RAD 4 , where their respective directions of movement diverge. The extractor frames EF continue their movement to the buffer storage 1038 and the mail frames F continue their movement to the shuttle 1045 and are redeployed as necessary.

In summary, regarding the embodiment of FIGS. 10J , 10 K, the extractor frames alternately move right-to-left to extract mail pieces from frames of one shuttle and then left-to-right to extract mail pieces from frames of the next shuttle. In such a bidirectional configuration, overall throughput is improved and there is no need to recirculate extractor frames to the beginning.

During the extraction of a mail piece from its respective mail frame F in the aforementioned methods and apparatus, the extractor frames EF must slide within the frame F, engage the mail piece, and push the mail piece out. FIGS. 10L , 10 Ma, 10 Mb, and 10 N illustrate one arrangement for accomplishing such an extraction of mail.

More specifically, the extractor frame EF, shown in a side view in FIG. 10L , includes “pop-up” pusher tabs 1046 - 1049 . Because the invention encompasses the possibility of using two types of mail frames, i.e., a heavy-duty frame and a light-weight frame, the extractor frame EF shown in FIGS. 10L , 10 M include two sets of pusher tabs for effecting mail piece extraction from either of the two types of mail frames. More specifically, FIG. 10L shows two sets of pusher tabs, viz., tabs 1046 , 1047 and tabs 1048 , 1049 positioned at different heights. The higher set, e.g., could be used for extracting flats and the lower set, e.g., could be used for extracting letters. Other variations are also possible.

FIG. 10 Na shows a perspective view of a mail frame constructed with slots 1051 for use with the extractor frame shown in FIGS. 10L , 10 Ma and 10 Mb. FIG. 10 Nb shows a side view of the mail frame constructed with slots 1051 for use with the extractor frame shown in FIGS. 10L , 10 Ma and 10 Mb.

The pop-up pusher tabs have two positions. In one position, shown in the upper view of FIG. 10 Ma, they lay flat to the extraction frame, allowing the extraction frame to be very thin. In the second position, shown in the lower view of FIG. 10 Mb, the pusher tabs pop up. As the extractor frame EF slides along the mail frame F, the pusher tabs 1046 , 1047 are caused to pop up, by appropriate manipulation of the ends of the slides 1052 , when aligned with the slots 1051 of the mail frame, to engage the mail piece and push it out of the frame. As can be seen from FIG. 10 Ma, when the slides 1052 are pulled outward in the direction O, the tabs lie flat. When the slides are pushed inward in the direction I, the tabs pop up, as the various sections pivot at hinges 1050 , facilitating engagement with the mail piece within the frame.

In the bi-directional extractor arrangement, such as that described above with reference to FIGS. 10J and 10K , movement of the shuttles, i.e., shuttle traffic, would occur in the following pattern. With reference to FIG. 10O , a shuttle 1055 containing frames with mail pieces docks and unloads its frames in the manner described above in connection with FIG. 10J . The mail pieces M are extracted from the frames F, as the mail-loaded frames are merged at MERGE 3 with the extractor frames EF. After the shuttle 1055 is emptied and the extraction process is completed, the shuttle 1055 subsequently receives emptied frames F in the next extraction process, as illustrated in FIG. 10K . In this regard, during the next extraction process in this bi-directional extractor arrangement, the shuttle 1056 (containing frames F, each with a mail piece M) docks and unloads its frames as does the shuttle 1044 in FIG. 10K . Extraction of mail is accomplished as described above in connection with FIG. 10K .

A particular advantage in the arrangement described above in connection with FIG. 10O is that each shuttle 1055 , 1056 can perform two functions, namely, (1) delivering frames F containing mail pieces M, and (2) subsequently receiving empty frames F.

The shuttles 1055 , 1056 can perform both functions while docked at the same docking station. Alternatively, after delivering its frames containing mail pieces, each of the shuttles can move to an adjacent docking station (i.e., to the right for shuttle 1055 , such as to docking station 1041 of FIG. 10J , and to the left for shuttle 1056 , such as to docking station 1043 of FIG. 10J ), and then receive empty frames F. This configuration (with two adjacent docking stations on each side of the bi-directional transport path of the extractor frames) is advantageous in that it allows a shuttle at one of the adjacent docking stations to finish receiving empty frames and undocking as another shuttle begins delivering frames containing mail pieces at the other adjacent docking station. Because simultaneous receiving and delivering of frames can occur, the overall frame throughput is increased. In FIG. 10O , arrows 1061 , 1062 , 1063 show exemplary movement of the shuttle 1055 and arrows 1071 , 1072 , 1073 show exemplary movement of the shuttle 1056 . Arrows 1063 and 1073 depict the movement of the shuttles 1055 , 1056 , respectively, each containing empty frames F, as they are transported for insertion of new mail pieces and redeployment in the automated mail processing system.

Mail Frames

The present invention relates to individualized frames for mail pieces, such as letters and flats, for use in moving such mail pieces in a facility-wide mail processing system. Such frames are herein referred to as a “frame,” a “folder,” or a “frame/folder.” Each frame is constructed for the purpose of containing a single mail piece as the mail piece is sorted and sequenced with other such containerized mail pieces, or as they are stored for subsequent processing. Each mail piece is placed/inserted into a frame when inducted into the system, and removed/extracted from its frame during preparation for dispatch.

It is beneficial to be able to singulate, divert, sort, and sequence mail in the same format orientation that the mail is conveyed. Without this capability, the orientation of the mail may need to be changed or the mail piece stack may need to be “opened up” to perform mail operations. Since mail comes in all shapes and sizes, a reliable way to handle mail in a stack is to temporarily attach or encase each mail piece (e.g., letter, flat or parcel) to a frame to maintain singulation and facilitate the conveying and sorting of mail in a stack. This frame could be an individual mail piece container that follows the mail piece around through many processes (possibly even through transportation) or an individual clamp or clasp (as discussed in another section herein). The handling mail packaged in separate frames in a stack has the following advantages.

Every packaged mail piece has the same dimensions, e.g., the same form factor, regardless of the size of mail. The form factor is also optimized to ensure that mail of many sizes can be efficiently stored therein. Therefore, the frame provides the sortation/conveying equipment the same form factor thus preventing jams and providing other advantages as discussed herein. Mail pieces can be conveyed in a stack (less speed and greater throughput with fewer jams). Mail pieces can be sorted, filtered, and diverted efficiently, e.g., allows control of one mail piece in a stack. The frames maintain mail piece singulation, position and identification and provides protection for the mail pieces.

Within a given system, frames of different types can be utilized to accommodate letters and flats, e.g., which can vary in size and shape. However, the frames within a system have a standard shape-factor, which makes automated handling easier; although different shapes are also contemplated by the present as discussed in the instant application. A frame can be considered as a file folder. Its use as containerizing mail pieces prevents jams, eliminates mail damage, and maintains a reduced sorting speed vis-à-vis conventional systems which transport mail pieces along their lengths. According to a particular embodiment, frames can be vacuum-packed to detect/contain/minimize biohazards. Each frame has a unique identifier, i.e., an ID, such as a bar code, that is physically located on the frame.

To these and other ends, the invention relates to a mail piece frame adapted to maintain a single mail piece in a mail processing system, the frame including (1) a frame portion that includes at least a pair of portions adapted to be engaged by a driving mechanism, e.g., lead screws, belts, etc. for transporting a plurality of successive frames within the mail processing system, and (2) a folder portion having at least one portion movably connected to the frame portion, the folder portion having at least a portion movable relative to the frame between a first position for facilitating selective insertion and extraction of a single mail piece within the container, and a second position, wherein the folder portion is empty of any mail piece.

According to a particular aspect, the engageable portions of the frame are positioned to orient the frame during travel within the mail processing system other than in a direction along the length of the frame. In this manner, a stack of successive containers occupies a minimal length along the travel direction relative to known systems. More particularly according to that aspect of the invention, the aforementioned orientation of the frame is an angle of 45° with respect to the direction of travel.

According to various embodiments according to the invention, in the first position of the folder, insertion and extraction of the mail piece is facilitated. In the second position of the folder, no mail piece is contained in the folder and the folder has a minimized width.

According to another aspect of a mail container according to the invention, the frame is rigid and the movable portion of the folder is movable away from the rigid frame to the first position. According to a further aspect of a mail container according to the invention, the frame is generally rectangular and the folder is generally rectangular. In a particular embodiment, the movable portion of the folder portion is pivotable away from the rigid frame to contain a mail piece at a common connection between the frame and the folder.

According to another aspect, the frame includes at least one actuator tab adapted to be manipulated by a mechanism for moving the folder to the first position. According to a particular embodiment, the movable portion of the folder is slidable relative to the frame, the movable portion of the folder being maintained generally parallel to the frame during movement to the first position. According to another aspect of the invention, at least one opening is maintained between the frame and the folder for insertion and extraction of a mail piece relative to the frame. Such an opening is located at a top and/or at a side of the container.

The individualized frame for each piece of mail (i.e., a letter or a flat), generally referred to herein as a frame (alternatively, as a folder or a frame/folder), can take any of various forms, including those further described herein and depicted in various drawing figures. As described elsewhere herein, the system sorts and sequences such containerized mail pieces, ultimately resulting in the placement of the mail pieces into trays for delivery by a postal carrier.

As described elsewhere herein, each mail piece is inserted into a frame. The process of inserting a mail piece into a frame is called “insertion”.

In a particular embodiment, in which the frame has a generally rectangular shape, the frame is conveyed via four lead screws, one positioned at each of the corners of the rectangle, as shown elsewhere herein. The lead screws turn synchronously to move the frames through the system. As mentioned above, successive frames are oriented at 45° to the direction of travel. Due to this stack orientation, the spacing between frames (center to center) can be very small. Therefore, high mail piece throughput can be achieved at low transport speeds, particularly relative to known mail transport systems, whereby the mail pieces are conveyed by pinch belts along their lengths, rather than at 45°. Although the invention encompasses transporting the frames at angles other than 45°, advantages are realized within the system, as explained elsewhere herein, with that angle.

As the thickness of the frame increases, or as spacing between frames increases, the transport speed can also be increased in order to achieve constant throughput. Furthermore, increased frame thickness requires an increased storage space. For these reasons, the thickness of individual frames should be as thin as possible.

