Patent Description:
<CIT> , which discloses the features of the preamble of claim <NUM>, relates to a method and apparatus for separating, feeding and sorting stacked products. <CIT> relates to feeding items such as mail pieces into a feeding system, more precisely to a singulation system for mail pieces such as parcels. <CIT> relates to a device for handling individually packaged goods.

In automatic processing of parcels and other items, items are typically processed in bulk, which means that as the items are being conveyed, there may be multiple items comingled in a <NUM>-dimensional space, allowing for highly efficient utilization of conveyors. Certain processing and handling steps require individualized manipulation of the items being processed, which requires de-mingling of the items in the <NUM>-dimensional space, so the items are conveyed one-by-one. This is often a manual process, but automated methods have existed for different aspects of the problem, such as for example the aspect of items that are laminated, i.e. stacked one on top of the other.

Known methods are challenged today by wider variation in the formats of items, higher standards of automation in which manual "tending" (spotting and resolving exceptions) is less acceptable, and in the footprint constraints in which more equipment is expected to fit in preexisting facilities. Thus, an improved system having de-shingling performance with a smaller footprint may be desired.

A first aspect of the present invention provides a system for delaminating a stream of articles according to claim <NUM>.

A second aspect of the present invention provides a method for delaminating a stream of articles according to claim <NUM>.

A third aspect of the present invention provides a non-transitory computer readable medium according to claim <NUM>.

To facilitate an understanding of embodiments, principles, and features of the present disclosure, they are explained hereinafter with reference to implementation in illustrative embodiments. In particular, they are described in the context of being a system and a method for delaminating a stream of articles, such as for example parcels, packages or other mail items. Embodiments of the present disclosure, however, are not limited to use in the described systems or methods.

The components and materials described hereinafter as making up the various embodiments are intended to be illustrative and not restrictive. Many suitable components and materials that would perform the same or a similar function as the materials described herein are intended to be embraced within the scope of embodiments of the present disclosure.

<FIG> depicts a schematic view of system for delaminating a stream of articles accordance with an exemplary embodiment of the present disclosure. The stream of articles comprises for example parcels, and it should be noted that the terms parcel and package are used interchangeably herein.

As noted, in automatic processing of parcels and other items, items are typically processed in bulk, which means that as the items are being conveyed, there may be multiple items comingled in a <NUM>-dimensional space, allowing for highly efficient utilization of conveyors. Certain processing and handling steps require individualized manipulation of the items being processed, which requires de-mingling of the items in the <NUM>-dimensional space, herein referred to as 'delamination', so that the items are conveyed one-by-one. The terms 'lamination' and 'delamination' as used herein refer to the arrangement and re-arrangement of a disordered stream of parcels or other items with respect to a <NUM>-dimensional space. After delamination, the parcels or other items are not stacked one on top of the other, but still may be arranged in a <NUM>-dimensional space, for example side-by side. 'Singulation' refers to the re-arrangement of a disordered flow or stream of articles into one or more single-file output streams (absence of side-by-side parcels).

<FIG> illustrates a system <NUM> for delaminating a stream <NUM> of articles, herein also referred to as delamination system <NUM> or simply system <NUM>. For example, a mail processing facility includes such a delamination system <NUM>. The stream <NUM> of articles comprises a plurality of parcels A, B, C, D and E. Typically, the stream <NUM> comprises many more parcels or items as an incoming stream travelling toward the delamination system <NUM>.

The delamination system <NUM> defines a transport path illustrated by arrow <NUM> and comprises an infeed conveyor belt <NUM>, an inclined and laterally tilted delamination unit <NUM> and an output conveyor belt <NUM>. Further, the system <NUM> comprises a detection unit <NUM> and a control unit <NUM>.

In operation of the delamination system <NUM>, bulk stacks of parcels or other mail items, such as parcels A, B, C, D, E, are loaded, either by human operators or automated by machines, onto the infeed conveyor belt <NUM>. The delamination unit or module <NUM> comprises multiple individually and selectively controlled rollers <NUM>, labeled as rollers <NUM> to <NUM>. The control unit or central processing unit <NUM>, through the detection unit <NUM>, detects positions and movement of parcels A, B, C, D, E on the delamination unit <NUM>, and in response controls and powers the multiple rollers <NUM> to effect delamination of stacks of parcels, such as stream <NUM>, into a sequence of delaminated parcels. After delamination, the parcels A, B, C, D, E continue to move downstream onto the output conveyor belt <NUM> for further processing, such as for example singulation or sorting.

