Patent ID: 12214382

DETAILED DESCRIPTION

Overview

Aspects of this disclosure are directed toward ensuring actual physical mail matches digital files provided to the USPS for postage discounts received on same mail via automated mail handling and monitoring systems to improve compliance with USPS intelligent mailing requirements and reduce labor costs associated with highly repetitive, manual, error-prone tasks throughout high volume mailing operations. New USPS mandates are exposing a gaping hole in the mail value stream-namely the gap between its physical and digital elements-which leads to the actual physical mailing not matching the digital documentation submitted to the USPS for postage discounts. As a result, the USPS must rework mail for which the USPS has already provided workshare postage discounts. This physical-digital gap has existed for years but must be addressed by the industry to preserve its $15 billion annual postage discounts from the USPS, not to mention the additional value recognized by mailers from labor, productivity, and error impacts.

Now with the unprecedented 100% visibility into the mailstream provided via new IMb, Mailer ScoreCard, Seamless Acceptance, eInduction, and related mandates, the USPS will begin assessing fines on unearned postage discounts from workshare failures in the near future. Per the Mailer ScoreCard mailers will now be graded on each of multiple performance metrics (FIG.6) with fines assessed for failure to meet minimum USPS established thresholds. As such, industry participants are highly motivated to both reduce the risk of errors and prove out their performance relative to their workshare discounts in a fully documented manner.

Automated (e.g., robotic) mail tagging, traying, sleeving, and palletizing devices are disclosed herein. In embodiments, an automated mail handling system can include all of the automated devices disclosed herein. In other embodiments, a mail handling system (i.e., partially automated system) only includes one or more of the automated devices with some tasks being performed manually or in a semi-automated (e.g., operator assisted) fashion.

A monitoring system is also disclosed. In embodiments, the monitoring system is configured to operate with (e.g., monitor and/or control) one or more of the automated devices disclosed herein to capture IMb data (e.g. a mail item, mail tray, and/or pallet identifier) of actual physical mail so as to ensure the digital file submitted to USPS matches same mail, thus avoiding penalties. For example, the monitoring system may be communicatively coupled with one or more of the automated devices to provide monitoring and/or control at the one or more corresponding mail handling operations. In some embodiments, the monitoring system is additionally or alternatively configured to operate with user-driven devices (e.g., handheld scanners, cameras, or other sensors) and/or user-monitoring devices (e.g., surveillance cameras) to provide monitoring for manual or semi-automated mail handling operations.

Current USPS standards and/or programs such as IMB, Mailer ScoreCard, Seamless Acceptance, eInduction and related initiatives for mail item/piece, mail tray, and mail pallet identifiers may change and/or evolve as USPS changes its operational processes, but the systems and methods disclosed herein will remain applicable for ensuring the actual physical mail matches the digital files submitted to USPS for postage discounts of same mail.

EXAMPLE IMPLEMENTATIONS

FIGS.1through3illustrate an automated mail handling system100in accordance with various embodiments of this disclosure. Those skilled in the art will appreciate that the embodiments illustrated in the drawings and/or described herein may be modified or fully or partially combined to result in additional embodiments. Accordingly, the illustrated and described embodiments should be understood as explanatory and not as limitations of the present disclosure.

InFIG.1, the automated mail handling system100is shown to include a conveyance system (e.g., conveyer belts, ramps, slides, etc.) connecting stations for mail traying, tagging, sleeving, and palletizing. For example, mail items (e.g., envelopes, packages, printed materials, etc.) are introduced by one or more inserters (could also be sorters and/or printer press)102. The system includes one or more mail traying devices104(sometimes referred to as “trayers”) configured to place the mail items into appropriately sized trays110. The conveyance system presents the trays to a mail tray tagging device120(sometimes referred to as a “tagger”) that scans one or more mail items in the tray to then apply a tag on each tray110according to its mail items therein. The conveyance system presents the trays to a mail tray sleeving device106(sometimes referred to as a “sleever”) that is configured to place a sleeve around each tray110. The sleeved trays110are then arranged in pallets112by a palletizing device108(sometimes referred to as a “palletizer”).

