CROSS-REFERENCE TO RELATED APPLICATIONS
TECHNICAL FIELD
[0002] The present invention relates to a method and system for processing mail items within
a document processing system.
BACKGROUND
[0003] Document processing facilities often use high speed document processing machines
such as sorters, to sort and direct mail items appropriately to one or more mail bins
for distribution. The efficiency of a sorter is generally dependent upon various factors,
one of which is the rate at which mail items can be fed as input into the sorter's
transport path by a feeder system. Typical feeder systems employ one or more motor
driven belts in combination with a set of picker fingers, advance paddles or other
means to progressively advance a plurality of mail items into the transport path.
The more expedient the input of the mail items, the more expeditiously the sorter
can process these mail items as they are guided downstream, through the sorter, along
the transport path.
[0004] Consequently, jams that occur within the feeder system negatively impact sorter throughput
and efficiency. As mail items placed into the feeder system vary in width due to variations
in mail item content and width, air gap between mail items, etc., the stack pressure
of mail items may also vary accordingly. Stack pressure refers to the relative pressure
buildup resulting from a dense plurality of mail items to be input singularly into
the transport path. The higher the stack pressure, generally resulting from the concentration
of too many mail items attempting to be fed to a single point of entry to the transport
path, the higher the likelihood of mail jams at the point of entry. Therefore, it
is desired to monitor the stack pressure as the mail items are fed to the transport
path and to adjust the mail feeding behavior according to the stack pressure to minimize
the mail jams.
SUMMARY
[0005] One aspect of the present application includes providing a method for adjusting a
mail feeding system. The method includes advancing a plurality of mail items in a
first direction toward a guide mechanism. The guide mechanism is configured to guide
the plurality of mail items to a transport path. The guide mechanism has a variable
angular displacement indicative of a stack pressure against the guide mechanism. The
variable angular displacement of the guide mechanism is compared with a pre-determined
angular displacement. The stack pressure is adjusted in response to the comparison
by advancing one or more of the plurality of mail items in a second direction opposite
to the first direction.
[0006] Another aspect includes providing for a method for guiding a plurality of mail items
to a transport path from a magazine of a document processing device. The method includes
advancing a first mail item and a second mail item in a first direction towards a
guide mechanism. The guide mechanism is configured to guide the first and the second
mail items to a transport path. Prior to entry to the transport path, a gap between
the first mail item and the second mail item is monitored. The guide mechanism is
adjusted from a first to a second feed rate in response to the gap between the first
mail item and the second mail item; and profile data associated with the first and
second mail item. The second mail item is fed at the second feed rate onto the transport
path based on the adjusting step.
[0007] Yet another aspect includes providing a feeder system. The system includes a variable
speed magazine for driving a plurality of mail items in a direction toward or away
from a transport path of a sorter. A guide mechanism guides each of the plurality
of mail items onto the transport path. One or more guide mechanism sensors are included
for continuously measuring a variable angular displacement indicative of a stack pressure
against the guide mechanism. One or more gripper belts associated with the guide mechanism
are capable of being driven in at least two speeds. The gripper belts suitably contact
at least one of the plurality of mail items as it is driven by the magazine. One or
more sensors are provided for monitoring a distance between successive mail items
fed onto the transport path by said guide mechanism. A feeder control system is included
for maintaining a consistent rate at which mail items are guided from the magazine
onto the transport path by the guide mechanism. In response to an indicated stack
pressure, the feeder control system drives the magazine in the direction toward or
away from the transport path. In response to the monitored distance, the feeder control
system adjusts the speed of the gripper belts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The drawing figures depict concepts by way of example, not by way of limitations.
In the figures, like reference numerals refer to the same or similar elements. In
the figures, like reference numerals refer to the same or similar elements.
[0009] FIG. 1 depicts an exemplary feeder system for advancing mail items to point of entry
to a transport path of a document processing device.
[0010] FIG. 2 depicts an exemplary guide mechanism of the feeder system for detecting the
buildup of stack pressure near the point or entry.
[0011] FIG. 3(a) depicts a flow chart for adjusting a feeder system based on stack pressure
on the guide mechanism as shown in FIG. 2.
[0012] FIG. 3(b) depict a flow chart guiding mail items to a transport path in feeder system
of FIG. 1.
[0013] FIG. 4 illustrates a network or host computer platform, as may typically be used
to implement a server.
[0014] FIG. 5 depicts a computer with user interface elements.
DETAILED DESCRIPTION
[0015] Described herein is a system and method for guiding mail items to a transport path,
wherein the stack pressure is monitored at the entry to the transport path and the
mail feeding behavior is adjusted based on the stack pressure.