Further, the invention encompasses a system containing multiple, e.g., millions, of frames. Therefore, in order to minimize the cost and weight of the system, the cost and weight of individual frames should be minimized. The physical dimensions of mail pieces handled by a system according to the invention can vary widely. Exemplary ranges of dimensions for letters and flats are the following:

Because of this wide dimensional range of mail pieces, the system can be implemented with the simultaneous use of multiple frame designs or structures, i.e., non-identical frames. For example, the system can use frames of both a “heavy-duty” design as well as frames of a “light-weight” design. In such a scheme, all letters and some thin light flats can be transported/processed in light-weight frames, and the remaining heavy, thick flats can be transported/processed in heavy-duty frames. In addition to mail pieces, the invention encompasses the transportation and processing of other articles, such as, but not limited to, sheets of paper, metal, wood, plastics, etc., as well as CD's, DVD's, and/or their jewel cases, books, photographs, etc.

The simultaneous use of multiple frame designs has a number of advantages. For example, a heavy-duty design can be more robust, to handle the relatively larger flats. A light-weight frame could be employed only to carry small mail pieces and, therefore, it can be constructed thinner and less expensively than the heavier frame design, while still reliably performing its intended function. The relatively thin and inexpensive light-weight frame offsets the more robust and expensive heavy-duty frame, such that the average cost, size, and weight of the frames can be reduced and within limits specified by the user.

The thickness of an empty frame, i.e., one carrying no mail piece, and the distance between immediately successive threads, i.e., adjacent threads, on the lead screws can be sized such that empty frames can occupy successive threads with no gap. The thickness (e.g., front to back) of a frame containing a mail piece can be greater than that of an empty frame. According to particular embodiments, described in greater detail below, such increase in thickness can be manifested on only one side of the frame, rather than on both sides. Therefore, such increased thickness can thereby only require one successive empty thread, e.g., on the side to which the thickness expands, rather that requiring a successive empty thread on both sides of the frame.

Many alternative configurations and embodiments for the system are described herein. This includes various configurations for both insertion and extraction. In some configurations, mail pieces are inserted into the frames from the side. In other configurations, they are inserted from above. Similarly, in some configurations mail pieces are extracted from the frame from the side. In other configurations, they are extracted from the folder through the bottom.

The term “frame,” as generally used herein, can be considered an abbreviated version of the term “frame/folder,” the latter term implying a two-part construction that includes both a “frame” part and a “folder” part. In this context, the frame part gives the frame/folder its structural rigidity and engages the lead screws. The folder part can be generally regarded as that part of the frame/folder that captures and carries the mail piece, albeit, in certain embodiments, in conjunction with the frame part. Generally, the frame of a frame/folder is the more rigid of the two parts and the folder of a frame/folder can be generally regarded as the movable part of the two parts, such movement facilitating insertion and extraction of a mail piece with respect to the frame/folder. Movement of the folder part can be manifested as any of various forms of movement, such as pivoting movement in the form of a hinged connection, pivoting in the form of a parallelogram linkage connection, and movement by virtue of movable components within the folder. Still further, movement of the folder can be manifested by merely the deformability of the material of which the folder is composed.

All frames within a system use a similar design, or shape. In some embodiments, described in greater detail below, the frame is rectangular with tabs extending horizontally from each of four corners. A pin extends vertically from one or each of two top tabs. These pins facilitate the diverting and merging of the frames while engaged with the lead screws. The top and bottom of the frame can be knife-edged (or has a rectangular edge) in order to ensure positive engagement with the lead screws. It is contemplated that such edges might incur frictional wear due to their movement on the lead screws. Therefore, the edges can be made to be easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame.

A frame, according to particular embodiments according to the invention is approximately ⅛″ thick (0.125 in.; 3.18 mm) A rectangle is cut out of the center of the frame, such that the material remaining on all four sides of the cutout is approximately 0.5-1.0 in. (12.7-25.4 mm) in width. This cutout reduces the overall weight of the frame; although other dimensions and sizes, etc. are contemplated by the present invention. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. In some designs, the folder part also nests inside the frame part, thus further reducing the overall thickness. As an alternative to creating the frame by cutting out a rectangular center, the four sides can be constructed by welding or otherwise connecting them together at the four joints.

To ensure that the frame/folder expands in only one direction, many of the designs incorporate a piece of thin, inflexible material, attached to one side of the frame and covering the entire area of the cutout. This thin, inflexible material is referred to as a backer. In the following description, reference is made to exemplary embodiments of frames, folders, and frame/folder combinations illustrated in the various drawing figures.

FIGS. 11 Aa- 11 Ad show an accordion type of frame, having a frame part 11001 and a folder part 11002 . FIG. 11 Aa shows the frame in perspective; FIG. 11 Ab shows the frame in side view, in an open state; and FIGS. 11 Ac and 11 Ad show, in top views, the frame in a closed state and in an open state, respectively. The perspective view of FIG. 11 Aa shows a pleated or accordion hinge side 11003 of the folder part and an opposite side 11004 , which can be used for insertion or extraction of a mail piece, which can be made of a light-weight material, such as aluminum or cardboard, for example. This construction aids in insertion and extraction of a mail piece, whereby the folder part 11002 ensures that each mail piece is justified and does not protrude outside the folder part and into the frame part on the far side of the folder/frame. This construction also allows the folder to collapse to the ⅛-inch dimensional requirement, when empty and/or closed, as depicted in FIG. 11 Ac.

FIGS. 11 Ba- 11 Bf show various views of a frame/folder according to certain aspects of the invention. In various alternative embodiments, the frame/folder design in these views accommodates mail piece insertion and extraction in any direction. In one embodiment, the frame/folder includes a rectangular frame 11005 and a sub-frame, or folder, 11006 . FIG. 11 Bd shows the sub-frame 11006 removed from any attachment to the frame, and FIG. 11 Ba shows a front view of the frame/folder, with the sub-frame 11006 assembled onto the frame 11005 . The sub-frame of the frame/folder could be completely removed during insertion and/or extraction of mail pieces. Alternatively, the top of the sub-frame could be disconnected and opened, while the bottom remains fixed to the frame. In another alternative, the bottom of the sub-frame could be disconnected and opened, while the top remains fixed to the frame. In yet another alternative, both the top and bottom could remain fixed to the frame, but due to the flexibility of the spring steel, the sides could be opened. All of these options are made possible by the configuration of the spring-steel closure tabs on the sub-frame, such as upper closure tabs 11007 and lower closure tabs 11008 , and their associated closure slots on the frame, such as upper closure slots 11009 and lower closure slots 11010 (as discussed below).

The frame 11005 is rectangular, or generally rectangular, with tabs extending horizontally from all four corners, such as tabs 11011 and 11012 . A pin 11013 depends vertically from each of the top tabs 11011 . These pins facilitate the diverting and merging of the frame/folders while being transported via the lead screws. The top 11014 and bottom 11015 of the frame 11005 are knife-edged (or have rectangular edges) for ensuring positive engagement with the lead screws. These edges might incur frictional wear due to their movement on the lead screws. Therefore, one option is to make the top and bottom edges 11014 , 11015 easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11005 has a thickness of approximately ⅛ inch (0.125 in.; 3.18 mm); although other dimensions are contemplated by the invention. The frame can be made by cutting out the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. The cutout reduces the overall weight of the frame/folder. It also allows the mail piece to “nest” inside the frame, within the thickness of the aforementioned material, such that the overall thickness of the frame/folder, while carrying a mail piece, is minimized. In this design, the edges of the sub-frame do not nest within the frame. Rather the edges are positioned flush against the frame and, therefore, they add to the overall thickness.

To ensure that the frame/folder expands in only one direction, by virtue of movement of the sub-frame (i.e., movement of the folder part of the frame/folder), the frame 11005 of this embodiment incorporates a piece of thin inflexible material 11016 , attached to one side of the frame, which covers the entire area of the cutout. This thin, inflexible material 11016 is referred to as a backer. In a particular embodiment, the sub-frame 11006 (see FIG. 11 Bd, e.g.) is made of a thin, generally rectangular piece of spring steel. Actuation tabs, such as tabs 11017 , protrude from the sub-frame 11006 . They facilitate the opening and closing of the frame/folder. The sub-frame 11006 also has four closure tabs, i.e., upper tabs 11007 and lower tabs 11008 , which extend vertically from each corner of the sub-frame. The frame 11005 has four closure slots, i.e., upper closure slots 11009 (see FIG. 11 Be) and lower closure slots 11010 (see FIG. 11 Bc), i.e., one in each of the horizontal tabs. As shown in FIGS. 11 Ba, 11 Bb, and 11 Bf, the closure tabs 11007 , 11008 of the sub-frame are inserted and captured in the closure slots 11009 , 11010 of the frame 11005 . When a mail piece is contained within the frame/folder and the frame/folder is being processed through the system, all four closure tabs of the sub-frame are captured within their respective closure slots of the frame.

The frame/folder can be opened for mail piece insertion in at least three possible ways. In one embodiment, the actuation tabs 11017 on the sub-frame 11006 are caused to be moved away from the frame 11005 some small distance. The spring steel of the sub-frame flexes, thereby opening a gap for side insertion of the mail piece. All four closure tabs remain in their respective closure slots. Alternatively, this actuation may also be configured to open a gap at the top, allowing for top insertion of the mail piece.

In another embodiment, the top two closure tabs 11007 are caused to slide out of, and completely disengage from, their respective closure slots 11009 . This allows top or side insertion of the mail piece. After mail piece insertion, the closure tabs are caused to be re-inserted into their respective closure slots.

In a further embodiment, all four closure tabs 11007 , 11008 are caused to slide out of, and completely disengage from, their respective closure slots 11009 , 11010 . The frame 11005 and the sub-frame 11006 are thus completely disconnected and handled separately during the insertion process. This allows for insertion of the mail piece from any direction. After the mail piece is inserted, the closure tabs are re-inserted into their respective closure slots.

The frame/folder can be opened for mail piece extraction in three possible ways. In one embodiment, the actuation tabs 11017 on the sub-frame 11006 are moved away from the frame 11005 some small distance. The spring steel of the sub-frame flexes, opening a gap for side extraction of the mail piece. All four closure tabs 11007 , 11008 remain in their respective closure slots 11009 , 11010 .

In another embodiment, the bottom two closure tabs 11008 are caused to slide out of, and completely disengage from, the closure slots 11010 . This allows bottom extraction of the mail piece. After mail piece extraction, the closure tabs are re-inserted into their respective closure slots.

In a further embodiment, all four closure tabs are caused to slide out of, and completely disengage from, the closure slots. The frame and the sub-frame are thus completely disconnected and handled separately during the extraction process. This allows for extraction of the mail piece from any direction. After the mail piece is extracted, the closure tabs are re-inserted into their respective closure slots.

With reference to FIGS. 11 Ba- 11 Bf, the frame/folder design accommodates top or side insertion and side extraction of mail pieces. The frame 11005 is rectangular with tabs 11012 projecting horizontally from all four corners. A pin 11013 projects vertically downward from each of the two top tabs 11011 . These pins facilitate the diverting and merging of frame/folders while being driven by lead screws. The top 11014 and bottom 11015 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. Because these edges might incur frictional wear due to their movement on the lead screws, the edges can be made easily removable and replaceable, such that, as wear occurs, the edges can be replaced, rather than disposing of the entire frame/folder.