The system100can be fully (or substantially fully) automated, including at least one trayer104, at least one tagger120, at least one sleever106, and at least one palletizer108. Any number of the foregoing devices can be implemented depending on system requirements. In some embodiments, the system100can be partially automated (i.e., semi-automated) with one or more of the foregoing devices. For example, a semi-automated mail handling system may include a trayer104and sleever106with manual arrangement of pallets. This example is provided for illustrative purposes only, showing that the system100can operate with any or all of the devices (i.e., trayer104, tagger120, sleever,106, palletizer108) described herein.

In embodiments, a monitoring system is configured to operate with (e.g., monitor and/or control) one or more of the automated devices disclosed herein to facilitate actual physical mail matches the digital files provided to the USPS for postage discounts received on same mail. By comparing the digital information regarding the mail item identifier, the tray identifier, and the pallet identifier with the stored physical information received from the one or more scanners; and identifying whether or not any discrepancies exist between the digital information regarding the mail item identifier, the tray identifier, and the pallet identifier and the stored physical information received from the one or more scanners users can ensure actual physical mail matches the digital files submitted to USPS for postage discounts of same mail. For example, the monitoring system may be communicatively coupled with one or more of the automated devices to provide monitoring and/or control at the one or more corresponding mail handling operations. In some embodiments, the monitoring system is additionally or alternatively configured to operate with user-driven devices (e.g., handheld scanners, cameras, or other sensors) and/or user-monitoring devices (e.g., surveillance cameras) to provide monitoring for manual or semi-automated mail handling operations.

FIG.2is a zoomed-in view of the traying device104showing its operation in greater detail. In implementations, mail items are introduced by one or more inserters (could also be sorters and/or printer press)102and collected by tray break in one or more stacker bins. The traying device104includes a mechanical (e.g., robotic) arm that is configured to remove an appropriately sized tray110from a tray de-nester. The mechanical arm then positions the empty tray110adjacent to a full stacker bin114and sweeps its contents (i.e., mail items) into the tray110. The mechanical arm then places the tray110onto a conveyer belt (of the conveyance system) for transport to a tagging and/or sleeving station.

Example implementations of the traying device104are also disclosed in U.S. Pat. No. 7,381,026, entitled “Mail Traying Apparatus,” which is incorporated herein by reference in its entirety. Embodiments of the mail traying device104can include any of the embodiments described in U.S. Pat. No. 7,381,026 or any portions thereof.

Referring now toFIGS.7through14, a mail traying subsystem (MTS)310(an embodiment of mail traying device104) may include an enclosure312which extends around most of the components thereof for safety purposes. MTS310also includes two conventional mail processing machines314(FIG.9), each of which collates filled mail envelopes in a collator and feeds the same into a plurality of mail stacking bins318which are supported above the floor of the enclosure312. The mail envelopes320are stacked in the stacking bins318so as to be standing on edge. Preferably, the machines314are positioned in the enclosure312, as depicted inFIG.7. AlthoughFIG.7illustrates that a pair of mail processing machines314are utilized, a single mail processing machine or any number (e.g., three, four, etc.) of mail processing machines can be used. Conveyors322feed the mail envelopes to respective ones of the machines314(FIG.9).

MTS310also preferably includes a mail tray denester324which de-nests empty mail trays326from stack328of mail trays supplied to the denester324by means of conveyors330,332and334. Conveyor335may also be utilized in the system to supply individual trays to the system, but conveyor335does not form a part of the denester324. Denester324is provided with an upstanding frame336having an upper end338, lower end340, an open rearward side342, a forward side344, and opposite sides346,348. Frame336defines a plurality of cells350,352and354, each of which is adapted to receive a stack328of mail trays326therein. Although three cells are illustrated, any number of cells may be utilized.

