Patent Description:
Machines for automatically sorting articles, such as mail, into one of an array of selected bins or compartments, are common. Typically, such sorting machines have a feeding mechanism that inducts articles one-at-a-time into belts and/or onto conveyors. Sensing components along the travel path monitor and track the movement of the articles. When necessary, control electronics command a diverting gate assembly or other redirecting mechanisms to reroute the article into a specific destination compartment or bin.

Documents <CIT> and <CIT> show two examples of sorting machines.

Furthermore, <CIT> discloses an automated sorting machine according to the preamble of claim <NUM>.

Conventional diverter gates move by either a solenoid or linear actuator. Unfortunately, the actuation of the conventional diverter gate causes the diverter to bounce during actuation. Having a loose diverter gate or an unexpected gate move at an unexpected time while the transport belt is moving could cause potential damage to such mechanism and or the system as a whole. Accordingly, there exists a need for a mechanically locking diverter that cannot move or bounce inadvertently.

According to the invention, an automated sorting machine as claimed in claim <NUM> is provided.

The system itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:.

While the system is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail.

Illustrative embodiments of the system of the mechanically locking diverter are described below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will, of course, be appreciated that in the development of any such actual embodiment, numerous implementation- specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

Reference may be made herein to the spatial relationships between various components and to the spatial orientation of various aspects of components as the devices are depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present application, the devices, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as"above,""below,""upper,""lower," or other like terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the device described herein may be oriented in any desired direction.

Referring now to <FIG> and <FIG> in the drawings, the preferred embodiment of a mechanically locking diverter <NUM> is illustrated. Diverter <NUM> is comprised of a diverter block <NUM>, a diverter pin guide <NUM>, a diverter flipper <NUM>, an actuator arm <NUM>, and an actuator <NUM>. Diverter flipper <NUM> pivots about a pivot pin <NUM>, such that diverter <NUM> is operable between a non-divert position in which diverter flipper <NUM> is in line with diverter pin guide <NUM>, as shown in <FIG>; and a divert position, in which diverter flipper <NUM> is angled relative to diverter pin guide <NUM>, as shown in <FIG>. Depending upon the position of diverter flipper <NUM>, a shoe <NUM> (see <FIG> ) will progress in the direction of the bold arrows shown in <FIG> and <FIG>.

Referring now also to <FIG> in the drawings, mechanically locking diverter <NUM> is shown in the divert position. Diverter flipper <NUM> includes a slot <NUM> configured to receive a pin <NUM>. Although slot <NUM><NUM> is shown as straight, it will be appreciated that the shape of slot may be varied depending upon the desired movement and/or acceleration of diverter flipper <NUM>. Pin <NUM><NUM> is coupled to diverter arm <NUM>, which is rotatably driven by actuator <NUM>. Actuator <NUM><NUM> is preferably recessed below diverter block <NUM>. As actuator <NUM> rotates actuator arm <NUM> and pin <NUM><NUM>, diverter flipper <NUM> is rotated between the non-diverted position and the diverted position. Because pin <NUM> is located in slot <NUM>, the position of diverter flipper <NUM> is controlled by the rotational placement of pin <NUM> in relation to slot <NUM>. Therefore, even when actuator <NUM><NUM><NUM> is without power, diverter flipper <NUM> will remain in the last controlled position. According to the invention, actuator arm <NUM> rotates approximately <NUM> degrees between the divert position and the non-divert position. Another embodiment of this design allows for the actuator arm to rotate approximately <NUM> degrees. This configuration creates a mechanical lock that holds diverter flipper <NUM> in either the divert position, the non-divert position, or both.

Referring now also to <FIG> in the drawings, mechanically locking diverter <NUM> is shown in the non-diverted position. As is shown, a base portion <NUM> (see <FIG>) of diverter flipper <NUM> is recessed within diverter block <NUM>, while a tab portion <NUM> of diverter flipper <NUM> extends above diverter block <NUM>.

Referring now also to <FIG> in the drawings, actuator <NUM> is illustrated. Actuator <NUM> selectively rotates a shaft <NUM>. Shaft <NUM> is configured for coupling to actuator arm <NUM>. Actuator <NUM> is preferably configured and/or programmed to rotate shaft <NUM> back and forth between and angle of approximately <NUM> degrees or more.