FIGS. 11 Ca- 11 Cd show an alternative frame/folder in accordance with aspects of the invention. FIG. 11 Ca depicts a front view of the frame/folder and FIG. 11 Cb depicts a rear view. This frame/folder shares certain attributes with other designs. For example, with reference to FIG. 11 Cb, it includes a rectangular frame 11025 , with horizontal tabs 11027 , 11028 and a large center cutout area. Similar to other designs, the sub-frame 11026 , or folder, has a thin flexible membrane 11031 , which allows for expansion to accommodate the mail piece. The membrane 11031 of the sub-frame is connected to the frame 11025 on all sides. The frame 11025 also has a thin backer 11032 . The backer could be made of a flexible material to allow for smooth bending for opening of the frame/folder, creating the bottom shelf 11039 as part of the whole of 11031 , 11032 , and 11039 . The backer is fixed to the frame 11025 on all four frame pieces. Alternatively, the backer 11032 could be made of an inflexible material to prevent protrusion into the negative direction by an included mail piece. A bottom shelf 11039 could be made of a similar or different inflexible and rigid material such as to support an included mail piece.

The thickness of the frame 11025 is approximately ⅛ inch (0.125 in.; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cut out of the center of the frame 11025 , such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. The cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. In this design, the sub-frame nests in the frame. Therefore, it does not add to the overall thickness. The left and right vertical members 11033 , 11034 of the frame 11025 have two thinned areas. These areas, in a particular embodiment, can be thinned to approximately 1/16 inch. They are positioned where the actuation tabs 11035 - 11038 of the sub-frame 11026 (discussed below) lay across the frame 11025 when the frame/folder is closed. The actuation tabs can also have a thickness of approximately 1/16 inch. Therefore, the actuation tabs can nest in the thinned areas, and the resulting thickness of the tabs upon the vertical members is about ⅛ inch. Alternatively, the tabs may not be a necessary attribute as the opening operation of the folder may be accomplished via a vacuum or suction cup gripping the folder's flat and smooth surface of 11031 or 11026 and moving in an opposite and upward direction.

For ensuring that the frame/folder expands in only one direction, this design incorporates a piece of thin, inflexible material 11032 , attached to one side of the frame 11025 , which covers the entire area of the cutout. This thin, inflexible material is referred to as a backer of the frame.

The folder can include a rigid rectangular sub-frame 11026 and a flexible membrane 11031 . The flexible membrane can flex to allow expansion to accommodate the thickness of a mail piece being inserted. The flexible membrane 11031 can be transparent. This provides the advantage of allowing an optical determination of the presence of a mail piece within a frame/folder. Actuation tabs 11035 , 11036 , 11037 , 11038 protrude from the sub-frame 11026 . They facilitate the opening and closing of the frame/folder. The flexible membrane 11031 can also form the bottom U-shaped pocket 11039 of the folder by extending from the bottom of the sub-frame 11026 to the bottom of the frame 11025 (or the bottom of the backer 11032 ).

Alternatively, the sub-frame 11026 can be made of a non-flexible material. The sub-frame 11026 is connected to the frame 11025 at all four corners. It is connected at each corner via hinges 11040 , 11041 . These hinges create a parallelogram linkage to allow for the sub-frame 11026 to extend away from the frame 11025 , or to collapse towards the frame, while remaining generally parallel to the frame. See, e.g., the perspective view of FIG. 11 Cc and the side view of FIG. 11 Cd, which shows the sub-frame positioned parallel to the frame, relative movement of which being controlled by manipulation of the actuation tabs of the sub-frame. This movement allows the opening of the frame/folder for mail piece insertion and extraction.

In an alternative embodiment of a frame/folder according to the invention, FIG. 11D illustrates a so-called “back door” opening folder. In this embodiment, the backer piece 11248 is attached only at the bottom edge 11247 of the frame 11245 and retains its normal vertical and tight to the frame orientation based on its spring properties. This backer allows spring flex along its vertical length but prevents conformance to include mail piece articles. A thin, conforming membrane 11246 comprises the folder area. This membrane is attached at all four sides of the frame. The folder membrane allows compliance for protrusion of mail piece to be in the positive direction as it is resisted upon by the non-conforming backer. Insertion and extraction may occur via side or top as the backer may be flexed away from the frame based upon its lower mounting and justification.

In a further embodiment, FIGS. 11 Ea- 11 Ec show a frame design with a two-part frame, one being a movable, sliding component 11045 and one being a static component 11046 . A mail piece is inserted from the top of the frame and extracted from the bottom. This frame enables an active insertion and semi-passive extraction operation. A feature of this frame design is that once the mail piece is gripped by the two components 11045 , 11046 , it is does not slide or alter its orientation within the frame due to gravity. When the mail piece is acted upon by gravity, it wants to move down, but because the sliding component 11045 has a rubbery surface 11047 , the mail piece will want to pull it down with it. Because the sliding component 11045 is mounted upon slanted sliding guides 11048 , the downward pull will also give the sliding component 11045 an additional clamping force to hold the mail piece.

The sliding component 11045 has a metallic frame structure 11049 . One side of the structure has a plate with a rubbery surface 11047 mounted thereon to maintain an inserted mail piece in position. Four holes 11050 are drilled at a downward angle through the frame structure and rubbery plate of the sliding component. The placement and angles of the holes correspond to those of the sliding guides 11048 on the static component.

The static component 11046 also has a metallic frame structure. However, it does not contain a rubbery surface like that of the sliding component. Instead, the static component 11046 has four sliding guides 11048 projecting from a surface thereof at an angle. These guides support the sliding component 11045 , and allow it to slide between open and closed positions. The static component 11046 has flanges 11052 so that it can travel between a set of four lead screws that lie above and below the frame.

FIG. 11 Ec schematically shows, with five successive illustrations, the operation of the frame of this embodiment. The frame begins closed, in the left-most illustration, with the sliding component 11045 resting on the sliding guides 11048 and pressed up against the static component's frame structure 11051 . An actuation from a bottom mounted plunger-like device or cam pushes the sliding component 11045 so that it slides upwardly along the sliding guides until the open position is reached and is maintained by the plunger or cam, as depicted in the second illustration from the left. In the open position, a gap 11053 has been created between opposing faces of the two components 11045 , 11046 . A mail piece M is inserted from above into the gap 11053 , as shown in the center illustration of FIG. 11 Ec, and removal of the plunger or cam allows the sliding component 11045 to a position forcing the mail piece against the static component 11046 , as shown in the next successive illustration. Because the sliding component is mounted on the angled sliding guides 11048 , the weight of the sliding component 11045 creates a horizontal force as well, holding the mail piece in place. As gravity pulls on the mail piece, it wants to move downward, but the sliding component has a rubbery or high friction surface so the mail piece wants to drag that down with the mail piece. The angled sliding guides 11048 convert this force into additional clamping force, ensuring that the mail piece does not slide away. Finally, when the mail piece needs to be extracted, another actuation opens the sliding component, as shown in the right-most illustration, and the mail piece m is free to fall out. The weight of the sliding component 11045 causes it slowly slide back into the closed position as the frame is made ready for the insertion of another mail piece.

FIGS. 11 Fa- 11 Fd show an alternative frame/folder design which accommodates top or side insertion and bottom extraction of mail pieces. As further described below, FIG. 11 Fa shows the frame/folder in an empty, collapsed position and FIGS. 11 Fb, 11 Fc and 11 Fd show the frame/folder in an open position.

With reference to FIG. 11 Fc, the frame 11065 of the frame/folder has a generally rectangular shape with tabs 11067 extending horizontally from all four corners. A pin 11068 extends vertically from each of the two top tabs; although in a contemplated embodiment, the pin can extend upwards from one or more of the corners and more preferably from an upper corner on a trailing edge of travel (which is contemplated by each of the embodiments). These pins facilitate the diverting and merging of frame/folders while in lead screws. The top 11069 and bottom 11070 of the frame 11065 is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges 11069 , 11070 incur frictional wear due to their movement on the lead screws, one option is to have the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11065 has a thickness of approximately ⅛ inch; although other dimensions are contemplated by the invention. The frame can be solid, with no cutout (as in embodiments described above), or it could be cutout with a thin inflexible material (i.e., a backer) positioned over the cutout. In this design, the folder does not nest in the frame. Rather, it is positioned flush against the frame and, therefore, it adds to the overall thickness of the frame/folder. The folder part of the frame/folder takes the form of a rigid rectangular sub-frame 11066 and a bottom ledge 11071 .

The sub-frame 11066 is connected to the frame 11065 on the left and right sides, as shown in FIGS. 11 Fa- 11 Fd, by one or more hinged lever-arms 11072 . These hinged lever-arms allow the sub-frame 11066 to be extended away from, or to be collapsed toward, the frame 11065 . This movement allows the opening of the frame/folder for mail piece insertion. The bottom ledge 11071 is the surface on which the mail piece rests. At its upper edge (in the collapsed position), the bottom ledge 11071 is connected to a slider 11073 and, at its lower edge, it is connected to a bottom support 11074 . Both of these connections are made via long hinges 11075 , 11076 , running the length of the bottom ledge 11071 . The bottom support 11074 is also hinged to the frame 11065 , via a long hinge 11077 , at its lower edge.

The slider 11073 is also fixed to the frame 11065 , such that it slides up and down along the frame. As the slider slides up, it pulls the bottom ledge 11071 and the bottom support 11074 toward the frame 11065 . This movement opens the bottom of the folder, such that the mail piece can be extracted. As the slider 11073 slides downward, the bottom ledge 11071 and the bottom support 11074 are pushed outward, to close the bottom of the folder. At their fully closed positions, the bottom ledge 11071 is horizontal and the bottom support 11074 is below the bottom ledge at approximately a 45° angle. In this position, the bottom support 11074 supports the bottom ledge 11071 and carries the weight of the mail piece.

In the closed position, the bottom ledge 11074 and the bottom support 11071 push upward on the sub-frame 11066 , and keep the sub-frame in its extended position. After the folder has been opened and the mail piece has been extracted, the sub-frame 11066 is allowed to collapse downward, due to gravity. In this empty, collapsed condition, the frame-folder is thinner. Therefore, it takes up less space in storage.

FIGS. 11 Ga- 11 Gc show an alternative frame/folder design which accommodates top or side insertion and side extraction of mail pieces. As further described below, FIG. 11 Ga shows the frame/folder in an empty, collapsed position and FIG. 11 Gb shows the frame/folder in an open position.