The numeral3102refers to a conventional robot including a controller and computer or processor of conventional design. Robot3102includes a base3104supported upon a floor, a pedestal3106and a robot or robotic arm3108including a tip or tool end3110. A mail tray support3112is pivotally secured to mounting plate3114by any convenient means so as to be movable therewith and with respect thereto. Support3112includes a pair of pivotal side members, support members or arms3116and3118having inwardly extending flanges3120and3122thereon, respectively, which are designed to support a mail tray326thereon and therebetween. It should be noted that support3112is shown to be tilted or canted inFIGS.7,8and10-13merely to show both the arms3116and3118. Normally, the arms3116and3118are parallel to one another in the same horizontal plane as seen inFIG.14. The arms3116and3118are pivotally movable with respect to each other by means of a pneumatic cylinder secured thereto and extending therebetween. The pneumatic cylinder is designed to enable the arms3116and3118to be moved from a closed, tray engaging position to an open, non-tray engaging position.

One or more power cylinders, either pneumatic or hydraulic, interconnect support3112and mounting plate3114to enable support3112to be pivotally movable with respect to mounting plate3114.

The numeral3128refers to a mail sweeper assembly which is mounted on mounting plate3114and which is positioned therebelow. Assembly3128includes a plate, blade or paddle3130which is mounted on the end of a rotatable and longitudinally movable shaft3132. Shaft3132is longitudinally movable between retracted and extended positions, and is rotatably movable between a first, non-envelope engaging position and an envelope engaging position. The shaft3132is rotatably and longitudinally movable by any convenient means. A second plate, blade or paddle3134is also rotatably mounted on mounting plate3114and is rotatable between a first non-envelope engaging position and a second envelope engaging position by any convenient means. As seen, paddle3134is spaced from paddle3130so that paddles3130and3134may be positioned at the opposite ends of the stack of envelopes in the stacker bin. Although the robot of this invention is ideally suited for use with the denester assembly previously described, the robot's primary purpose is to tray mail into a mail tray regardless of the manner of supplying and/or denesting empty mail trays for handling by the robot.

Referring again toFIGS.1through3, the tagging device120can be configured to tag the trays110at the traying stage, or after. For example, the tagging device120may include a printer configured to produce a placard or tag with a unique identifier (e.g., an intelligent mail barcode (IMB)) for the filled tray110. In other embodiments, the tray110can be tagged before the sleeving stage (e.g., after exiting the traying stage). In some implementations, the tagging device120may be located between the trayer104and the sleever106and is configured to tag each tray110after the tray110leaves the traying device104.

Referring toFIGS.28through31D, a tagging device500(an embodiment of tagging device120) can include mail item scanning robot502and a printer512that produces applies an appropriate placard or tag for a tray5110. The tagging stage may be immediately preceding the sleeving stage (e.g., as shown inFIG.3).5110Trays from the one or more inserters102(sorters and/or presses) travel on a singular delivery line. The mail item scanning robot502performs a mail item scan of the tray contents by detecting tray contents and making appropriate scan-if single mail item address-up, then scan mail item; if bundled mail items address-up, then scan top mail item; if filled tray5110then tagging device detects nature (loose/medium/tight filled). The mail item scanning robot502includes a robotic arm504with an end-of-arm tooling506that comprises a wedge508and a scanner510(e.g., a barcode reader, camera, or other sensor), whereby the mail item scanning robot502maneuvers the end-of-arm tooling504to expose an address window of single mail item to scan said mail item.

In an embodiment, the robotic arm504plunges the end-of-arm tooling506into the tray5110, causing the wedge508to separate mail items in the tray in order to expose an address window of at least one mail item. The scanner510then scans the mail item to obtain information (e.g., a mail item identifier (e.g., IMB)) that can be used (e.g., by a controller) to direct the printer502to produce an appropriate placard or tag for the tray5110.FIGS.31A through31Dshow detailed views of the robotic arm504and end-of-arm tooling506. The robotic arm504can include a base516and at least one extension518coupled by a motorized hinge517that actuates the extension518relative to the base516. The end-of-arm tooling506can include a base portion522that is coupled to the extension518by another motorized hinge520that actuates the end-of-arm tooling506relative to the extension518. In embodiments, motorized hinges517and520can have one axis of rotation or multiple axes of rotation. The wedge508(or multiple wedges as shown inFIGS.31A through31D) can include one or more angled surfaces. For example, inFIGS.31A through31D, wedge508is shown to include a first surface524and a second surface526that intersect at an angle to form wedge508.

