System and method for directly connecting an advanced facer canceler system to a delivery bar code sorter

Systems and methods that allow for orienting and delivering mail between a postage verifier and a mail sorter. A postage verifier includes an optical character reader for decoding addresses on mail pieces that do not have bar codes. A reverter orients mail from the postage verifier into a position required for processing by the mail sorter. A combination of mail carrying modules carry the mail from the reverter to the mail sorter. The mail sorter prints bar code information on mail lacking bar codes, when the data is available, and sorts the mail based on the bar code information.

I. BACKGROUND OF THE INVENTION

This invention relates generally to the field of mail processing, and more specifically to the field of processing and directing mail between machines.

Mail processing systems must accurately and quickly process large amounts of mail. The performance and cost of conventional mail processing are hindered by the need for many operators and the time required to manually move mail between machines.

Conventional mail systems process stamped mail through a plurality of separate machines including an advanced facer-canceler system/input subsystem (AFCS/ISS), an optical character reader (OCR) machine, and a delivery bar code sorter/output subsystem (DBCS/OSS). AFCS/ISS places incoming mail into a single file line in a pinch belt, checks for appropriate postage on mail, cancels the postage, and places the mail in stackers. AFCS/ISS positions the mail upright between a pair of pinch belts with either the stamp leading and the address on the front side or the stamp trailing and the address on the back side. AFCS/ISS obtains a picture image of each piece of mail and prints a mail identifier on each mail piece that is stored along with the image. The image is used to determine mail type such as printed address and script address. After canceling the postage, AFCS/ISS sorts the mail into one or more bins based on mail type. Each mail type has two bins, one for mail with the stamp leading and one for mail with the stamp trailing.

The machines that next process the mail, such as DBCS/OSS, require that all the mail be positioned with the stamp leading. An operator takes the stamp trailing mail from one bin and places it in a stamp leading position to combine with the mail in the stamp leading bin. Based on the mail type, the operator then moves the mail to the next processing point. Pre-bar coded mail is taken directly to the DBCS/OSS. Bar codes on the mail indicate the destination of the mail piece. Printed and scripted mail is taken to the OCR to have the mail processed to determine what bar code label is appropriate for a given piece of mail. OCR prints a bar code onto the mail. Bar-coded mail is then taken to a DBCS/OSS for further processing.

DBCS/OSS sorts the mail into a plurality of stackers based on the bar code data which reflects the mail destination.

The present invention reduces the number of processing operators required and speeds the processing of the mail.

II. SUMMARY OF THE INVENTION

Systems and methods consistent with the present invention process and carry mail between a postage verifier and a mail sorter.

A mail processing interface is provided between a postage verifier and a mail sorter. The interface includes a reverter for orienting mail received from the postage verifier, a first mail carrying module configured to receive mail from the reverter, a transport configured to receive mail from the first mail carrying module, and a second mail carrying module configured to receive mail from the transport and to output mail to the mail sorter.

A mail processing system includes a postage verifier, a reverter orienting mail received from the postage verifier, a first mail carrying module configured to receive mail from the reverter, a transport configured to receive mail from the first mail carrying module, a second mail carrying module configured to receive mail from the transport, and a mail sorter configured to receive mail from the second mail carrying module.

A processing method processes mail through a postage verifier having an optical character reader, mail interface system, and a mail sorter. The mail interface system includes an upward module carrying mail up to an overhead transport positioned at a height above an output of the postage verifier, and a downward module carrying mail down from the overhead transport to the mail sorter. The method includes verifying and canceling postage, positioning mail pieces in a same configuration in a single file line, directing mail pieces up the upward module, directing mail pieces through the overhead transport, directing mail pieces down the downward module to a mail sorter, and sorting the mail based on destination.

IV. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Reference will now be made in detail to embodiments consistent with this invention that are illustrated in the accompanying drawings. The same reference numbers in different drawings generally refer to the same or like parts.