With reference to FIG. 11 Gc, the frame 11075 is rectangular with tabs 11077 projecting horizontally from all four corners. A pin depends vertically from each of the two top tabs 11077 (which can be extending upward from a single upper corner). These pins facilitate the diverting and merging of frame/folders while in lead screws. The top 11079 and bottom 11080 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to have the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame has a thickness of approximately ⅛ inch; although other dimensions are contemplated by the invention. It could be solid, with no cutout, or it could be cut out with a thin inflexible material (backer) in place of the cutout. In this design, the folder does not nest in the frame. Instead, it is positioned flush against the frame, and therefore adds to the overall thickness.

The folder includes a rigid rectangular sub-frame 11076 and a bottom ledge 11081 . The sub-frame 11076 is connected to the frame 11075 at the top two corners via hinged upper lever-arms 11082 . These hinged lever-arms allow the sub-frame 11076 to be extended away from, or be collapsed towards, the frame 11075 . This movement allows the opening of the frame/folder for mail piece insertion. The bottom ledge 11081 is the surface on which the mail piece rests. The bottom ledge 11081 is connected to the sub-frame 11076 via a long hinge 11083 , running along the lower edge of sub-frame. The bottom ledge 11081 is also connected to the frame, via two hinged lower lever-arms 11084 .

The configuration of the lower lever-arms 11084 is such that, when the frame-folder is open, i.e., in the position depicted in FIGS. 11 Gb and 11 Gc, the bottom ledge 11081 is horizontal and at the same level as the bottom lead screws. An advantage of having the bottom ledge at that level allows it to be externally supported during insertion of the mail piece. At the point of insertion, a robust, flat surface could be positioned between the bottom lead screws, such that the bottom ledge 11081 slides across the surface, and is supported by the surface. Therefore, as the mail piece is inserted, the momentum of the mail piece is absorbed by the surface, and does not have to be absorbed by the bottom ledge alone. When the frame-folder does not contain a mail piece, the frame-folder can be folded into its closed position, as depicted in FIG. 11 Ga. The hinged lever arms 11082 , 11084 , allow the sub-frame 11076 and the bottom ledge 11081 to be collapsed upwards, toward the frame 11075 . In this empty, collapsed condition, the frame-folder is thinner, and therefore it takes up less space in storage.

FIG. 11H shows an alternative frame/folder design in accordance with aspects of the invention. This frame/folder design accommodates top or side insertion and bottom extraction of mail pieces. The frame 11085 is rectangular with tabs 11087 projecting horizontally from all four corners. A pin may depend vertically from each of the two top tabs (or a single tab), as illustrated and described in prior embodiments. The pins facilitate the diverting and merging of frame/folders while engaged with lead screws. The top and bottom of the frame 11085 is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event these edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11085 has a thickness of approximately ⅛ inch (0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cut out of the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inches (approximately 12.7-25.4 mm); although other dimensions are contemplated by the invention. This cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. Although it has been noted with many embodiments that a cutout is provided, those of skill in the art should realize that the cutout may also be eliminated. In this design, the edges of the folder do not nest in the frame. Instead, the folder is positioned flush against the frame and, therefore, adds to the overall thickness. Alternatively, the folder could be constructed that it lays within the frame construct when closed and therefore does not add to the overall thickness.

To ensure that the frame/folder expands in only one direction, this design incorporates a piece of thin, inflexible material 11090 (such as spring steel), attached to one side of the frame and covering the entire area of the cutout. This thin, inflexible material is referred to as a backer.

The folder can include a rigid rectangular sub-frame 11086 and a flexible membrane 11091 . The flexible membrane can be flexible to allow expansion to accommodate the thickness of the mail piece. The flexible membrane 11091 can be transparent. This would have the advantage of allowing for optical determination of the presence of a mail piece within the frame/folder. Actuation tabs can be provided to protrude from the sub-frame 11086 . They would facilitate the opening and closing of the frame/folder. Alternatively, the sub-frame could be made of a non-flexible material.

The sub-frame 11086 is connected to the frame 11085 at the top-left and top-right corners via hinges 11092 . In a particular embodiment, two or three hinges are provided at each of the corners, such that the top of the sub-frame can be extended away from, or collapsed toward, the frame. This movement allows the opening of the frame/folder for mail piece insertion. The bottom of the sub-frame 11086 has multiple bottom tabs 11093 . The bottom of the frame has a matching number of catches 11094 . The bottom tabs 11093 are normally positioned inside the catches 11094 , such that the bottom of the frame/folder normally stays closed. For example, the bottom would be closed during insertion and as the frame/folder and mail piece travel throughout the system. At extraction, the bottom tabs are disengaged from the catches, to allow bottom extraction of the mail piece (such as by gravity). This disengagement occurs via lifting of the sub-frame 11086 , such that the bottom tabs 11093 are lifted up and out of the catches 11094 .

FIG. 11I shows, in a front view, an alternative frame/folder design in accordance with aspects of the invention. This frame/folder design accommodates top or side insertion and side extraction of mail pieces. The frame 11095 is rectangular with tabs 11097 projecting horizontally from all four corners. A pin may depend vertically from each of the two top tabs. The pins facilitate the diverting and merging of frame/folders while engaged in lead screws. The top 11098 and bottom 11099 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make these edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame has a thickness of approximately ⅛ inch (0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cut out of the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. This cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. In this design, the sub-frame nests in the frame. Therefore it does not add to the overall thickness.

On the inside corners of the cutout are four hooks 11100 . The folder 11096 has four elastic bands 11101 , one on each corner. The folder's elastic bands are wrapped, or looped, around the hooks to couple the folder 11096 to the frame 11095 . This elastic mounting is advantageous in that the folder may be vibrated, without the vibration being transferred to the frame 11095 . Other elastic constructions are encompassed for connecting the folder 11096 and the frame 11095 together for the same purpose.

The folder 11096 of the frame/folder of the illustrated embodiment is a V-shaped membrane, similar to a standard file cabinet folder. The folder is open along the top and along the sides. Therefore, insertion of mail pieces into the folder can be accomplished through the top or side. The mail piece is then retained in the bottom 11102 of the V-shaped membrane. A series of holes 11103 extend through the bottom region of the folder. They are positioned such that they extend above and below the bottom 11102 of the folder's “V”.

In the design of the frame/folder of FIG. 11I , mail pieces can be simultaneously extracted from a batch of frame/folders. Extraction of the mail pieces is accomplished in the following manner. Rods 11104 extend through the holes 11103 . More particularly, the rods 11104 are inserted at the bottom of the holes such that the top of the rods are below the bottom of the “V” and, therefore, below the bottoms of the mail pieces within the multiple frame/folders of the batch from which the mail pieces are extracted.

The rods 11103 are then moved slightly upwards, such that they lift the mail pieces out of the bottom of the “V”. In that position, the mail pieces rest upon the top of the rods 11104 . The rods 11104 are connected to a rotating mechanism, such that the rods are rotated around their longitudinal axes.

All of the rods 11104 rotate in the same direction. This rotation, occurring while the mail pieces are positioned upon the rods, pushes the mail pieces to one side, i.e., in the direction S, to the right in FIG. 11I , and out the side of the folder. In this manner, the mail pieces are extracted from the folder. The rods 11104 can have a circular cross section and extend straight along their lengths (i.e., extend perpendicularly of FIG. 11I ). In alternative embodiments, the rods can be differently shaped. For example, they can have a twisted shape along their lengths and/or they can have cam-shaped cross sections, which could impose a jostling action to the mail pieces. In any event, such shapes encompassed by the invention have the purpose of further facilitating the extraction of the mail piece by helping to push the mail piece to the side and out of the folder 11096 .

In an alternative embodiment, mechanical vibration of the folder 11096 can be utilized to assist in extracting the mail pieces from the folder. Such vibration would ensure that the mail pieces do not stick or adhere to the folder, if such were found to occur for any of a variety of reasons, such as humidity or the presence of a foreign substance on any of the mail pieces. Vibration could be accomplished in any of a number of ways. For example, the shape of the rotating rods and their associated holes can be such that when the rods rotate, they rub against the side of the holes, creating a vibration in the folder. Alternatively, additional rods, such as rods 11105 , can be employed to engage the folder 11096 in a different configuration, with the sole purpose of vibrating the folder. For example, such rods 11105 can be positioned to engage an arm 11106 that projects outside the frame and extends into folder 11096 and through the side of the frame 11095 .

FIG. 11J shows an alternative frame/folder design in accordance with aspects of the invention. This frame/folder design accommodates top or side insertion and side extraction of mail pieces.

The frame 11115 of the frame/folder is rectangular with tabs 11117 extending horizontally from all four corners. As in previously described embodiments, a pin may depend vertically from each of the two top tabs or a single tab on a trailing edge of travel. The pin(s) facilitate the diverting and merging of frame/folders while in lead screws. Also as in previously described embodiments, the top and bottom of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The folder 11116 of the frame/folder includes a front membrane 11116 a and a back membrane 11116 b . The membranes are connected to each other all along their common bottom edge. They are also connected at both top corners by means of glue or by means of other fasteners. For the purpose of allowing insertion of a mail piece from the top, the membranes are not connected along the majority of the length of the top edge. In addition, they are not connected along at least a side from which a mail piece is to be extracted. They may or may not be connected along the opposite side.

The frame/folder has four actuation tabs 11118 , 11119 , one at each corner. When the frame/folder is closed, the top actuation tabs 11118 point downwards, and the bottom actuation tabs 11119 point upwards. The actuation tabs are coupled to the frame via “living” hinges 11120 . In addition to the front and back membranes being connected to each other along a bottom edge, as mentioned above, the back membrane 11116 b is connected to the frame 11115 . The front membrane 11116 a is connected to the actuation tabs 11118 , 11119 , i.e., at both the top and bottom.

The frame/folder is opened via the actuation tabs. More specifically, the actuation tabs 11118 , 11119 are caused to flip from their vertical (closed) position to a horizontal (open) position. By moving from the closed to the open position, the actuation tabs cause the front membrane 11116 a of the folder to be moved away from the back membrane due to the lever-action of the actuation tabs and the living hinges 11120 . The front membrane 11116 a of the folder 11116 has a C-shaped cutout 11121 on one side. Through the C-shaped cutout 11121 , a vacuum pick-head engages an exposed portion the mail piece and extracts the mail piece in a direction out the side of the frame/folder. As explained elsewhere herein, such extraction can be accomplished by means of movement of the vacuum head itself or by the movement of the frame-folder by means of the lead screws while the vacuum head remains stationary but maintains the mail piece with vacuum engagement.