As shown inFIG.30, the printer512includes an applicator514configured to extend from the printer512and apply the placard or tag to the tray5110. Scanned mail item data is used by tagging device500to determine an appropriate tray identifier (e.g., IMB for the tray). The tagging device500can then apply a tray tag or placard with the identifier. Once the tray5110is tagged, the tray5110continues along a conveyor to a reject tray tag scanner to confirm correctness of the tag. The tray5110then continues to the sleeving station.

FIG.3is a zoomed-in view of the sleeving device106and the palletizing device118. The sleeving device106may include at least one sensor (e.g., camera, photodiode array, physical mass or dimension sensor, magnetic sensor, or the like) configured to detect an incoming tray110and determine its size using machine-vision algorithms or other sensor algorithms for determining dimension. For example, a processor coupled to the one or more sensors can be configured to determine a shape of the tray110or spatial separation between portions of the tray110. The sleeving device106is configured to select an appropriately sized sleeve based on the determined tray size. For example, the sleeving device106may be configured to retrieve a sleeve from two or more sleeve queues holding two or more sizes of sleeves, respectively. The sleeving device106can flip open or pop open the sleeve and then direct the tray110through the opened sleeve. In embodiments, the sleeving device106includes a mechanical (e.g., robotic arm) configured to retrieve a sleeve from a sleeve cartridge or sleeve bank and pull the sleeve into a staging area, flip or pop the sleeve open, place it on a funnel and secure it a path along which the tray110is pulled by the conveyance system. The sleeving device106can further include a plurality of paddles, mechanical arms, or the like that guide the tray110into the open sleeve.

Example implementations of the sleeving device106are also disclosed in U.S. Pat. No. 8,621,831, entitled “Robotic Mail Tray Sleever Apparatus,” which is incorporated herein by reference in its entirety. Embodiments of the mail tray sleeving device106can include any of the embodiments described in U.S. Pat. No. 8,621,831 or any portions thereof.

FIGS.15through27illustrate example implementations of a robotic mail tray sleeving system410(an embodiment of mail tray sleeving device106) for sleeving a mail tray412. System410includes a conveyor system414, a sleeve blank presentment device416, a robotic arm418, having end of arm tooling420, and a tray induction system422. Conveyor system414transports tray412to a position proximate to sleeve blank presentment system416. Robotic arm418grasps a sleeve blank424, opens the sleeve blank to form a sleeve and positions the opened sleeve proximate to induction system422. Robotic arm418then releases sleeve424and tray412is positioned inside sleeve424before moving downstream of system410.

Conveyor system414may be specialized as shown herein. Sleeve blank presentment device416is shown as two side-by-side rectangular holders for providing sleeves of two different sizes to system410. An operator may restock each of the holders “on the fly” such that system410operates continuously during restocking. This allows for a higher average cyclic rate for the system as it operates over time. Robotic arm418is shown as a six axis robotic arm, but a multi axis robotic arm may also be used. The numerous degrees of freedom available in this design allow for greater tolerances during installation as any variation in actual relative position of the robotic arm418to conveyor system414, sleeve blank presentment device416, and tray induction system422may be corrected by altering the program controlling robotic arm418after installation.

Referring toFIGS.16-18, end of arm tooling420may generally include a base plate426, a robotic arm adapter428, a coupler430, suction heads432, suction head couplers434, and sleeve opening system436. Each of suction heads432are coupled to base plate426by suction head couplers434. Each suction head may be in fluid communication with its own air supply for creating a partial vacuum. Alternatively, all four suction heads may be in fluid communication with the same air supply. End of arm tooling420may be coupled to robotic arm418(shown inFIG.15) at coupler430.

