Sorter having a container shuttle system

A sorter system includes a first conveyor for transporting items to designated containers, a second conveyor for transporting containers containing the items, and a shuttle unit. The shuttle unit may include a base defining a loading area proximate to the first conveyor and a staging area proximate to the second conveyor and a tray disposed on the base for receiving containers on a first section and a second section. The tray may be movable between a first position in which the first section is in the loading area and a second position in which the first section is in the staging area. The shuttle unit may further include a transport device for selectively moving a container on the first section of the tray from the staging area onto the second conveyor.

FIELD OF THE INVENTION

The present invention relates to a sorter and, more particularly, to a sorter having a container shuttle system.

BACKGROUND OF THE INVENTION

Sorter systems are known in the art. These systems sort completed mailpieces and direct the mailpieces to storage pockets or bins, depending on the system's configuration. The mailpieces are directed to the particular bins based on a predetermined sorting scheme. Typical sorting schemes involve sorting mailpieces based on a common destination, such as a geographic region or a common postal code, for example.

In typical conventional sorting systems, once a bin is full, an operator is notified by an indicator light, for example. The operator must then clear the full bin and replace it with an empty one to allow the sorter system to continue operating. Handling heavy bins may create difficulties for the sorter system operator. Those difficulties may be further compounded where the bins are arranged on multiple levels, requiring overhead lifting.

In addition, in some cases, the sorter system is shut down when one or more pockets or bins are full to allow for their replacement. Thus, the refilling of bins may adversely affect the efficiency of the sorting operation.

Attempts have been made to automate bin handling in sorter systems, but conventional systems have been overly large and complex.

SUMMARY OF EXEMPLARY ASPECTS

In the following description, certain aspects and embodiments of the present invention will become evident. It should be understood that the invention, in its broadest sense, could be practiced without having one or more features of these aspects and embodiments. It should also be understood that these aspects and embodiments are merely exemplary.

In accordance with the purpose of the invention, as embodied and broadly described herein, one aspect of the invention relates to a sorter system comprising a first conveyor for transporting items to designated containers, a second conveyor for transporting containers containing the items, and a shuttle unit.

In one embodiment, the shuttle unit comprises a base defining a loading area proximate to the first conveyor and a staging area proximate to the second conveyor. The shuttle unit may further comprise a tray disposed on the base for receiving containers on a first section and a second section. The tray may be movable between a first position in which the first section is in the loading area and a second position in which the first section is in the staging area.

In a further embodiment, the shuttle unit comprises a transport device for selectively moving a container on the first section of the tray from the staging area onto the second conveyor.

As used herein, “items” include papers, documents, postcards, envelopes, brochures, enclosures, booklets, magazines, media items, including CDs, DVDs, computer disks, and/or other digital storage media, and packages having a range of sizes and materials. The items may be unwrapped or may be covered with a wrapping material such as paper, a polymer wrap, such as polyethylene, for example, or other wrapping material.

Further, as used herein, “container” means a bin, a pocket, or other storage unit used to contain items.

In another aspect, the invention relates to a method of sorting items comprising transporting items to designated containers using a first conveyor, transporting containers containing the items using a second conveyor, and receiving containers on a first section and a second section of a tray. The tray may be disposed on a base that defines a loading area proximate to the first conveyor and a staging area proximate to the second conveyor.

In one embodiment, the method further comprises moving the tray between a first position in which the first section is in the loading area and a second position in which the first section is in the staging area, and selectively moving a container on the first section of the tray from the staging area onto the second conveyor using a transport device.

Aside from the structural and procedural arrangements set forth above, the invention could include a number of other arrangements, such as those explained hereinafter. It is to be understood that both the foregoing description and the following description are exemplary only.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Embodiments of the system according to the invention are described with reference to certain applications in mailpiece sorter systems. It should be understood, however, that embodiments of the invention may be used in association with other systems configured to handle and transport items. Further, many sorter systems are modular and may include more or fewer modules than those described herein based on the particular application.

A sorter system10utilizing an embodiment of a container shuttle system according to the invention is shown inFIG. 1. The sorter system10includes a feeder module12for feeding items for sorting. In one embodiment, the items are arranged on the feeder on edge and advanced using a conveyor13, for example, towards a feeder belt14, shown schematically inFIG. 1. Other feeding arrangements may also be used.