In an alternative embodiment, the C-shaped cutout continues through the back membrane 11116 b and the frame, rather than merely through the front membrane 11116 a . In this manner, a plurality of frame/folders can travel by a stationary vacuum pick-head, with the pick-head passing through the C-shaped cutouts.

FIGS. 11 Ka- 11 Kd show an alternative frame/folder design in accordance with aspects of the invention. This frame/folder design accommodates side insertion and side extraction of mail pieces.

The frame 11125 of the frame/folder is rectangular with tabs 11127 extending horizontally from all four corners. As in previously described embodiments, a pin may depend vertically from each of the two top tabs. These pins facilitate the diverting and merging of frame/folders while in lead screws. As in previously described embodiments, the top and bottom of the frame is knife-edged (or has a rectangular edge) in order to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The folder of the frame/folder includes two continuous, conveyor-style membranes, i.e., a pair of endless belts 11126 a , 11126 b , thereby forming a so-called “pinch-belt” folder. Membrane 11126 a forms the front of the folder and membrane 11126 b forms the back of the folder. Each of the membranes wraps around a pair of vertical, rotating rods; i.e., one rod on the left, and one rod on the right. As seen in the drawings, membrane 11126 a wraps around rods 11129 a , 11129 b and membrane 11126 b wraps around rods 11130 a , 11130 b . Attached to the outside of each membrane is a pull tab. Pull tab 11131 is attached to membrane 11126 a and pull tab 11132 is attached to pull tab 11132 is attached to membrane 11126 b . The pull tabs are made of an inflexible material. As a result of this configuration, as the pull tabs 11131 , 11132 are moved in a direction in or out relative to the frame/folder, and the membranes rotate about the rods, in the form of a pair of conveyor belts.

The membranes and their respective pull tabs can be in either of two positions, namely, a normal position and an extended position. The membranes and their pull tabs are in the normal position throughout most of the system's daily operations, such as during mail piece sequencing and storage. In the normal position, the pull tabs project just beyond one side of the frame/folder. In this normal position, the pull tabs are accessible to be engaged via mechanization, but do not stick out excessively, to minimize the risk of unintended snagging. The membranes and their pull tabs are in the extended position for a few moments during extraction and, in some embodiments, during insertion, to facilitate transfer of the mail pieces from (and, in some embodiments, to) the folder, as described below.

In certain embodiments, in preparation for mail piece insertion, the pull tabs 11131 , 11132 are engaged via mechanization and are pulled outward, so that they project relatively far from the folder. Then, as the mail piece is inserted into the folder, the membrane is rotated in the opposite direction, and the pull tabs move inward, as shown in the top view of FIG. 11 Kd, i.e., back to the normal position. The movement of the membrane is in the same direction as mail piece insertion, so that, during insertion, there is no relative motion or slip between the mail piece and the inside of the membrane.

In an alternative embodiment, the membranes and their pull tabs stay in the normal position throughout the insertion process. Thereby, in such embodiment, there is relative motion or slip between the mail piece and the inside of the membranes.

During extraction, the pull tabs are pulled from their normal position to their extended position. This movement serves to rotate the membranes about their rotator rods. The insides of both membranes, i.e., the sides contacting the mail piece, move in the same direction. Due to frictional forces between the mail piece and the insides of the membranes, the mail piece, thereby engaged, also moves in this direction. Thus, the mail piece is ejected from the folder, where it is then captured by other mechanization. After the mail piece is removed from the folder, the pull tabs are pushed back, i.e., inward, returning them to their normal positions, as depicted in the front and top view of FIG. 11 Kd.

FIGS. 11 La- 11 Ld show an alternative frame/folder design in accordance with aspects of the invention. This frame/folder design accommodates top insertion and side extraction of mail pieces.

The frame 11135 of the frame/folder is rectangular with tabs 11137 , 11138 extending horizontally from all four corners. As in previously described embodiments, a pin may depend vertically from each of the two top tabs 11137 . The pins facilitate the diverting and merging of frame/folders while in lead screws. The top 11139 and bottom 11140 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The folder 11136 of the frame/folder includes a front membrane 11136 a and a rear membrane (similar to the front membrane). The membranes are connected to each other throughout the extent of a common bottom edge. They are also connected at both top corners by means of glue or by means of other fasteners. For the purpose of allowing insertion of a mail piece from the top, the membranes are not connected along the majority of the length of the top edge. In addition, they are not connected along at least a side from which a mail piece is to be extracted. They may or may not be connected along the opposite side.

The frame/folder has two actuation tabs 11141 , one in each of the top corners. When the frame/folder is closed, the actuation tabs extend downward. The actuation 11141 tabs are coupled to the frame via living hinges 11142 . In addition to the front and back membranes 11136 a , 11136 b being connected to each other, the back membrane 11136 b is connected to the frame. The front membrane 11136 a is connected to the actuation tabs 11141 at the top and at the bottom of the frame.

The frame/folder is opened via the actuation tabs 11141 . More specifically, the actuation tabs are caused to flip from the vertical (closed) position to a horizontal (open) position. Thus, the front membrane of the folder moves away from the back membrane (at the top) due to the lever-action of the actuation tabs and the living hinges.

The inside of the folder has a slider 11148 built into it. The slider facilitates the extraction process. The slider can be in two positions, namely, a normal position and an extraction position. The slider is in its normal position throughout most of the daily operations, such as during mail piece insertion, sequencing, and storage. FIG. 11 Ld shows the slider moving to the normal position. During mail piece extraction, the slider is moved from its normal position to the extracted position, as depicted in FIG. 11 Lb. As the slider is moved to the extraction position, it pulls the mail piece out of the folder.

The slider has one or more pull tabs 11143 . When the slider is in its normal position, the pull tab(s) 11143 protrude slightly from the folder, on the extraction side. Thus, during extraction, the pull tabs can be engaged by mechanization, and pulled to move the slider into the extraction position.

The pull tab(s) 11143 are attached to one or more “horizontals” 11144 . The horizontals are housed by, and move within, tracks 11145 . The tracks are built into the inside of the folder. The horizontals are also attached to “pullers” 11146 . As the slider is moved to the extraction position, the pullers sweep through the folder, engaging the mail piece and moving it out the open side of the folder. The pullers and/or the horizontals are attached to the frame via an elastic material 11147 . After extraction of the mail piece is complete, the pull tab(s) 11143 is(are) released. The elastic material 11147 then serves to pull the slider back into the folder, from the extraction position to the normal position.

Variations of the frame/folders thus far described are also encompassed by the invention. For example, the frame can be made of plastic with metal and strip magnets and a soft membrane center for expansion. Further, the frame could be constructed with pins on the side in a downward fashion to support the folder, and a center pin in an upward fashion for driving the folder from the mid-point. Still further, the frame could be made rigid with a spring steel frame having a mid point restraint on each side, with a flexible membrane center, a stiff backer material, and actuation tabs on either side. As a still further variation, the frame could be made rigid with a spring steel frame, side and bottom restraint, flexible membrane center, a stiff backer material, and actuation tabs on one side.

Further still, the frame/folder could have a folder with living hinges all around. The top of the folder is opened using side tabs and living hinges on the top to drive the opening to its full open position via pressure between side tabs and top hanging mechanism. The folder bottom is opened via a mechanism that separates the bottom flaps and let the mail fall. The bottom flaps are held closed via memory in the living hinge material and also via small springs. Further, replaceable wear strips can be fitted at the top and bottom of the frames.

FIGS. 11 Ma and 11 Mb show a plastic frame with metal strips 11162 and magnet strips 11149 , with a soft membrane 11150 center for expansion. This frame/folder design accommodates insertion and extraction of mail pieces in any direction, i.e., such as at the top or either side. It includes two identical halves, which are not permanently coupled to each other, as shown in FIG. 11 Ma, and can therefore be separated from each other as necessary. In order to hold the mail piece, the two halves are combined and held together by magnets, such that one half is the front side of the frame/folder, and the other half is the back side.

Each half, one of which is shown in FIG. 11 Mb, is rectangular (or other shape) with tabs 11151 extending horizontally from two adjacent corners. The edges with these two horizontal tabs can be where the frame/folder engages the lead screws. The edge might be knife-edged (or have a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder. As noted above, one or more pins can extend upward from the tabs in order to facilitate the diverting of the mail pieces.

Each half can have a thickness of approximately 1/16 inch (0.0625 in.; 1.59 mm), such that the frame/folder has a thickness of about ⅛ inch (approximately 0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cut out of the center of each half, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (approximately 12.7-25.4 mm); although other dimensions are contemplated by the invention. This cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. Instead, it is positioned flush against the frame and, therefore, adds to the overall thickness.

The cutout in each half is covered by a thin material 11150 , in order to contain the mail piece while adding minimal thickness. Either both halves could have an inflexible material, or both could have a flexible material, or one could have a flexible material and the other could have an inflexible material. The thin material can be transparent. This would have the advantage of allowing for optical determination of the presence of a mail piece within a frame/folder.

Two actuation tabs 11152 protrude from each half. They are parallel to the horizontal tabs and are located near the other end of the half. They facilitate the opening and closing of the frame/folder.

Each half has two magnetic strips 11149 and two ferrous metal strips 11162 fixed on the side that will face the other half (or other count). The four strips form a rectangle around the cutout. The magnetic strips 11149 are on adjacent sides to each other (i.e. they are at 90° to each other). Similarly, the metal strips 11148 are on adjacent sides to each other. The remainder of the half is made of plastic, or some other non-ferrous material, such that the magnets do not interact with it. One advantage of this type of frame is that the two halves can be mated together as a part of the mail insertion process.

Two halves are combined to form the frame/folder, as shown in FIG. 11 Ma. They are combined with one of the halves upside-down from the other; such the horizontal tabs from one half are on top, and the horizontal tabs from the other half are on bottom. They are combined with the magnets and metal strips facing each other, such that the attraction between them holds the two halves together. In an alternative embodiment, the metal strips are replaced with magnetic strips, with their polarity in the opposite direction of the original magnetic strips. Therefore, when the halves are combined, the polarity of the original magnetic strips and the new magnetic strips are aligned such that they will be attracted to each other, thus holding the two halves together.

FIG. 11N illustrates an embodiment of a folder according to the invention. A specific frame is not shown, but a wide variety of possible frame designs can be utilized with the folder. This folder design accommodates top insertion and bottom extraction of mail pieces. More specifically, FIG. 11N shows an embodiments of an individual container, i.e., folder, for sorting mail in accordance with aspects of the invention (without the frame). The folder design includes living hinges all around. The top 11153 of the folder is moved to an open position using side tabs 11154 . Living hinges 11155 on the top drive the opening to its full open position via pressure between side tabs 11154 and a top hanging mechanism. The folder bottom includes doors 11156 opened via a mechanism that separates the bottom flaps 11157 and allows the mail fall from within the folder. The bottom flaps are held closed via memory in the living hinge material, i.e., elastic, and also via small springs.