Sleeve opening system436may be coupled to base plate426by any of a variety of means including welding or fastening. Sleeve opening system436includes an arm438and a base440. Arm438includes a first end comprising a cam portion442having an aperture444that comprises the pivot point of cam portion442. Aperture444is positioned to be a working portion of cam portion442that may be engaged to move a second end of arm having a contact446at a point distal to cam portion442. Base portion440may comprise a plate portion448and an extension450through which aperture444also passes. Arm438may be pivotally coupled to extension450by a pin, rivet, or other fastening means. Actuator452urges a rod454that is engaged to arm438at aperture455such that substantially linear motion of rod454translates to an arcuate motion of contact446about aperture444and along path456. Thus, when actuator452urges rod454contact446is pivoted in a plane perpendicular to the plane defined by base plate426. Actuator452and rod454may comprise pneumatic piston, a screw drive, or any other known means of translating substantially linear motion into arcuate motion. Alternatively, other drive systems could be used including belts, chains and other devices.

Referring toFIGS.19-27, a method of sleeving mail trays is illustrated using an embodiment of the robotic sleeving system disclosed herein. As shown inFIG.19, system4100begins a sleeving cycle with robotic arm4118in a generic “home” position. InFIG.20, robotic arm4118engages a sleeve4124ain device4116by means of the end of arm tooling4120. As shown inFIG.21, robotic arm4118moves sleeve4124ato a first conveyor line4114aon which a first tray4112ais travelling. InFIG.22, the end of arm tooling is used to open sleeve4124aby exerting a force on a side surface of sleeve4124ain a way that biases sleeve4124ainto an open position. In general, this operation may be carried out in a configuration such that gravity is also biasing sleeve4124ainto the open position. InFIG.23, sleeve4124ais placed onto tray induction system4122aas tray4112aadvances. As shown inFIG.24, after placing sleeve4124aon tray induction system4122a, end of arm tooling releases sleeve4124aand moves to repeat the process. InFIG.25, robotic arm4118uses end of arm tooling4120to engage a second sleeve4124band position sleeve4124bproximate to a second conveyor line4114b. As shown inFIG.26, the end of arm tooling4120opens sleeve4124bsimilarly to how sleeve4124awas opened. InFIG.27, sleeve4124bis placed on tray induction system4122bas tray4112a, now within sleeve4124a, advances past system4110.

In general, a method consistent with some embodiments would include the following steps: (a) providing a conventional mail tray containing mail envelopes being transported on the conveyor; (b) positioning a source of empty sleeves (e.g., device416) in a position proximate to the conveyor; (c) providing a robot including a multi-axis robot arm (e.g., arm418) having a sleeve support and sleeve former (e.g., end of arm tooling420) secured to an end thereof; (d) positioning the robot relative to the conveyor and the source of sleeves so that the robot sleeve support and sleeve former may be moved therebetween; (e) providing a tray entering a conveyor (e.g., conveyor414) in a staging zone upstream of the robot, where sensors determine the tray type and/or size for the robot as the tray moves down the conveyor; (f) causing the robot arm to move to the source of empty sleeves, pick the correct sleeve type/size using suction from the end of arm tooling, and to then position an empty sleeve in the end of arm tooling; (g) forming the empty sleeve into the sleeve's ready (open) position while in motion toward the tray induction system (e.g., system422); (h) moving the robot arm while positively retaining the formed sleeve during motion so that the empty sleeve in the end of arm tooling is positioned at the tray induction system in the sleeve's open position; (i) moving the end of arm tooling and the formed sleeve so as to place the formed sleeve onto the funnel device of the tray induction station; (j) securing the opened sleeve in the tray induction station by means of the funnel device and movable stops as described herein; (k) releasing the opened sleeve to the tray induction station from the robot by ending the end of arm tooling suction; (l) sending the robot back to the source of sleeves so that the robot end of arm tooling may pick the correct sleeve type/size for the next tray entering a conveyor (e.g., conveyor4114b) at a point upstream of the robot where sensors determined the next tray type and/or size for the robot as the next tray moves down the conveyor; (m) concurrently, while the robot is picking the next sleeve for the next tray, inducting the previous tray into the sleeve via a paddle device that pushes the tray into the opened sleeve along guided side rails contained within the tray induction station; (n) discharging the sleeved tray from the tray induction station onto the conveyor; (o) concurrently moving the robot arm and empty sleeve support from the source of empty trays for the next sleeve to the next tray induction station; and (p) similarly repeating the cycle for additional tray/sleeve sizes and/or types detected as the trays are transported down the conveyor.