Current mail processing systems require an operator to arrange and carry mail between an AFCS/ISS, OCR and DBCS/OSS. Systems and methods consistent with the present invention provide an OCR at a postage verifier, such as the AFCS/ISS, and include a direct connect system to allow mail to be automatically processed and transported between the postage verifier and a mail sorter, such as the DBCS/OSS.

FIG. 1shows a mail processing system consistent with the present invention. The system includes AFCS/ISS100, OCR110, remote encoding system (REC)200, data control system300, database310, direct connect system400, machine control system405, and DBCS/OSS500. AFCS/ISS100, performs the same as the conventional AFCS/ISS described above, and further includes an OCR110and a connection to direct connect system400. AFCS/ISS100directs processed mail to either direct connect system400or to a set of stackers. Direct connect system400arranges and carries mail to DBCS/OSS500. DBCS/OSS500performs like the conventional DBCS/OSS described above, and additionally accepts mail from the direct connect system400and prints bar codes on mail as needed.

Data control system300is connected to AFCS/ISS100, DBCS/OSS500, and REC200. Data control system300organizes bar code information and mail identifiers. Data control system300includes a processor and memory with database310.

FIG. 2is a flowchart showing steps for processing mail using the elements shown inFIG. 1. AFCS/ISS100checks for postage on received mail and stamps a cancellation mark on the mail (step210). AFCS/ISS100also prints a mail piece identifier on each piece of mail. AFCS/ISS100determines if a mail piece already contains a bar code (step220) and, if so, forwards the mail piece to direct connect system400. Mail that does not have a bar code is processed by OCR110located within AFCS/ISS100(step230). OCR110attempts to analyze address information from an optical image of the mail, obtained by AFCS/ISS100, to generate bar code data for the mail piece. If OCR110is not able to decode an address (step240), the image of the mail piece is sent to REC200(step250). Individuals located at REC200view the image of the mail piece and input bar code information. The bar code information determined by OCR110or input at REC200is forwarded to data control system300for storage in database310along with the mail piece identifier (step260). AFCS/ISS100outputs mail to direct connect system400(step270). Direct connect system400places all mail pieces in the same orientation, such as stamp leading, and carries the mail over a work area and back down to enter DBCS/OSS500(step280).FIG. 3shows a piece of mail30being carried in an upright position in a pair of pinch belts34(one shown) with stamp32leading.

DBCS/OSS500directs mail into a plurality of stackers based on the destination indicated on a bar code on a mail piece. DBCS/OSS500determines if a mail piece has a bar code (step290). DBCS/OSS500uses the bar code to direct the mail piece to a stacker associated with the destination (step292). If a mail piece does not have a bar code, DBCS/OSS500queries database310at data control system300using the mail piece identifier, requesting bar code information (step294). If bar code information is in database310, DBCS/OSS500receives the bar code information from data control system300, prints the bar code on the mail piece (step296) and directs the mail to the appropriate destination stacker (step292). Otherwise, the mail is placed in a reject stacker (step298). About fifteen percent of the mail will be placed in the reject stacker. Some of these pieces may be rejected because the individuals at REC200have not entered the bar code information in time. The reject pieces may be re-run through the DBCS/OSS500at a later time after REC200has entered more bar code data into database310.

InFIG. 4, machine control system405in direct connect system400is connected to each of the elements in direct connect system400, AFCS/ISS100and DBCS/OSS500to control whether mail is deposited in stackers or directed to the next machine in line. Machine control system405may also select the source of mail to be processed by the DBCS/OSS500. Machine control system405includes a processor402, memory404and sensors. Sensors are located throughout each of the connected elements to note any failures, such as paper jams, and report the failure through the control system to an operator. A control panel allows an operator to receive information from machine control system405and to control the overall system.

FIG. 4shows the elements of direct connect system400. Mail is received from AFCS/ISS100at a reverter410piece by piece in a pinch belt. Reverter410detects that a piece is received preferably by use of a photodetector. Reverter410tracks the spacing between pieces using the photodetector and if pieces are too close together for processing, a mail piece is output to stackers420. There may be one or more stacks in stackers420facing either toward or away from an operator. In one embodiment, three stackers facing toward the operator are used, one for pre-bar coded mail, a second for script and printed mail, and a third for rejected mail.