In this embodiment, the feeder belt14is configured to contact a surface of an approaching item and to redirect the item's direction of travel substantially perpendicularly to advance the item for downstream processing. The feeder belt14may feed a single item at a time. Often, however, contact between items causes multiple items to advance. The multiple items may be overlapping to various degrees.

From the feeder module12, the items are fed to a singulation module16, which singulates the overlapping items to ensure that only one item at a time is processed by the system. The singulated items are fed along a transport path P for processing by various modules. Many item processing systems, such as mailpiece handling systems, for example, optimally process items that are spaced apart at a predetermined pitch.

The items next pass through a scanning module18, where an image of at least a portion of each item is obtained. The scanned image may be used by the controller19to determine the destination container for the item. In the illustrated sorter system10, the items then pass through a weighing module20, where the weight of the item is obtained.

In some applications, a sorter system is used to apply markings, such as an address or code, for example, to the face of items being processed. Such markings may be added using a printer or labeler. Both a printing module22and a labeling module24are included in the illustrated sorter system10.

Finally, the items are directed to the destination container26using a conveyor module28having a first conveyor30. For systems with containers26on multiple levels, an elevator arrangement (not shown) may be used to move the items to the appropriate level. A plurality of containers26are shown inFIG. 2arranged on an embodiment of the container shuttle system32according to the invention. As discussed below, containers26are transported from the container shuttle system32using a second conveyor34.

The sorter system10utilizing embodiments of the container shuttle system32may limit operator injury by minimizing or eliminating handling of heavy containers and may improve the overall efficiency of the sorting operation through optimization of container allocation and automation of the removal and placement of containers. In addition, due to the low profile of the container shuttle system32, containers may be nested (e.g., stacked) in some embodiments, allowing for greater sorting density and associated increased operational efficiency.

According to an embodiment of the invention, the sorter system10comprises a first conveyor30for transporting items to designated containers26. Diverters36are provided, as shown inFIG. 2, for directing items from the first conveyor30into a designated container26. The sorter system10further comprises a second conveyor34for transporting containers26containing the items. The second conveyor34may transport the containers26away from the sorter system10for further processing and/or delivery.

The sorter system10further comprises the container shuttle system32. An embodiment of the container shuttle system32is shown inFIGS. 2 and 3. In the illustrated embodiment ofFIG. 2, the container shuttle system32comprises three shuttle units38. Systems comprising other numbers of shuttle units38may also be used.

As shown, each shuttle unit38comprises a base40defining a loading area42proximate to the first conveyor30and a staging area44proximate to the second conveyor34. The shuttle unit38also comprises a tray46disposed on the base40for receiving containers26on a first section48and a second section50. In various stages of operation, the tray46may have containers26present in either or both sections48,50.

As shown inFIGS. 2 and 3, the tray46comprises raised side edges to prevent unwanted lateral motion of the containers26. The ends of the tray46are open to allow the desired motion of the containers26toward the second conveyor34.

The tray46is movable between a first position in which the first section48is in the loading area42and a second position in which the first section48is in the staging area44. In the embodiment shown inFIG. 2, the tray46of the left shuttle unit38is in the second position and the trays46of the center and right shuttle units38are in the first position. As shown, with the tray46in the first position, the second section50extends beyond the base40. In that configuration, the second section50is accessible to an operator, as described below.

In an embodiment, the shuttle system38further comprises a drive element52, shown schematically inFIG. 3, for moving the tray46. The drive element52may comprise a servo motor. Alternatively, the drive element52may comprise an air cylinder or other actuator. The sorter system10further comprises a controller19, as discussed above, for controlling the drive element52to selectively move the tray46between the first position and the second position to allow a container26in the first section48and a container26in the second section50to receive items associated with different sorting schemes, as discussed below.

The shuttle unit38further comprises a transport device54for selectively moving a container26on the first section48of the tray46from the staging area44onto the second conveyor34. The transport device54is selectively movable between a retracted position within the base40and an extended position in the staging area44. The transport device54is shown in the extended position inFIG. 3.

In one embodiment, the transport device54is moved between the retracted and extended positions using a pneumatic actuator (not shown). Other types of actuators may also be used. As shown inFIG. 3, the tray46defines an opening56for receiving the transport device54in the extended position.

In a further embodiment, the transport device54comprises a conveyor belt. In the illustrated embodiment, two conveyor belts are used to engage the lower surface of a container26and move it from the staging area44onto the second conveyor34. Systems utilizing a different number of conveyor belts may also be used. In addition, other types of transports may also be used.