Referring again toFIGS.1through3, in some embodiments, the system100further includes a strapper116configured to secure the sleeved tray110with straps prior to its transport to the palletizing station. The palletizing device108may include a sensor or scanner (e.g., barcode reader) configured to detect the unique identifier (e.g., IMB) on the placard or tag of each tray110. For example, the sensor or scanner can be a user handled sensor or scanner, or in other embodiments, the sensor or scanner can be coupled to an end-of-arm tooling of the palletizing device108. A controller (e.g., computing system including a processor or microcontroller) may be configured to assign the tray110apallet position based on the tray/pallet identifier. The palletizing device108includes a mechanical (e.g., robotic) arm that places each tray in a determined position within a pallet112. When the pallet112is complete an indicator light, graphical user interface, and/or speaker/alarm can provide a visual and/or audible alert for an operator to remove the filled pallet112and place an empty pallet112into the vacated position. In some implementations, this process can also be automated, for example, using pallet conveyor, self-driving (e.g., computer controlled) or remotely controlled forklifts. In some embodiments, the palletizer includes a printing/tagging device configured to generate and/or apply a tag or placard with an identifier (e.g., IMB) for each pallet112. In other embodiments, the pallet112can be tagged after leaving the palletizer108, for example, a pallet placard may be printed and placed on the pallet112by the operator prior to its removal from the palletizing station.

At the palletizing (or traying, or sleeving, or tagging) station, tray (and/or mail item and/or pallet) information may be read and sent to a database storing information regarding the mail item, tray, and pallet identifiers (e.g., respective IMBs). The database may include detailed information, such as origination, destination, and/or mail item information (e.g., priority info, details regarding contents (e.g., value, confidential status), etc.). For example, scan data can be sent to a database; this data is then pushed into a text (e.g. “.xml”) file; which is then married to an “exceptions” file (e.g., another text (e.g., “.txt”) file); the Exceptions (.txt) and Scan Data (.xml) are reconciled so that final (mail.dat) can be delivered to USPS. This bridges the physical-digital gap between what actually occurs in the real world (to the physical mail items, trays, pallets, etc.) and the summary text file (e.g., a “mail.dat”) file that includes a subset of the information (e.g., IMBs corresponding to each pallet, trays, and/or mail items contained therein).FIG.5shows an example mail.dat file with mail item, tray, and pallet identification info (e.g., mail item, tray, and pallet IMBs). In some implementations, a respective controller118(and/or a shared central controller) is in communication with the trayer104and palletizer108, and possibly the sleever106and/or any standalone tagging devices and so forth. The controller118may be coupled to sensors (e.g., barcode scanners) configured to detect identifier information from mail item, tray, and/or pallet tags or placards before, after, or during any of the operational stages described above (e.g., during or after the traying stage and/or the palletizing stage) The controller118may be implemented as a computing system or network of computing systems that monitor and/or control the tagging, traying, sleeving, and/or palletizing operations described herein. In some implementations, where one or more of the tagging, traying, sleeving, and/or palletizing operations are completed manually, the controller118may be communicatively coupled with handheld scanners or configured to receive information downloaded from handheld scanners that can detect identifier information at, after, or before any of the operational stages described herein. Identifier information for actual physical mail is then used to ensure it matches the digital file being submitted to USPS for postage discounts of same mail. Additionally, identifier information for actual physical mail processed can provide audit traceability of the actual mail production to ensure mailer can demonstrate documentation of USPS compliance.