Most of the folder is made from a single piece of molded plastic. Two thin, flat, rectangular portions form the front and back sides of the folder. Since both sides of this folder are made of relatively rigid molded plastic, the thickness of the folder expands with the width of the mail piece, and both sides remain straight, flat, and in parallel planes (neither side deforms with the mail piece).

Each of the left and right edges of the folder is formed with a living hinge (expanding and contracting flaps or a fold line throughout) 11158 . There are also living hinges 11153 , 11155 on the top of the folder, i.e., at the far left edge and the far right edge. The space between the living hinges 11153 , 11155 serves as the top opening to allow top insertion of a mail piece. As the living hinges flex back and forth, the front and back sides of the folder move nearer or farther from each other.

The bottom of the folder is formed by two doors 11156 , one attached to the front side of the folder, one attached to the back side of the folder. The bottom doors are attached to the front and back sides via living hinges 11159 . These living hinges are biased to be maintained in a closed position. The doors may also be kept closed by springs 11160 connecting the doors to each other at the far right and far left. Therefore, the doors normally stay closed, and open only when actuated by the actuation tabs 11157 .

The folder has two top actuation tabs 11161 , four side actuation tabs 11154 , and four bottom actuation tabs 11157 . The folder is opened via the top and side actuation tabs to allow top insertion of a mail piece into the folder. To allow for bottom extraction of the mail piece, the bottom of the folder is opened via the four bottom actuation tabs. The folder can also include pins as noted above.

FIG. 11O shows embodiments of individual containers for sorting mail in accordance with aspects of the invention. A rigid frame 11165 is shown with spring steel folder 11166 , mid point restraint on each side, flexible membrane center, stiff backer material, and actuation tabs on either side.

This frame/folder design accommodates top insertion and bottom extraction of mail pieces. The frame 11165 is rectangular with 11167 , 11168 tabs extending horizontally from all four corners. A pin 11169 depends vertically from each of the two top tabs 11167 . The pins facilitate the diverting and merging of frame/folders while in lead screws. Again, this may also be a single pin which extends upward from a trailing edge of direction, as well as any combination of embodiments noted above. The top 11170 and bottom 11171 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make the edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11165 has a thickness of approximately ⅛ inch (0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cutout of the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. This cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. In this design, the edges of the folder do not nest in the frame. Instead, it is positioned flush against the frame and, therefore, adds to the overall thickness.

To ensure that the frame/folder expands in only one direction, this design incorporates a piece of thin, inflexible material 11172 , for example but not limited to spring steel, attached to one side of the frame and covering the entire area of the cutout. This thin, inflexible material is referred to as a backer. The folder includes a semi-flexible, for example but not limited to spring steel sub-frame 11166 and a flexible membrane 11173 . The flexible membrane can be transparent. This has the advantage of allowing for optical determination of the presence of a mail piece within the frame/folder. Actuation tabs 11174 protrude from the sub-frame. They facilitate the opening and closing of the frame/folder.

The membrane 11173 is flexible for allowing expansion to accommodate the thickness of the mail piece. The sub-frame 11166 hinges at two hinge points 11175 . These hinge points are located approximately half way down the vertical sides of the subfolder 11166 . These hinge points are also the points at which the sub-frame 11166 is connected to the folder. The top of the sub-frame is hinged open via the top actuation tabs 11174 to allow top insertion of a mail piece into the frame/folder. The bottom of the sub-frame is hinged open via the bottom actuation tabs 11176 to allow bottom extraction of a mail piece from the frame/folder.

The sub-frame 11166 can be made of spring steel, such that after being opened, as the actuation tab is released, the subfolder automatically closes by the elasticity of the sub-frame. Alternatively, the frame/folder can be held closed by magnets mounted on the frame and/or the sub-frame. The magnets could be thin, long strip magnets.

FIGS. 11 Pa- 11 Pd show an alternative embodiment of a frame/folder in accordance with aspects of the invention. The rigid frame 11185 , shown in FIG. 11 Pc removed from the sub-frame 11186 of FIG. 11 Pd, is made of steel, has side and bottom restraint, a flexible membrane center, stiff backer material, and actuation tabs on one side.

This frame/folder design, shown in FIG. 11 Pa (in a front view) and in FIG. 11 Pb (in a rear view), accommodates top or side insertion and side extraction of mail pieces, from one side only. The frame 11185 is rectangular with tabs 11187 , 11188 extending horizontally from all four corners. A pin 11189 depends vertically from each of the two top tabs 11187 . The pins facilitate diverting and merging of frame/folders while in lead screws. The top 11190 and bottom 11191 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make these edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11185 has a thickness of approximately ⅛ inch (0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cutout of the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. The cutout reduces the overall weight of the frame/folder. It also allows the mail piece to nest inside the frame, such that the overall thickness is minimized. For this design, on the inside edge of the frame, portions 11193 of the frame are thinner, having a thickness of approximately 1/16 inch (0.0625; 1.59 mm); although other dimensions are contemplated by the invention. The sub-frame 11186 , shown removed from the frame in FIG. 11 Pd, is mounted flush against the thinner portions of the frame 11185 . See FIG. 11 Pa. The sub-frame is also approximately 1/16″ thick; although other dimensions are contemplated by the invention. Therefore, the total thickness where the frame and sub-frame meet is only about ⅛″ thick; although other dimensions are contemplated by the invention. There are also two thin ( 1/16″ thick) regions 11194 , or cutouts, on the frame to accommodate the ( 1/16″ thick) actuation tabs 11192 , such that the frame/folder is only ⅛″ thick where the actuation tabs cross the frame; although other dimensions are contemplated by the invention.

To ensure that the frame/folder expands in only one direction, this design incorporates a piece of thin, inflexible material (possibly spring steel), attached to the back side of the frame and covering the entire area of the cutout. This thin, inflexible material is referred to as a backer. The backer can be transparent. This has the advantage of allowing for optical determination of the presence of a mail piece within a frame/folder.

The folder of the frame/folder includes a rigid rectangular sub-frame 11186 and a flexible, stretchable membrane 11196 . The sub-frame 11186 also has a horizontal member 11197 and a vertical member 11198 that form a cross. This cross gives the sub-frame additional rigidity, and helps support the flexible membrane 11196 . The sub-frame is constructed of a flexible, springy material, such as spring steel. The flexible membrane can be transparent. This has the advantage of allowing for optical determination of the presence of a mail piece within a frame/folder. Actuation tabs 11192 , 11192 protrude from the sub-frame on one side. They facilitate the opening and closing of the frame/folder.

The stretchable, flexible membrane is elastically deformable for allowing expansion to accommodate the thickness of a mail piece. The sub-frame 11186 is fastened to the frame 11185 at connection points 11198 along the bottom and on one side. Any of a variety of connection methods and fastening types could be used. For example, such fasteners include screws, nuts and bolts, high strength adhesives, or spot welds. The connections can be made at discrete points (such as spot welds) or continuous strips (such as a linear continuous weld). The connections could extend across the entire bottom and entire side, or they could connect only some portion of the bottom or side. The frame/folder is opened via the actuation tabs to allow top or side insertion of a mail piece into the frame/folder. It is opened in the same manner to allow side extraction of the mail piece. The sub-frame is flexible and springy (and could be made of spring steel), so that after being opened, as the actuation tab is released, the subfolder automatically closes by the elasticity of the subfolder.

FIG. 11Q shows an embodiment of a frame/folder in accordance with aspects of the invention. This frame/folder design accommodates side insertion and side extraction of mail pieces.

The frame 11205 of the frame/folder is rectangular with tabs 11207 , 11208 extending horizontally from all four corners. A pin 11209 depends vertically from each of the two top tabs 11207 . The pins facilitate diverting and merging of frame/folders while in lead screws. The top 11210 and bottom 11211 of the frame is knife-edged (or has a rectangular edge) to ensure positive engagement with the lead screws. In the event the edges were to incur frictional wear due to their movement on the lead screws, one option is to make these edges easily removable and replaceable, such that as wear occurs the edges can be replaced, rather than disposing of the entire frame/folder.

The frame 11205 has a thickness of approximately ⅛ inch (0.125 in; 3.18 mm); although other dimensions are contemplated by the invention. A rectangle is cut out of the center of the frame, such that the material remaining on all four sides of the cutout has a width of approximately 0.5-1.0 inch (12.7-25.4 mm); although other dimensions are contemplated by the invention. This cutout reduces the overall weight of the frame/folder. It also allows a mail piece to nest inside the frame, such that the overall thickness is minimized. In this design, the edges of the folder do not nest in the frame. Instead, the folder is positioned flush against the frame, and therefore adds to the overall thickness.

To ensure that the frame/folder expands in only one direction, this design incorporates a piece of thin, inflexible material 11212 (such as spring steel) attached to one side of the frame and covering the entire area of the cutout. This thin, inflexible material is referred to as a backer.

The folder includes a rigid rectangular sub-frame 11206 . The sub-frame may be made out of plastic. The sub-frame has two long, horizontal hinges 11213 at the top, and two more hinges 11214 at the bottom. These hinges can be living hinges. The very top and the very bottom of the sub-frame are mounted flush to the frame. In this hinge configuration, weight of the mail piece and the sub-frame tends to hang downwards and moves the sub-frame closer to the frame. Therefore, the frame/folder is biased closed by gravity and is thinnest in this closed position.

A portion of the sub-frame 11206 has a cutout 11215 . The area of the cutout allows an “end-effecter” or vacuum pick-off head to act through the sub-frame on the mail piece. Such action can be that for extracting a mail piece from the frame/folder. The end-effecter can utilize vacuum, friction, or some other means to extract the mail piece. Alternatively, such end-effecter could serve to push and/or pull the mail piece.

The cutout 11215 can have any of a variety of patterns in accordance with the invention. For example, it could be rectangular, circular, an elongated slot, be oval shaped, diamond shaped, or triangular. It could also be a pattern of multiple shapes. For example, the cutout could comprise multiple horizontal slots. The cutout could also be in any of a variety of positions. For example, the cutout could be in a bottom corner, with all the mail pieces justified to that corner of the frame/folders. It could also be across the entire bottom of the sub-frame. This cutout would have the additional advantage of allowing for optical determination of the presence of a mail piece within a frame/folder.

In certain embodiments, this frame/folder design would open for extraction via vacuum suction serving to pull the sub-frame and/or the mail piece away from the frame. In other embodiments, the sliding motion of the mail piece will sufficiently wedge open the folder for extraction. In other embodiments, actuation tabs can be connected to the sub-frame to allow opening the frame/folder for extraction.