The delamination unit <NUM> comprises multiple individually and selectively controlled rollers <NUM>, labeled as rollers <NUM> to <NUM>, arranged on a laterally tilted inclined plane <NUM>. The plane <NUM> is herein also referred to as the primary (conveyor) plane <NUM>. Further, the delamination unit <NUM> comprises multiple secondary (conveyor) planes <NUM>, <NUM> that are oriented in such a way as to allow sophisticated manipulation and control of a wider range of formats with respect to the articles A, B, C, D, E. Gravity and balance of friction, a multi-plane arrangement and individual controls are employed. In addition, the range in item sizes is taken into account in determination of the arrangement and extent of individual secondary planes <NUM>, <NUM>.

The multiple secondary planes <NUM>, <NUM> of the delamination unit <NUM> are provided through specific arrangement and grouping of the rollers <NUM>. Planes <NUM> label planes within a group of rollers, whereas planes <NUM> label planes between groups.

The example of <FIG> illustrates five groups of rollers <NUM>, which are groups <NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D and <NUM>-E. Each group comprises four rollers <NUM>. Group <NUM>-A includes rollers <NUM>-<NUM>, group <NUM>-B includes rollers <NUM>-<NUM>, group <NUM>-C includes rollers <NUM>-<NUM>, group <NUM>-D includes rollers <NUM>-<NUM> and group <NUM>-E includes rollers <NUM>-<NUM>. It should be noted that the delamination unit <NUM> may comprise many different configurations with respect to number of groups of rollers <NUM> and number of rollers <NUM> within a group. For example, delamination unit <NUM> may comprise <NUM> rollers with ten groups of rollers, wherein five groups each comprise three rollers, three groups each comprise four rollers, and two groups each comprise two rollers.

Each group <NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D and <NUM>-E comprises a secondary plane <NUM> defined by the outer rollers of each group. For example, rollers <NUM> and <NUM> of group <NUM>-A define plane <NUM>.

Further, the delamination unit <NUM> comprises additional secondary planes <NUM> between the groups <NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D and <NUM>-E of rollers <NUM>. Each first roller <NUM> of each group <NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D and <NUM>-E may define one or more planes <NUM>. For example, rollers <NUM>, <NUM> and <NUM> define a plane <NUM>, and rollers <NUM>, <NUM> and <NUM> define a plane <NUM>. The arrangement of a height of each roller <NUM> in relationship to one another establishes the multiple planes <NUM>, <NUM>.

According to the invention, the detection unit <NUM> comprises a vision unit with at least one image sensor. In our example, the vision system comprises two image sensors <NUM>, <NUM>, wherein each sensor <NUM>, <NUM> is for example a digital camera. The sensors <NUM>, <NUM>, e.g., digital cameras, are arranged so that they cover essentially a whole surface, i.e. length and width, of the delamination unit <NUM> to detect locations of the articles A, B, C, D, E. Specifically, the image sensors <NUM>, <NUM> are arranged and configured to detect a position, size and orientation of each of the articles A, B, C, D, E and to transmit position, size and orientation data to the control unit <NUM>. It should be noted that the detection unit <NUM> may comprise more or less than two image sensors, and that instead of digital cameras, other devices capable of providing position, size and orientation data may be utilized.

The delamination system <NUM> further comprises the control unit <NUM> with at least one processor <NUM>. The control unit <NUM> interfaces with the detection unit <NUM> and the delamination unit <NUM>, specifically with each of the rollers <NUM> of the delamination unit <NUM>. The control unit <NUM> is configured to receive data and information from the detection unit <NUM>, to process the data and information, and to control and power individually the rollers <NUM> based on processed data and information. The data transmission between the control unit <NUM> and the detection unit <NUM> and delamination unit <NUM> may be wired, for example via Ethernet cable, or may be wireless, for example via Internet (Wi-Fi).