FIG.4is a block diagram illustrating a mail monitoring system200and a corresponding operational flow in accordance with an embodiment of this disclosure. The monitoring system200can include a client server202(e.g., controller118or a client server coupled to controller118) that is configured to store detailed information regarding mail items, corresponding identifier information, and a mail summary (e.g., mail.dat) file. The client server202may be configured to control a printer206to print content and/or a label for each mail item. Once labeled and/or sorted, the mail items can be processed through various stages.

The mail items can be presented to the trayer208A (e.g., trayer104) by an inserter or press204(e.g., inserter102). The mail items (or a subset of the mail items) are scanned (e.g., by scanner209A) and placed into a mail tray110by the trayer208A, or can be manually transferred in some embodiments of system200. In some embodiments, the scanner209A can be coupled to the trayer208A or integrated within the trayer structure (e.g., as part of an end-of-arm tooling or the like). In other embodiments, the scanner209A can include a user-driven (e.g., handheld) scanner. The mail item scan data from scanner209A is sent to controller218(e.g., controller118or another controller/server coupled to controller118).

The mail tray can be transported (e.g., carried or conveyed) to a tagging station. At least one mail item in the mail tray110is scanned (e.g., by scanner209B) and the appropriate mail tray tag is applied to the mail tray110by tagger208B (e.g., tagger120), or manually. The applied mail tray tag may be re-scanned (e.g., by scanner209B or another scanner). In some embodiments, the scanner209B can be coupled to the tagger208B or integrated within the tagger structure (e.g., as part of an end-of-arm tooling or the like). In other embodiments, the scanner209B can include a user-driven (e.g., handheld) scanner. The mail item and mail tray scan data from scanner209B is sent to controller218.

The tagged mail tray110can be transported (e.g., carried or conveyed) to a sleeving station. The mail tray110is sleeved by sleever208C (e.g., sleever106), or manually. Prior to sleeving the mail tray110, at least one mail item in the mail tray may be scanned (e.g., by scanner209C). The corresponding mail tray tag can also be scanned (e.g., by scanner209C or another scanner). In some embodiments, the scanner209C can be coupled to the sleever208C or integrated within the sleever structure (e.g., as part of an end-of-arm tooling or the like). In other embodiments, the scanner209C can include a user-driven (e.g., handheld) scanner. The mail item and mail tray scan data from scanner209C is sent to controller218.

The sleeved mail tray110can be transported (e.g., carried or conveyed) to a palletizing station. The sleeved mail tray110is loaded onto a pallet112by palletized108, or manually. Before, after, or in conjunction with loading the sleeved tray110onto the pallet, the tray110is scanned (e.g., by scanner209D). The tray110may be loaded into an appropriate pallet position (e.g., by the palletizer or manually) based on a tray identifier scanned by scanner209D. In some embodiments, the scanner209D can be coupled to the palletizer208D or integrated within the palletizer structure (e.g., as part of an end-of-arm tooling or the like). In other embodiments, the scanner209D can include a user-driven (e.g., handheld) scanner. A standalone tagging device or a tagging device coupled to or incorporated within the palletizer structure (e.g., as part of an end-of-arm tooling or the like) is configured to apply a tag to the pallet with an appropriate pallet identifier, which may be based on the scanned mail tray identifier. The scanner209D (or another scanner) is configured to scan the pallet identifier. The mail tray and mail pallet scan data from scanner209D is sent to controller218.

The scanned identifier information may be stored by a monitoring/auditing computer (e.g., controller218). This information can be compared with stored routing tables and/or USPS customer supplier agreement (CSA) tables. When a pallet112is completed and tagged with an identifier tag or placard, the mail tray and mail pallet scan data from scanner209D is sent to controller218. The pallet information is also stored by the monitoring/auditing computer (e.g., controller218). Finished pallets210(e.g., pallet112) are transported to a drop off location. Prior to or in conjunction with transferring a finished pallet210onto a vehicle212for transport, the pallet identifier can be scanned again (e.g., by scanner209E). For example, scanner209E can include a user-driven (e.g., handheld) scanner. The pallet scan data from scanner209E can be sent to controller218.