Referring now also to <FIG> in the drawings, actuator arm <NUM> is illustrated. Actuator arm <NUM> is coupled to shaft <NUM>, preferably via a clevis connection <NUM> forming a rotational axis <NUM>, thereby selectively rotating pin <NUM>. Actuator arm <NUM> includes a mount <NUM> for a pin <NUM> (see <FIG>). Mount <NUM> is a specific distance away from rotational axis <NUM> of actuator arm <NUM>, such that a <NUM>-degree or more rotation about rotational axis <NUM> will correspond with a significant enough rotation in diverter flipper <NUM> to divert shoes <NUM> or let shoes <NUM> pass by. Referring now also to <FIG> in the drawings, pin <NUM> is shown. Pin <NUM> is disposed between actuator arm <NUM> and diverter flipper <NUM>. Pin <NUM> is of sufficient length to connect actuator arm <NUM> to diverter flipper <NUM> via a' pin-and-slot connection located on diverter flipper <NUM>. Referring now also to <FIG> in the drawings, diverter flipper <NUM> is illustrated. As is shown, diverter flipper <NUM> moves between the divert position and the non-divert position based upon the location of pin <NUM> in slot <NUM>. As is shown, base portion <NUM> is shaped and dimensioned to be recessed within diverter block <NUM>, while tab portion <NUM> extends above diverter block <NUM>. Diverter flipper <NUM> features a deflector <NUM>, either a pin deflector, a roller deflector, or both. Deflector <NUM> is a face or component that comes into contact with the pin or roller on shoe <NUM>, thereby causing shoe <NUM> to divert down a different path. Deflector <NUM> is sufficiently strong to withstand the force of the pin or the roller being diverted by deflector <NUM>. Slot <NUM><NUM> of diverter flipper <NUM> is of sufficient width to allow pin <NUM> to slide within the bounds of slot <NUM>. Slot <NUM> is long enough to allow at least <NUM> degrees or more of rotation about the axis of actuator <NUM>. In addition, slot <NUM> is located far enough away from the rotational axis of diverter flipper <NUM> to allow for diverter flipper <NUM> to divert shoe <NUM> or let shoe <NUM> pass by.

Referring now also to <FIG> in the drawings, diverter pin guide <NUM> is illustrated. Diverter pin guide is coupled to the top of diverter block <NUM>. Diverter pin guide <NUM> works with diverter flipper <NUM> to direct shoes <NUM> down one of two different rail paths, so that shoes <NUM> may push packages into a selected sort locations.

Referring now also to <FIG> in the drawings, diverter block <NUM> is illustrated. Diverter block <NUM> includes of a diverter flipper channel <NUM>, an actuator mount <NUM>, and a shaft <NUM>. Diverter flipper channel <NUM> is large enough to receive and allow diverter flipper <NUM> to rotate enough to divert shoe <NUM> let it shoe <NUM> pass by. Channel <NUM> is configured such that actuator arm <NUM> is close to the wall of the channel when diverter flipper <NUM> is diverting shoes <NUM> and when diverter flipper <NUM> is not diverting shoes <NUM>. The configuration of actuator arm <NUM> being perpendicular (or just beyond perpendicular) to the wall of channel <NUM> creates a mechanical lock between the diverter flipper <NUM> and diverter block <NUM>. Thus, actuator arm <NUM> operates between a first position corresponding to the non-divert position of diverter flipper <NUM>, and a second position corresponding to the divert position of diverter flipper <NUM>. Such lock prohibits external forces on diverter flipper <NUM> from moving diverter flipper <NUM>. The lock can only be released by rotating actuator arm <NUM> out of a perpendicular angle from the wall, which allows diverter flipper <NUM> to be freely moved until actuator arm <NUM> is perpendicular to the other wall of channel <NUM>. Actuator mount <NUM> is located far enough away from a central axis to acquire the desired rotation of diverter flipper <NUM>. Shaft <NUM> is of sufficient size to fit into the rotational axis of diverter flipper <NUM>. Diverter block <NUM> may include one or more ports, channels, and/or apertures for allowing dust and debris to fall out and/or be removed.