AFCS/ISS100keeps track of the order in which it is sending the pieces of mail and signals the reverter410indicating whether a piece is stamp leading or stamp trailing. If the stamp is trailing, reverter410directs the mail piece into a reverting section to turn the piece of mail around so that the address is facing out and the stamp is leading as shown inFIG. 3. If a piece of mail is already in the stamp leading position, the mail piece bypasses the reverting section. After turning a piece of mail around, reverter410inserts the piece of mail back into the same order in the mail flow.

Reverter410receives information about the mail type of each mail piece from AFCS/ISS100. An operator, at the control panel associated with machine control system405, may direct the reverter to sort mail, or a specific type of mail, into stackers420. Machine control system405may direct reverter410to place mail in stacker420if there is an error downline, such as when the upward module430is stopped. In an alternative embodiment, AFCS/ISS100may place mail directly into stackers420.

AFCS/ISS100and DBCS/OSS500are typically located across a pedestrian aisle. Upward module430carries the mail up using a pair of pinch belts to overhead transport440. Overhead transport440uses a pair of pinch belts to carry the mail across to downward module450. Upward module430, overhead transport440, and downward module450, may include turns and angles as needed, such as to avoid other equipment. Downward module450carries the mail down using a pair of pinch belts to DBCS/OSS500. If DBCS/OSS500is not accepting mail, machine control system405may divert mail to stackers460. Stackers460may include one or more stacks. In one embodiment, there are two stacks at stackers460. In another embodiment, stackers460may feed mail to DBCS500.

DBCS/OSS500receives mail from either downward module450or feeder510. Machine control system405controls which source DBCS/OSS500uses to receive mail. An operator at DBCS/OSS500may also select which source should receive mail. This allows for DBCS/OSS500to be used separate from direct connect system400. For example, if DBCS/OSS500is down and mail collects in stackers460, an operator may place the mail from stackers460into feeder510once DBCS/OSS500is operational. If there is an error with direct connect system400or AFCS/ISS100, DBCS/OSS500may be used to process mail inserted into feeder510.

The upward module430, overhead transport440, and downward module450may be bypassed by using stacker420and feeder510. An operator may carry mail from stacker420to feeder510for processing by DBCS/OSS500.

In one embodiment, reverter410, stackers420, upward module430, overhead transport440, downward module450and stackers460have indicating lights within the view of an operator that indicate the location of any jams.

In one embodiment, the gap between mail pieces is 30+/−5 msec and the reverter module may reject pieces of mail that have a gap of less than 25 msec.

In another embodiment, the overhead transport is at a height of less than eleven feet. In yet another embodiment, the overhead transport may be positioned below the height of a person or at the height of the AFCS/ISS if desired.

There are many variations that may be made consistent with the present invention. For example, in another embodiment, the reverter410is located after the downward module450. The reverter may also position mail in different orientations based on what is required by machines downline. A database that stores mail identifiers and related information may be located anywhere accessible to DBCS/OSS. Other postage verifiers may be used in place of the AFCS/ISS, and other bar code sorting machines may be used in place of DBCS/OSS.

In general, the mail carrying elements of the preferred embodiment are pinch belts. However, the mail carrying areas may have sections where the belts are loose, leveler sections that fix skewed pieces of mail, and belt areas. Structure other than pinch belts may be used such as belts, vacuum assisted belts, slotted belt chains, or rollers.

In another embodiment, the AFCS/ISS may send specific types of mail to the direct connect system, such as script and print, and send other types of mail to stackers420or stackers460, such as pre-bar coded mail.

The foregoing description is presented for purposes of illustration and description. It is not exhaustive and does not limit the invention to the precise form disclosed. Modifications and variations are possible in light of the above teachings or may be acquired from practicing the invention. The scope of the invention is defined by the claims and their equivalents.