The finished pallets210can be transported (e.g., by vehicle212) to a postal authority214(e.g., USPS) that takes control of the finished pallets210to perform at least a portion of the delivery process. The client server202can be configured to provide original mail item information (e.g., the mail.dat file) to a post presort server216. In an embodiment, the monitoring/auditing computer (e.g., controller218) is configured to provide actual mail item, tray, and/or pallet information (e.g., scanned IMBs or another mail.dat file generated from the scanned IMBs) to the post presort server216. In another embodiment, the monitoring/auditing computer (e.g., controller218) can be configured to determine the difference (e.g., a delta) between actual mail item, mail tray, and/or pallet information and is further configured to provide post presort server216with said information so that the final mail item information (e.g. the final mail.dat file) can be completed. This then ensures physical elements match the digital elements and allows for streamlined audit traceability of each pallet, (and/or mail item and/or tray) before it is further transported by the postal authority214. Accordingly, errors that can result in hefty penalties will be avoided and users are able to earn discounts currently being missed due to human error.

Per the Mailer ScoreCard mailers will now be graded on each of multiple performance metrics (FIG.6) with fines assessed for failure to meet minimum USPS established thresholds.FIG.6shows a spreadsheet that shows an example of USPS mailer scorecard metrics that can be impacted by the mail monitoring system in manual and automated (or semi-automated) mail handling system implementations. Quantity and type of USPS mailer scorecard metrics is subject to change and the mail monitoring system can be adapted to address any such changes accordingly. Validation Type is Pallet-Label (P-L), Pallet Content (P-C), Tray Label (T-L), and/or Tray Content (T-C). The “XX” (double-X means) notation indicates that the referenced manual or automated mail handling station is an opportunity to do a “double check” (i.e., T-L & T-C check) at the same location. Far right columns provide quantifications of the present relative value and risk level for each USPS Mailer Scorecard metric allowing mailers to prioritize implementation segments of mail handling system.

Access and control to the monitoring system may be selected from a variety of preset permissions, configurations, and/or custom selections. In some implementations, all monitoring/auditing is performed on-site (e.g., via controller118or network of controllers118). For example, the system may be configured for self-monitoring. In other implementations, the monitoring/auditing operations may be delegated to a vendor or third party auditor with oversight of the on-site control systems (e.g., a vendor having established communication with the one or more controllers118). Additionally, the monitoring/auditing operations can be shared among the mailer (i.e., the mail owner) and its vendor (i.e., mail service provider) in team monitoring arrangements. For example, the vendor may have access to full details collected by the monitoring system, while the mailer may be able to access summarized information to oversee the mailing operations. In some implementations, a third party auditor can also share access with the mailer and the vendor. Different permission levels or access can be limited to one or two of these parties, or provided to all of these parties and/or other parties involved in overseeing the system operations.

It should be recognized that the various functions, control operations, processing blocks, or steps described throughout the present disclosure may be carried out by any combination of hardware, software, or firmware. In some embodiments, various steps or functions are carried out by one or more of the following: electronic circuitry, logic gates, multiplexers, a programmable logic device, an application-specific integrated circuit (ASIC), a controller/microcontroller, or a computing system. A computing system may include, but is not limited to, a personal computing system, a mobile computing device, mainframe computing system, workstation, image computer, parallel processor, or any other device known in the art. In general, a “computing system” or “controller” is broadly defined to encompass any device having one or more processors, which execute instructions from a carrier medium.

Program instructions implementing functions, control operations, processing blocks, or steps, such as those manifested by embodiments described herein, may be transmitted over or stored on carrier medium. The carrier medium may be a transmission medium, such as, but not limited to, a wire, cable, or wireless transmission link. The carrier medium may also include a non-transitory signal bearing medium or storage medium such as, but not limited to, a read-only memory, a random access memory, a magnetic or optical disk, a solid-state or flash memory device, or a magnetic tape. In embodiments, the carrier medium can also include a cloud or network based storage solution.

Furthermore, it is to be understood that the invention is defined by the appended claims. Although embodiments of this invention have been illustrated, it is apparent that various modifications may be made by those skilled in the art without departing from the scope and spirit of the disclosure.