According to the invention, the control unit <NUM> is configured, through operation of the at least one processor <NUM>, to correlate at least positions of the articles A, B, C, D, E with the plurality of individually controlled rollers <NUM>, and to individually control the rollers <NUM> based on the position data to delaminate the stream <NUM> of articles A, B, C, D, E. Further, the control unit <NUM> is configured to correlate size and orientation of the articles A, B, C, D, E with the plurality of individually controlled rollers <NUM>. Specifically, the control unit <NUM> is configured to individually control speed and direction of each of the rollers <NUM> of the delamination unit <NUM>.

According to the invention, the detection unit <NUM> is configured to continuously track the positions of the articles A, B, C, D, E. In a further exemplary embodiment of the present disclosure the detection <NUM> unit <NUM> is configured to continuously transmit position data to the control unit <NUM>. The control unit <NUM> is further configured, through operation of the at least one processor <NUM>, to optimize the speed and direction of each roller <NUM> based on continuously transmitted position data to delaminate and/or singulate the stream <NUM> of articles A, B, C, D, E.

<FIG> depicts a flow chart of a method <NUM> for delaminating a stream of articles in accordance with an exemplary embodiment of the present disclosure. While the method <NUM> is described as a series of acts that are performed in a sequence, it is to be understood that the method <NUM> may not be limited by the order of the sequence. For instance, unless stated otherwise, some acts may occur in a different order than what is described herein. In addition, in some cases, an act may occur concurrently with another act. Furthermore, in some instances, not all acts may be required to implement a methodology described herein.

The method <NUM> may start at <NUM> and includes an act <NUM> of receiving position data of articles A, B, C, D, E carried by the delamination unit <NUM> comprising the plurality of individually controlled rollers <NUM>. The method <NUM> also includes an act <NUM> of correlating the position data with the plurality of individually controlled rollers <NUM>, and an act <NUM> of controlling speed and direction of each of the plurality of individually controlled rollers <NUM> based on the position data to delaminate the stream <NUM> of articles A, B, C, D, E. At <NUM>, the method <NUM> may end. It should be appreciated that this described method <NUM> may include additional acts and/or alternative acts corresponding to the features described with respect to the delamination system <NUM> and control unit <NUM> (see <FIG> and <FIG>).

In an embodiment, the method <NUM> may further include act(s) of receiving size and orientation data of the articles A, B, C, D, E carried by the delamination unit <NUM>, correlating the size and position data with the plurality of individually controlled rollers <NUM> of the delamination unit <NUM>, and controlling the speed and direction of each of the plurality of individually controlled rollers <NUM> based on the size and orientation data to delaminate the stream <NUM> of articles A, B, C, D, E.

In another embodiment, the method <NUM> may further include an act of individually controlling speed and direction of each of the rollers <NUM> of the delamination unit <NUM>. In another embodiment, the method <NUM> may further include an act of updating and/or optimizing the speed and direction of each roller <NUM> based on continuously received position data to delaminate and/or singulate the stream <NUM> of articles A, B, C, D and E.

In our example as depicted in <FIG>, a delamination process may be performed as described below. An object of the delamination system <NUM> is to move the items or articles A, B, C, D, E onto the downstream conveyor <NUM> individually, e.g., singulated, or at a minimum delaminated.

Item A: Activate rollers <NUM> and <NUM> forward (clockwise) until trailing edge of item A clears roller <NUM>, then active rollers <NUM> through <NUM> forward until trailing edge of item A clears roller <NUM>, then activate rollers <NUM> through <NUM> forward until trailing edge of item A clears roller <NUM>.

Item E: Activate rollers <NUM>, <NUM> and <NUM> forward unit trailing edge of item E clears roller <NUM>, while potentially activating rollers <NUM> through <NUM> reverse (counterclockwise) to hold item B. When trailing edge of item E passes roller <NUM>, activate rollers <NUM>, <NUM> and <NUM> forward.

Item B: Activate rollers <NUM> through <NUM> forward, while potentially pulling item D back by reversing roller <NUM>, etc..

The size of the rollers <NUM>, e.g., their pitch, is such that the item with a shortest length has contact with at least two rollers <NUM> at all times. The number of rollers <NUM> in the short planes (planes <NUM>) may be targeted at a significant mode in standard distribution of item lengths process by the system <NUM>.