[0016] As used herein, a "mail item" refers to any article having human or machine readable
content generated thereon, and particularly that intended for delivery to a given
recipient. Mail items may include, but are not limited to, envelopes, newsletters,
newspapers, magazines, post cards, parcels or packages of varying thicknesses (e.g.,
flat mail), coupon booklets, brochures, and other like documents. Such documents may
or may not be generated for the purpose of being distributed via an outgoing distribution
channel (e.g., delivery company, postal authority), but rather, may be generated for
direct/personal carry, private delivery, or internal distribution.
[0017] Also, as used herein, the phrase "document or mail processing system" refers to any
high speed transport device(s) capable of processing mail items at considerably high
rates with considerably high precision. Document processing systems may include, but
are not limited to, inbound sorting equipment, outbound mail sorting equipment, and
even various forms of inserter machines, mail integrity systems, or the like for office,
commercial, or industrial settings. While the following discussion will present the
teachings in an exemplary fashion with respect to a sorter device, it will be apparent
to those skilled in the art that the teachings may apply to any type of document processing
device requiring mail item input, and specifically, any system desiring or requiring
means for dynamically compensating for excessive mail item density or gap variations
occurring during input.
[0018] FIG. 1 depicts an exemplary feeder system 100 for advancing a stack of mail items
102 to a guide mechanism 200 at an entry point 104 of a transport path 106 of a sorter
device. Typically, feeder systems 100 comprise the front end portion of a sorting
device, employing various physical elements (e.g., drive belts, rollers, and pulleys)
for receiving mail items as input and readying said mail items for processing by the
other components of the sorter as it traverses the transport path 106. In the context
of the examples presented herein, the feeder system 100 may also comprise various
control devices (e.g., motors, sensors, programmable controllers) that operate independently
or interdependently to effectively handle mail items. All of these devices may or
may not be under the control of a central feeder control mechanism 170, which coordinates
and tracks the actions of said devices within the feeder 100. Generally speaking,
the various actions, tolerances and thresholds expected to be maintained or achieved
by the devices can be defined as profile data. Examplary profile data, as provided
to the feeder control system 170 in advance of a particular job run, may include but
is not limited to: magazine belt speed data, stack pressure sensor threshold requirement
data, variable gripper belt speed data, sensor status data, job characteristic data
(e.g., mail item dimensions), etc., all data which may vary by client or job being
processed.
[0019] The feeder control system 170 may further be integrated or communicable with a sorter
control computer configured for interaction with the sorter. Regardless of configuration,
one skilled in the art will recognize that various means of facilitating electro-mechanical
control within a dynamic system exist, and that any control configuration is within
the scope of the teachings described herein.
[0020] The stack of mail items 102 is placed into the feeder system 100 in an upright position
such that the face of each mail item is exposed as it is transported down the transport
path 106 at a given transport speed (e.g., as measured in inches per second (IPS)).
For the purposes of the discussion herein, the face of a mail item within a stack
thereof is to be taken synonymously as the stack plane, i.e., the two-dimensional
plane that is advanced in the direction of the entry point to enable a leading edge
of the mail item to enter the transport path 106 via the point of entry 104. Of course,
those skilled in the art will recognize upon full discussion of the exemplary embodiment
herein that other orientations of mail items are within the scope of the teachings
as well.
[0021] Once entered onto the transport path 106, each mail item may be processed by various
inline modules, such as imaging devices, printers, barcode readers, etc. (not shown).
Such mail items typically being processed by these modules in response to one or more
delivery point identifiers (e.g., ZIP Code designations) or address components (e.g.,
address block data) as marked thereon. The stack of mail items 102 advance down the
base 108 of a magazine 107 of the feeder system 100 towards a point of entry 104 of
the sorter transport path 106 with the aid of a stack plate 110, wherein the stack
plate 110 is able to traverse the length of the magazine 107 in the direction X or
Y as shown. The stack plate 110 of the magazine 107 is driven by a synchronized pair
of motor driven belts 120 and 122, each belt containing grooves for affixing the bottom
edge of the stack plate 110 and the bottom edge of the mail stack 102. As belts 120
and 122 of the magazine 107 are driven by the belt motor 130 at a fixed or variable
velocity in either direction X or Y, the stack plate 110 accordingly retracts or advances
the mail items 102 at a respective rate. A presence detector 155 may be used to detect
the presence of mail items 102 during advancement.