In another embodiment, the shuttle unit38further comprises a retention device58for selectively engaging a container26in the loading area42to prevent movement of the container26with the tray46. The retention device58is selectively movable between a retracted position within the base40and an extended position in the loading area42. The retention device58is shown in the extended position inFIG. 3.

Similar to the transport device54, in one embodiment the retention device58is moved between the retracted and extended positions using a pneumatic actuator (not shown). Other types of actuators may also be used. As shown inFIG. 3, the tray46defines an opening56for receiving the retention device58in the extended position. In the illustrated embodiment, the opening56comprises two slotted openings configured to accommodate either the transport device54or the retention device58, depending on the position of the tray46.

In one embodiment, the retention device58comprises a flat bar having a high friction surface. The flat bar is configured to engage a lower surface of a container26and prevent the container26from moving with the tray46. In the illustrated embodiment, the retention device58comprises two flat bars coated with a high friction rubber material. Other materials may also be used. Further, the illustrated retention element58is configured to contact the lower surface of the container26and lift the container26off the tray46.

One embodiment of the operation of the sorter system10is now described. Initially, one or more trays46are configured with two empty containers26, one in the first section48and one in the second section50. The middle tray inFIG. 2is configured in that arrangement. Next, a set of items is loaded on the conveyor13of the feeder module12. The items are then singulated in the singulation module16and each item is scanned in the scanning module18. As discussed above, the scanned image is used by the controller19to determine the destination container26for the item. The items are fed through the system and onto the first conveyor30.

The items travel on the first conveyor30above the containers26in the loading area42. The diverters36are actuated to direct the items into respective containers26according to the designated sorting scheme. Eventually, the sorting of items to a container26is complete. This may occur when the container26is full or when there are no additional items to be directed to that container26under the designated sorting scheme.

When the sorting of items to a container26is complete, the drive element52is actuated to move the tray46between the first position, as indicated by the middle tray inFIG. 2, and the second position, as indicated by the left tray inFIG. 2. When the tray46moves to the second position, the full container26in the first section48is moved to the staging area44and the empty container26in the second section50is moved to the loading area42. The empty container26in the loading area42is immediately ready to receive items from the first conveyor30.

Next, the transport device54, comprising two conveyor belts in the illustrated embodiment, moves from the retracted position within the base40to the extended position in the staging area44. In the extended position, the conveyor belts pass through the openings56in the tray46, engage the bottom of the container26, and lift the container26slightly above the surface of the tray46. As directed by the controller19, the conveyor belts then actuate to move the container26from the staging area44onto the second conveyor34. The conveyor belts then move to the retracted position.

At this point, the tray46is in the second position with a container26in the second section50in the loading area42. Next, the retention device58, comprising two flat bars in the illustrated embodiment, moves from the retracted position within the base40to the extended position in the loading area42. In the extended position, the flat bars pass through the openings56in the tray46, engage the bottom of the container26, and lift the container26slightly above the surface of the tray46. As directed by the controller19, the tray46then moves from the second position to the first position without moving the container26. The flat bars are then moved to the retracted position, setting the container26back on the surface of the tray46in the first section48.

Thus, after this maneuver, the tray46is in the first position with one container26in the first section48disposed in the loading area42, as indicated by the right tray inFIG. 2. With the tray46in the first position, the second section50extends beyond the base40. In that configuration, the second section50is accessible to an operator who may now place an empty container26on the tray46in the second section50. According to embodiments of the invention, an operator may avoid handling heavy containers because the partially- and fully-filled containers are moved onto the second conveyor34by the container shuttle system32. An operator may be required to handle only empty containers.

In a further embodiment, the controller19may be configured to control the drive element52to selectively move the tray46between the first position and the second position to allow a container26in the first section48and a container26in the second section50to receive items associated with different sorting schemes. For example, instead of assigning a single sorting scheme, such as a postal code, for example, to a given loading area, two sorting schemes may be assigned to a given loading area. In operation, the controller19drives the tray46between the first and second positions to place the appropriate container26in the loading area42as respective items arrive.

It will be apparent to those skilled in the art that various modifications and variations can be made to the structure and methodology described herein. Thus, it should be understood that the invention is not limited to the examples discussed in the specification. Rather, the present invention is intended to cover modifications and variations.