Since the rollers <NUM> of the delamination unit <NUM> are individually controlled in terms of their speed and direction, the delamination system <NUM> allows unique control over items, such as items A, B, C, D, E, depending on their length and position. The detection unit <NUM>, e.g., vision unit, continuously tracks the positions of items so that the rollers' speed and direction are continuously updated and optimized by the control unit <NUM> to delaminate or even to singulate.

It should be appreciated that acts associated with the above-described methodologies, features, and functions (other than any described manual acts) may be carried out by one or more data processing systems, such as for example control unit <NUM> via operation of at least one processor <NUM>. As used herein, a processor corresponds to any electronic device that is configured via hardware circuits, software, and/or firmware to process data. For example, processors described herein may correspond to one or more (or a combination) of a microprocessor, central processing unit (CPU,) or any other integrated circuit (IC) or other type of circuit that is capable of processing data in a data processing system. As discussed previously, the processor <NUM> that is described or claimed as being configured to carry out a particular described/claimed process or function may correspond to a CPU that executes computer/processor executable instructions stored in a memory in form of software and/or firmware to carry out such a described/claimed process or function. However, it should also be appreciated that such a processor may correspond to an IC that is hard wired with processing circuitry (e.g., an FPGA or ASIC IC) to carry out such a described/claimed process or function.

In addition, it should also be understood that a processor that is described or claimed as being configured to carry out a particular described/claimed process or function may correspond to the combination of the processor <NUM> with the executable instructions (e.g., software/firmware apps) loaded/installed into a memory <NUM> (volatile and/or non-volatile), which are currently being executed and/or are available to be executed by the processor <NUM> to cause the processor <NUM> to carry out the described/claimed process or function. Thus, a processor that is powered off or is executing other software, but has the described software installed on a data store in operative connection therewith (such as on a hard drive or SSD) in a manner that is setup to be executed by the processor (when started by a user, hardware and/or other software), may also correspond to the described/claimed processor that is configured to carry out the particular processes and functions described/claimed herein.

In addition, it should be understood, that reference to "a processor" may include multiple physical processors or cores that are configures to carry out the functions described herein. Further, it should be appreciated that a data processing system may also be referred to as a controller that is operative to control at least one operation.

It is also important to note that while the disclosure includes a description in the context of a fully functional system and/or a series of acts, those skilled in the art will appreciate that at least portions of the mechanism of the present disclosure and/or described acts are capable of being distributed in the form of computer/processor executable instructions (e.g., software and/or firmware instructions) contained within a data store that corresponds to a non-transitory machine-usable, computer-usable, or computer-readable medium in any of a variety of forms. The computer/processor executable instructions may include a routine, a sub-routine, programs, applications, modules, libraries, and/or the like. Further, it should be appreciated that computer/processor executable instructions may correspond to and/or may be generated from source code, byte code, runtime code, machine code, assembly language, Java, JavaScript, Python, Julia, C, C#, C++ or any other form of code that can be programmed/configured to cause at least one processor to carry out the acts and features described herein. Still further, results of the described/claimed processes or functions may be stored in a computer-readable medium, displayed on a display device, and/or the like.

<FIG> depicts a block diagram of a control system, herein also referred as a data processing system, in which an embodiment can be implemented, for example as a control system <NUM> for a delamination system <NUM> as described before and can be configured to perform processes as described herein.

The control system <NUM> depicted includes processor <NUM> connected to a level two cache/bridge <NUM>, which is connected in turn to a local system bus <NUM>. Local system bus <NUM> may be, for example, a peripheral component interconnect (PCI) architecture bus. Also connected to local system bus <NUM> in the depicted example are a main memory <NUM> and a graphics adapter <NUM>. The graphics adapter <NUM> may be connected to display <NUM>.