FIG. 11R shows, in a front view, an alternative frame/folder in accordance with aspects of the invention. This frame/folder 11225 can be configured to share certain attributes with other designs, but it is particularly adapted to be used with a right angle divert (RAD) of a roller conveyance system, shown in FIG. 9U , where a frame/folder F, like that of 11225 , is depicted. The frame hangs from horizontal tabs 11227 , which tabs are supported on respective sets of rollers. Between the tabs 11227 , the top of the frame is recessed at 11228 to prevent interference with rollers as the frame passes through the divert, as shown in FIG. 9U . One or both of the horizontal tabs may have a vertical pin 11229 protruding upward. One or more vertical pins 11230 may protrude downward. While the frame passes through a divert, the pins travel in guide tracks. The guide tracks include a cam-diverting mechanism. The cam directs the pin down either the divert track or the main track, thus causing the frame to either divert or go straight.

FIG. 11S shows an alternative frame/folder in accordance with aspects of the invention. This frame/folder 11235 can be configured to share certain attributes with other designs, but it is particularly adapted to be used with a right angle divert (RAD) of a pinch belt divert mechanism and tooth belt conveyance system, shown in FIGS. 9O and 9P , where a frame/folder F, like that of 11235 , is depicted. The frame 11235 includes horizontal tabs 11237 , each of which having a downwardly projecting vertical pin 11238 which engage the toothed belts on each side, which support and transport the frame. As explained in connection with FIGS. 9O and 9P , when the frame is to be diverted, it is lifted out of the toothed belts and engaged by intermediate friction belts via a center top pin 11239 . The friction belts support the frame and transport it until it is above the toothed belts of the new pathway. When the vertical downward pins are over the toothed belts of the new pathway, the friction belts release the center pin 11239 , such that the frame drops into the toothed belts, and commences to travel along the new pathway.

As shown in FIG. 11T , the mail piece frame is made of thin plastic film (e.g., polyfilm), monofilament line and several hooks. It also would be large enough to contain (length of 15″ and height of 12″) the largest flat mail piece. Its overall thickness of the empty frame should be negligible to minimize storage space. Because of the way the frame is folded, as the extraction rod shown in FIG. 11T is raised, the mail piece is also raised. The mail piece is extracted when the extraction rod is fully raised. A mail piece holder is constructed to hold many frames side by side. The extraction rod can be raised to about an inch of the top when the mail is to be delivered by a postal carrier. This is enough to still hold the mail piece captive, but will allow the carrier to thumb through the addresses. Therefore the mail piece frame does not need extensive machinery to extract the mail piece.

FIG. 11U shows an alternative embodiment of the frame. As shown in FIG. 11U , the frame has expandable ribs running up and down that are spaced to allow a device to vacuum unload the mail from the frame. As such, the frame should be expandable to hold the largest width of mail piece (1.3″). Mail pieces that are thicker than 0.25 inches on the transport or 0.125 in the storage area would use the same expandable container, but the system would allocate more than one slot to prevent interference with the container on the next slot on the conveyor.

As also shown in FIG. 11U , the frame includes alignment tabs, sidewall alignment surfaces and sideway movement gear teeth. The alignment tabs, sidewall alignment surfaces provide for alignment in the container and on the conveyor, respectively. The gear teeth allow for sideway movement, e.g., for movement onto other conveyors, using a gear and worm system, known to those of skill in the art. The frame additionally includes a capture latch and movement initiation mechanisms. The capture latch may be conveying on the conveyor or holding in the container.

Using the frame embodiment of FIG. 11U , for example, the mail piece frame can ride on a conveyor at 45 degrees. The frame of FIG. 11U can be transported on two conveyors at right angles, with a threaded rod and a belt with timing nubs. As such, the frame can be conveyed primarily with a Teflon timing belt (cogged belt) with nubs designed to keep the containers in alignment. Assisting also in keeping the alignment is a designed threaded rod. When the mail piece is being conveyed down the conveyor, threaded rods are over the “forward movement divots” in the container (See, FIG. 11V ). The outer threads on the rods only the frame when it gets slightly out of alignment. Because of the divots the inner teeth on the rod do not touch the frame. When the frame needs to be conveyed sidewards, a solenoid initiated pin contacts the “movement initiated hammer zone” on the side of the container. This stops the forward motion of the frame and initiates the sideward motion. As the frame moves sidewards, the inner teeth of the threaded rods contact the “sidewards movement gear teeth”. The movement of the threaded rod mates with the gear teeth and reliably diverts the container off the conveyor. A similar threaded rod and timing belt is waiting to capture and move the container.

Output Packaging of Mixed Mail Pieces

The present invention relates to an apparatus for the output packaging of mixed mail pieces. More particularly, the invention provides for the collection of mail pieces into one homogenous mass for handling and/or transportation after such mail pieces, such as letters and flats, have completed processing within a mail processing system. In this regard, the invention allows mail pieces of mixed dimensions to be collected into a uniform stack and then be moved into a transportable container. Moreover, the apparatus of the invention provides for mixed mail pieces to be intermixed and handled automatically into a transportation container or packaging.

To these and other ends, the invention relates to an apparatus for output packaging of mixed mail pieces after the mail pieces have completed processing in a mail processing system. More particularly, the apparatus includes a staging area for receiving a stream of stacked mixed mail pieces, a stream of empty containers, each of the empty containers being adapted to contain a predetermined segment of the mixed mail pieces, and a plurality of stack-segmenting elements movable selectively and individually from outside the stream of stacked mail pieces to within the stream, whereby a containerable stack segment is created at the staging area by at least a downstream one of the stack-segmenting elements and an upstream one of the stack-segmenting elements. The apparatus further includes a slide panel for receiving, from the staging area, the containerable stack segment held by the upstream and downstream stack-segmenting elements, the slide panel being movable from a receiving position to a releasing position, whereby movement of the slide panel to the releasing position exposes the containerable stack segment held by the upstream and downstream stack-segmenting elements to one of the empty containers. The stack segment is then released by the stack-segmenting elements and the stack segment is positioned within the one of the empty containers.

According to a particular embodiment, the plurality of stack-segmenting elements takes the form of a plurality of paddles selectively positionable within the stream of mixed mail pieces. The paddles are effective for maintaining the perpendicularity of the mail pieces relative to a reference support surface. More particularly, according to such embodiment, the plurality of paddles includes three such paddles. A first of the constitutes a downstream paddle for engaging a downstream end of the containerable stack segment, whereas second and third paddles are upstream paddles which are movable alternately to replace one another in positions for (1) retaining the stream of mixed mail pieces, and (2) creating the containerable stack segment with the downstream paddle.

According to another aspect of the invention, the stream of empty containers is positioned along a path lower than a height of the slide panel. Thereby, successive ones of the empty containers are positionable directly beneath the slide panel, whereby the release of the containerable stack segment by the stack-segmenting elements allows the stack segment to fall by means of gravity into the one of the successive ones of the empty containers. In a particular embodiment, the slide panel is movable to the release position in a direction away from containers containing respective mixed mail stack segments.

According to a particular embodiment, each of the empty containers has a volume substantially equal to a volume of respective ones of the containerable stack segments formed by the apparatus. Further according to a particular embodiment, the containerable stack segment is held by the upstream and downstream stack-segmenting elements by means of pressure applied toward each other to compress the stack segment. Further, the stack segment is released by means of the upstream and downstream stack-segmenting elements releasing the pressure.

The present invention contrasts with conventional mail-processing systems, in which mail pieces are not processed and outputted in a mixed mail stream having a variety of dimensional characteristics. Rather than requiring human intervention to containerize the processed and outputted mixed mail pieces, the present invention provides an automated apparatus for receiving and containerizing such mixed mail stream.

In this regard, and with reference to FIG. 12 , a stream of mixed mail pieces 1201 enters a staging area 1209 of the conveyor apparatus, such mail pieces having been stacked by means of a mixed mail stacker arrangement (not shown), which is well-known to those skilled in the art and common in the mail processing industry. According to the invention, through the use of a plurality of stack-segmenting elements, here in the form of three paddles 1202 , 1203 , and 1204 , the mail stack 1205 is managed to a size that can be accommodated by the transportable container 1207 to which it is advanced. That is, the paddles create a containerable stack segment having a volume substantially equal to a volume of respective ones of the transportable containers. In addition, the paddles 1202 , 1203 , and 1204 maintain perpendicularity of the mail pieces with reference to a reference support surface, such as the mail stacker's bottom plate or deck. The paddles can be driven, e.g., rotated, by use of a solenoid or a gear system, both known to those of ordinary skill in the art.

When the process according to the invention is initiated, the paddle 1204 can be considered a downstream paddle and is positioned just beyond the upstream paddle 1202 . As the stream of mixed mail pieces 1201 advances and the mail stack 1205 has reached a predetermined size for the transportable container 1207 , paddle 1203 is moved down into place in the front of the mail stack 1205 , thereby separating the desired mail stack 1205 from the influx of new mail pieces 1201 . The sized mail stack 1205 is conveyed to a slide panel 1206 between the paddles 1202 and 1204 . The paddles 1202 and 1204 slightly compress the mail stack 1205 by being moved closer together and they move in unison towards the slide panel 1206 with the sized stack 1205 .

A stream of empty transportable containers 1207 is fed by means of a conveyance such as, for example, driven rollers or a belt drive, slightly below the level of the slide panel 1206 . An empty transportable container 1207 is in direct vertical position under the slide panel 1206 so that the mail stack 1205 can be dropped into the container. The slide panel 1206 is made to slide in the direction of required mail edging. This action ensures that mail pieces are maintained justified to the desired edge. Additionally, the direction of travel of the slide panel 1206 is such that it becomes positioned over the empty transportable container 1207 . That is, the slide panel is not moved in the direction of filled transportable containers 1208 , so that the slide panel 1206 does not compete for space occupancy with mail pieces in the filled transportable containers 1208 , exposing the compressed mail stack 1205 to the empty transportable container that is in direct vertical position beneath the slide panel 1206 . The paddles 1202 and 1204 , which have maintained the stack 1205 in position, are then driven slightly away from each other, thereby releasing the compression force on the mail stack 1205 and allowing the force of gravity to drop the homogenous mass into the awaiting empty transportable container 1207 .

Once the mail stack 1205 has dropped into the transportable container 1207 , the slide panel 1206 is returned to its original position to receive a successive stack of mail pieces. The filled transportable container 1208 is moved in the same direction of travel as the empty transportable container 1207 had been directed by the conveyance. The paddle 1204 is moved to slip in place behind the upstream paddle 1203 that retains the new influx of mail, thereby creating a new mail stack 1205 , while the other upstream paddle, i.e., paddle 1202 , rotates up and moves forward into a position in preparation of separating the newly created mail stack 1205 from the continuing influx of new mail pieces 1201 .