Referring now also to <FIG> in the drawing, the preferred embodiment of an automated sorting machine <NUM> is illustrated. Sorting machine <NUM> includes at least one longitudinal rail <NUM>, at least one transverse slat <NUM>, at least one shoe <NUM> that is slidingly retained on slat <NUM>, and at least one shortened diverter rail <NUM><NUM>. Packages ride on slats <NUM> of sorting machine <NUM>. Slats <NUM> terminate at a side wall <NUM>, and may include a bumper member (not shown) to prevent damage to shoes <NUM> as shoes <NUM> contact side walls <NUM>. Shoes <NUM> include a roller <NUM> and a pin <NUM>, by which mechanically locking diverter <NUM> controls the path of shoe <NUM>. In response to appropriate signals, diverter <NUM> is actuated into the divert position, whereupon shoe <NUM> is caused to move transversely along diverter rail <NUM>, thereby selectively kicking the package off into a specific location or bin. Shoes <NUM> are returned to the inner position on slats <NUM> by appropriate re-divert rails (not shown).

It will be appreciated that the solenoid or linear actuator accelerates diverter <NUM> to high speeds upon actuation. Due to this high speed, typical diverters tend to bounce upon impact of a hard stop. Additionally it will be appreciated that shoes <NUM> are quite massive and move at very high speeds along rails <NUM> and slats <NUM>. Another advantage of the unique locking feature of mechanically locking diverter <NUM> is that diverter flipper <NUM> is mechanically locked into either the divert position or the non-divert position by pin <NUM> and slot <NUM>. This locking configuration helps to prevent diverter flipper <NUM> from bouncing when diverter flipper <NUM> is actuated or impacted by pin <NUM> of shoe <NUM> as shoe <NUM> passes by diverter flipper <NUM>. Without this unique locking feature, diverter flipper <NUM> would be susceptible to undesirable movement and/or damage when impacted by pin <NUM>.

Referring now also to <FIG> in the drawings, a conveyor sortation system is illustrated. For reference, <FIG> shows a conventional standard diverter rail design. As is shown in <FIG>, the diverter rails <NUM> are shortened, compared to the diverter rails <NUM> of <FIG>. In addition, divert rails <NUM> do not turn back in the longitudinal direction. By utilizing shortened diverter rails <NUM>, the distance that the shoe is guided is reduced. As is shown in <FIG>, the terminal divert position <NUM> is the maximum final position of a diverted shoe, such as shoe <NUM>, with respect to the linear axis of movement of the shoe along a corresponding slat, such as slat <NUM>. In the system of <FIG>, the shoes slam into the side walls of the slats. Another advantage of shortened diverter rails <NUM> is that the corresponding shoes, i.e., shoes <NUM>, remain at least <NUM>,<NUM> meters (<NUM> inches) away from the terminal divert position <NUM>, i.e. side walls <NUM> of slats <NUM>. As shoes <NUM> travel past the ends of divert rails <NUM>, the friction of shoes <NUM> along slats <NUM> causes shoes <NUM> to stop or slow down prior to contacting side walls <NUM> of slats <NUM>. This prevents shoes <NUM> from being damaged by repeated contacting of side walls <NUM>. In addition, it is preferred that the angle between a straight portion of the diverter rail <NUM> and a centerline <NUM> of the main rail be at least <NUM> degrees or greater.

Claim 1:
An automated sorting machine (<NUM>), comprising:
at least one longitudinal rail (<NUM>);
a plurality of transverse slats configured to travel longitudinally along the rail (<NUM>); at least one shoe slidingly retained on at least one of the slats;
at least one diverter rail (<NUM>); and
at least one diverter (<NUM>) disposed along the longitudinal rail (<NUM>), the diverter (<NUM>)
comprising:
a diverter block (<NUM>);
an actuator (<NUM>) coupled to the diverter block (<NUM>);
an actuator arm (<NUM>) coupled to the actuator (<NUM>), the actuator arm (<NUM>) being operable between a first position and a second position;
a diverter flipper (<NUM>) pivotally coupled to the diverter block (<NUM>), the diverter flipper (<NUM>) having a slot (<NUM>) and being operable between a non-divert position corresponding to the first position of the actuator arm (<NUM>) and a divert position corresponding to the second position of the actuator arm (<NUM>); and
a pin (<NUM>, <NUM>) coupled to the actuator arm (<NUM>) and being disposed within the slot (<NUM>) of the diverter flipper (<NUM>), such that rotation of the actuator arm (<NUM>) between the first position and the second position pivots the diverter flipper (<NUM>) between the non-divert position and the divert position;
characterized in that
the first position and
the second position of the actuator arm (<NUM>) are separated by approximately <NUM> degrees, thereby creating a mechanical lock that holds the diverter flipper (<NUM>) in either the non-diverted position or the diverted position.