Other peripherals, such as local area network (LAN)/wide area network (WAN)/Wireless (e.g., Wi-Fi) adapter <NUM>, may also be connected to local system bus <NUM>. Expansion bus interface <NUM> connects local system bus <NUM> to input/output (I/O) bus <NUM>. I/O bus <NUM> is connected to keyboard/mouse adapter <NUM>, disk controller <NUM>, and I/O adapter <NUM>. Disk controller <NUM> can be connected to a storage <NUM>, which can be any suitable machine usable or machine readable storage medium, including but not limited to non-volatile, hard-coded type mediums such as read only memories (ROMs) or erasable, electrically programmable read only memories (EEPROMs), magnetic tape storage, and user-recordable type mediums such as floppy disks, hard disk drives and compact disk read only memories (CD-ROMs) or digital versatile disks (DVDs), and other known optical, electrical, or magnetic storage devices.

I/O adapter <NUM> can be connected to mail processing and imaging devices <NUM>, for example to image, scan, transport, label, address-process, sort, and otherwise processes the articles, such as parcels A, B, C, D, E of stream <NUM>, in accordance with the various embodiments described herein. Also connected to I/O bus <NUM> in the example shown is audio adapter <NUM>, to which speakers (not shown) may be connected for playing sounds. Keyboard/mouse adapter <NUM> provides a connection for a pointing device (not shown), such as a mouse, trackball, track-pointer, etc..

Those of ordinary skill in the art will appreciate that the hardware depicted in <FIG> may vary for particular implementations. For example, other peripheral devices, such as an optical disk drive and the like, also may be used in addition or in place of the hardware depicted. The depicted example is provided for the purpose of explanation only and is not meant to imply architectural limitations with respect to the present disclosure.

LAN/WAN/Wireless adapter <NUM> can be connected to a network <NUM> (not a part of data processing system <NUM>), which can be any public or private data processing system network or combination of networks, as known to those of skill in the art, including the Internet. LAN/WAN/Wireless adapter <NUM> can also communicate with parcels A, B, C, D, E as described herein and perform other data processing system or server processes described herein. Data processing system <NUM> can communicate over network <NUM> with one or more server systems <NUM>, which are also not part of data processing system <NUM>, but can be implemented, for example, as separate data processing systems. A server system <NUM> can be, for example, a central server system at a central mail processing facility.

Claim 1:
A system (<NUM>) for delaminating a stream (<NUM>) of articles (A, B, C, D, E) comprising:
a delamination unit (<NUM>) comprising a plurality of individually controlled rollers (<NUM>) configured to carry a stream (<NUM>) of articles (A, B, C, D, E),
a detection unit (<NUM>) comprising at least one sensor (<NUM>), and
a control unit (<NUM>) comprising at least one processor (<NUM>) and interfacing with the delamination unit (<NUM>) and the detection unit (<NUM>),
wherein the detection unit (<NUM>) is configured to detect a position of each of the articles (A, B, C, D, E) and to transmit position data to the control unit (<NUM>), and
wherein the control unit (<NUM>) is configured, through operation of the at least one processor (<NUM>), to correlate positions of the articles (A, B, C, D, E) with the plurality of individually controlled rollers (<NUM>), and to individually control the rollers (<NUM>) based on the position data to delaminate the stream (<NUM>) of articles (A, B, C, D, E)
wherein the individually controlled rollers (<NUM>) of the delamination unit (<NUM>) are grouped (<NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D, <NUM>-E) and arranged in a primary plane (<NUM>);
wherein each group (<NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D, <NUM>-E) comprises at least two of the individually controlled rollers (<NUM>),
wherein the primary plane (<NUM>) is a laterally tilted inclined plane,
characterized in that,
the groups (<NUM>-A, <NUM>-B, <NUM>-C, <NUM>-D, <NUM>-E) of rollers (<NUM>) are arranged in multiple different secondary planes (<NUM>, <NUM>), and in that,
the control unit (<NUM>) is configured, through operation of the at least one processor (<NUM>), to individually control speed and direction of each of the rollers (<NUM>) of the delamination unit (<NUM>),
and in that,
the detection unit (<NUM>) is configured to continuously track the positions of the articles (A, B, C, D, E), and the control unit (<NUM>) is further configured, through operation of the at least one processor (<NUM>), to optimize the speed and direction of each roller (<NUM>) based on continuously transmitted position data provided by the detection unit (<NUM>) to delaminate and/or singulate the stream (<NUM>) of articles (A, B, C, D, E),
and in that,
the detection unit (<NUM>) comprises a vision unit with at least one image sensor (<NUM>, <NUM>).