During the above-mentioned output packaging of mixed mail pieces, the paddles are moved in the following manner. Paddle 1204 waits behind paddle 1202 or 1203 . Paddle 1202 or 1203 then separates the new influx of mail pieces from the desired mail stack. The upstream paddles 1202 and 1203 then alternately replace one another as the operation of a paddle that separates the influx of new mail 1201 from the desired mail stack 1205 , and the operation of a paddle that compresses, conveys, and decompresses/drops the desired mail stack 1205 in conjunction with paddle 1204 .

According to an additional embodiment, in place of the tray insertion and take-away conveyor system, a shrink sleeve bagging device can be installed at the end of the stacker. The shrink sleeve bagging device would then accept mail pieces directly into it, and use heat to shrink a thin plastic material around the mail stack, thereby packaging the mixed mail pieces into one homogenous mass package, similar to the means by which flat mail pieces are bundled or hay is baled.

The design of the apparatus here described allows for automatic sweeping of a filled mail stacker and transportable container filling. The apparatus here described can be utilized by any system that packages or containerizes mail piece-like articles, including single or multi-sheet documents, and has need to handle the multiplicity of pieces as one homogenous mass. This system can be used with any combination of mail pieces such as, for example, flats and letters, or can be used with folders/frames as described in the instant application.

Receiving Sort Plans and Configuration Information from a Centralized Sever in a Facility-Wide Sorting and/or Sequencing System

The invention is directed generally to mail handling and processing and, more particularly, to a method and system for receiving sort plans and configuration information from a centralized server in a facility-wide mail sorting and/or sequencing system. As the facility-wide mail and flats sequencing system may contain numerous interrelated subsystems having redundant components, a fault in any one component may cause any (or all) subsystems to route mail differently throughout the system. Accordingly, in embodiments, a sort plan server is provided to modify and distribute a sort plan to various subsystems. FIG. 1A may be representative of the sort plan server and subsystems in accordance with aspects of the invention.

For example, in accordance with aspects of the invention, a sort plan server may obtain a system-wide sort plan, determine the consequences of a path within the system being unavailable based upon system data from a system manager, compose individual subsystem specific versions of the sort plan based on the system data, and distribute the subsystem specific versions of the sort plan to the respective subsystems. In this manner, implementations of the invention provide the system manager the ability to acquire a system level sort plan, modify it as necessary for individual subsystems, and then forward it to the subsystems. Accordingly, in implementations, each subsystem server is directed to sequence mail pieces according to the sort plan and also to route mail pieces based upon system availabilities (or non-availabilities).

Within the conventional postal service paradigm, there is a centralized server for each processing and distribution center (P&DC) where all sort plans reside. This centralized server acts as a centralized repository for all sort plans for the P&DC, and distributes sort plans to individual Mail Processing Equipment (MPE) or Mail Handling Equipment (MHE) of the P&DC via a wide area network (WAN). These sort plans determine how mail will be sorted. For example, a sort plan controls the sorting and sequencing of the processed mail in a particular MPE or MHE. More specifically, in current mail processing systems, a sort plan determines which mail is forwarded to which pocket or holdout bin of a particular MPE or MHE.

In conventional systems, all sorting is done in independent islands of automation. Therefore all machines are independent, and each MPE or MHE retrieves its sort plans from the centralized server directly. Put another way, what is happening on one MPE or MHE does not affect the sorting taking place on another MPE or MHE. Moreover, in conventional systems, the postal service (e.g., USPS) creates sort plans for a specific machine (MPE or MHE) based upon addresses of mail that will be sorted using the specific machine. Once the postal service creates a sort plan for a particular machine for a particular group of addresses, the sort plan is run on the machine without modification and without regard to what is happening on other machines (MPE or MHE) in the P&DC.

However, in next generation sequencing systems, the sorting and sequencing of the mail may be accomplished by the paths in which the mail follows as it is processed, rather than by merely routing a mail piece into a designated output bin. For example, in the inventive facility-wide mail sorting and/or sequencing system described in this application, mail pieces may go through many subsystems, components, and paths before it is output as sequenced mail. For example, according to aspects of the invention, mail pieces may travel through any one of many presort accumulators, sequencing segments, storage segments, etc., while being arranged in a sequenced stream of mail pieces.

Moreover, in accordance with aspects of the invention, flats and letter feeders and sequencing elements are combined into machines as many subsystems, where each of these subsystems utilizes a sort plan. In embodiments, these machines may have many different sorting and sequencing subsystems, each with individual controllers running a sort plan that is distributed to the machine. Due to network topology, some subsystems are located physically on segregated data networks and may not have access to the facility WAN. For example, in embodiments of the facility-wide mail sorting and/or sequencing system, network flow of traffic is partitioned for efficiency reasons. Also, to control accessibility, some subsystems and/or components might be partitioned from the WAN. In such cases where access to the WAN is not available to a subsystem and/or component, the subsystem will not be able to access the centralized sort plan server to receive a sort plan. However, according to aspects of the invention, a sort plan server that does have access to the WAN can obtain the sort plan and distribute the sort plan to the various subsystems and/or components.

Furthermore, subsystem and component availability is a significant operational parameter in the facility-wide mail sorting and/or sequencing system. For example, in embodiments of the invention, the facility-wide mail sorting and/or sequencing system comprises many redundant paths, components, and subsystems. According to aspects of the invention, this redundancy allows mail to be routed to a different path, component, or subsystem when a particular path, component, or subsystem is unavailable (e.g., due to a jam, bottleneck, scheduled maintenance, etc.). Accordingly, in embodiments of the invention, in order to provide sort plans to remote components, and to coordinate sorting between the various interrelated subsystems and components, a sort plan server function is provided within the facility-wide mail sorting and/or sequencing system that obtains, controls, and forwards sort plans to the subsystems and/or components within the system.

FIG. 13 shows a block diagram of a system 1400 for implementing sort plans according to aspects of the invention. A centralized server 1405 is operated and maintained by the postal service (e.g., the USPS) and may be relied upon to create sort plans. The centralized server 1405 is available to plural P&DC via the WAN 1410 , as is known such that further explanation is not believed necessary.

According to aspects of the invention, a facility-wide mail sorting and/or sequencing system includes a sort plan server 1415 (e.g., system level sort plan server)_that has access to the centralized server 1405 via the WAN 1410 . The sort plan server 1415 may be implemented on the computing infrastructure of FIG. 1A . In this manner, the sort plan server 1415 can obtain a system-wide sort plan from the centralized server 1405 . In embodiments, the sort plan server 1415 is implemented in a computing infrastructure, such as that described with respect to FIG. 1A . For example, the sort plan server 1415 may comprise software and/or hardware arranged to perform the functions described herein. The sort plan server 1415 may be comprised in or communicatively connected to a system manger 1417 , as described in greater detail below and in other sections of this application.

In embodiments, the sort plan server 1415 is communicatively connected to subsystems of the facility-wide mail sorting and/or sequencing system, including one or more of the following subsystems, but not limited to, induction subsystems 1420 , sequencing subsystems 1422 , storage subsystems 1424 , transportation subsystems 1426 , and dispatch subsystems 1428 . The subsystems 1420 , 1422 , 1424 , 1426 and 1428 are described in detail in other portions of the application, such that further explanation beyond what is described below is not believed necessary. For clarity purposes only, the subsystems are described with reference numerals that may not be consistent with other sections of the application. This is done merely to place these subsystems in context with the present section and related components. However, those of skill in the art should realize that the subsystems described herein may be interchanged with the subsystems described in other sections of the instant application. The sort plan server 1415 may be connected to the subsystems 1420 , 1422 , 1424 , 1426 and 1428 in any suitable manner, including, but not limited to: Internet, intranet, LAN, wireless, etc.

In implementations of the facility-wide mail sorting and/or sequencing system, each subsystem may comprise a plurality of individual components. For example, the induction subsystem 1420 may comprise a plurality of presort accumulators 1430 a . . . n , the sequencing subsystem 1422 may comprise a plurality of sequencer segments 1435 a . . . n , and the storage subsystem 1424 may comprise a plurality of storage segments 1440 a . . . n . Although three components are shown, each subsystem 1420 , 1422 , 1424 , 1426 and 1428 may have any number of components. Moreover, the invention is not limited to the specific components shown (e.g., presort accumulators 1430 a . . . n , sequencer segments 1435 a . . . n , and storage segments 1440 a . . . n ); instead, it is contemplated that the subsystems will comprise other types of components besides those shown.

According to aspects of the invention, the system manager 1417 is operatively connected to each of the components such that the system manager 1417 can receive and/or gather data regarding the operation status of each component. For example, the system manager 1417 is configured and structured to detect or determine when a particular component is operating normally, is offline for any reason (e.g., maintenance), or is experiencing a problem (e.g., a jam). In embodiments, the sort plan server 1415 receives or obtains such system data from the system manager 1417 . In this manner, the sort plan server 1415 may operate to customize the system wide sort plan received from the centralized server 1405 , and to distribute the customized sort plan (or appropriate portions of it) to the various subsystems and/or components. The customization and distribution may be based upon the system data received from the system manager 1417 .

In embodiments, each subsystem 1420 , 1422 , 1424 , 1426 , and 1428 comprises a respective subsystem server (as represented in FIG. 1 ), which may receive the sort plan from the sort plan server 1415 and communicate appropriate control signals to the components included in the respective subsystem. Additionally or alternatively, each subsystem server may deliver a sort plan (instead of control signals) to one or more of its respective components. For example, in very large systems, sort plans may be delivered to both subsystems and components. The subsystem server(s) may also be implemented on the computing infrastructure of FIG. 1A .

FIG. 14A shows a block diagram of a hierarchical sort plan system within the inventive facility-wide mail sorting and/or sequencing system. Similar to the manner described in FIG. 13 , the sort plan server 1415 receives a system wide sort plan from centralized sort plan server 1405 . Also, similar to FIG. 13 , the sort plan server 1415 may modify the system wide sort plan based upon system data obtained from the system manager. However, the sort plan server 1415 need not modify the system sort plan if modification is not necessary.

Still referring to FIG. 14A , the sort plan server 1415 transmits the sort plan or respective portions of the sort plan, in modified or unmodified form, to subsystem level sort plan servers 1450 a . . . n associated with the various subsystems (e.g., 1420 , 1422 , 1424 , 1426 , 1428 ). In the hierarchical implementation shown, each subsystem level sort plan server may further modify the sort plan and distribute the sort plan to the respective components 1455 a . . . n associated therewith. In this manner, a top level sort plan server receives (and possibly modifies) the sort plan, and distributes it to individual subsystems, which in turn receive (and again possibly modify) and distribute it to sub