[0022] The stack may be in a fixed position between the stack plate 110 and one of the grooves
within the belts 120 and 122, resulting in a fixed stack pressure, i.e., a rigid contraction
or density to be maintained as the stack advances toward the entry point 104 (in direction
Y) of the transport path 106. Alternatively, the grooves within drive belts 120 and
122 may become level with the plane of the feeder base 108 at a release point 150,
wherein the stack plate 110 advances the mail items without further reliance upon
grooves on belts 120 and 122. This configuration in turn results in repositioning
of mail stack 102, i.e., loosening or expansion, so that the stack pressure is subsequently
minimized while still maintaining relative upright orientation with respect to the
entry point 104 and transport path 106. Those skilled in the art will recognize that
such variation from a rigid or fixed stack pressure to a more relaxed stack pressure
proximate to actual entry to the transport path 106 further reduces the accumulation
of excess stack pressure at the point of entry 104.
[0023] To enable an individual mail item within the mail stack 102 to be processed by the
sorter, each item must be sufficiently separated or pulled from the stack to enable
only one item at a time to be conveyed to the transport path 106 through the point
of entry 104. One or more stripper fingers, suction devices and/or other combinations
of elements capable of exerting restrictive, pulling or complimentary counter force
may be used to single out (i.e., singulate) and separate individual mail items from
stack 102 for entering to the transport path 106. In conjunction with a singulator
means 210, a guide mechanism 200 as illustrated by way of example in FIG. 2 may provide
a complimentary force to advance the leading edge 160 of a mail item in the direction
of the transport path 106 upon contact with a mail item, thereby minimizing the accumulation
of excessive mail items proximate to the point of entry 104. As will be seen, increased
density of mail items at the point of entry 104, referred to herein as a stack pressure,
may cause jams, considerable gaps between successive mail items (e.g., doubles) or
other processing defects that affect the sorter's efficiency and processing capability.
[0024] According to one embodiment as shown in FIG. 2, the guide mechanism 200 acts as a
physical buffer that prevents the overrun of mail beyond the extent of the belt drives
120 and 122 and/or positions the mail item or stack in proximity to the point of entry
104. Furthermore, the guide mechanism 200 is coordinated to generate a frictional
force complimentary to any static force exerted by the singulator 210 to advance mail
items at the point of entry 104 toward the transport path 106. As will be discussed
in further detail, said frictional force is provided via a plurality of variable speed,
motor-driven friction belts capable of driving mail items upon contact. Still further,
the behavior of the guide mechanism 200 in response to contact with mail items as
they are advanced towards the point of entry 104, as detected by presence sensor 155,
further triggers varying behaviors of the overall feeder system 100. The guide mechanism
200 is affixed about a vertical pivot axis Z (i.e., a drive shaft) to a guide motor
drive 202 positioned below the feeder base 108. In one embodiment, the motor drives
202 and 130 are independently controlled by different motor controllers, such that
the guide motor drive 202 operates independently of the belt motor 130 that drives
belts 120 and 122, resulting in asynchronous operations of respective motors 202 and
130. Consequently, the motor drive 202 of the guide mechanism 200 may drive its gripper
belts 206 at one speed (e.g., as inches per second (IPS) 208), while belts 120 and
122 may be driven at a different speed. Alternatively, both motor drives 130 and 202
may be coupled to a twin axis motion controller 204, wherein the motors 130 and 202
can be synchronized or adjusted with respect to each other at the discretion of the
controller 204.
[0025] The gripper belts 206, when rotated in the direction shown in FIG. 2, exert a frictional
force upon contact with the face of a mail item proximate to the point of entry 104.
The frictional force, resulting from the rotational velocity of the gripper belts
206 in accord with a variable speed guide motor controller 202 or the like, is exerted
onto the mail item in the direction of the transport path 106. As stated, a complimentary
static counter force is exerted by the singulator 210 upon the mail stack 102 at the
point of entry 104 to ensure that a single mail item is stripped from the stack 102
and advanced towards the transport path 106. According to the exemplary embodiment
described herein, the guide mechanism 200 varies its rotational position (i.e. the
angular displacement), as it comes in contact with the mail stack 102, in a range
including a rest position 214, a drive position 216 and a reverse position 218. Each
angular displacement affects the behavior of the feeder system as described hereafter.
Skilled artisans will recognize that future implementations of the examples presented
herein may involve displacement of a linear nature versus rotational.
[0026] As depicted in FIG. 2, prior to contact with the mail stack 102, the guide mechanism
200 maintains a natural rest position 214 corresponding to an angle of 0 degrees (or
alternatively, may be perceived as corresponding to a value less than zero). As the
mail stack 102 is advanced toward the guide mechanism 200, it is detected by the presence
sensor 155 and eventually begins to contact the guide mechanism 200. Consequently,
the angular displacement about the pivotal axis Z also steadily increases, and eventually
to an angle of α degrees wherein the stack plane 272 is approximately parallel to
the drive position 216. This causes the face of the foremost mail item within the
stack to substantially come into contact with drive belts 206 in a manner suitable
for advancing the leading edge of the mail item to the transport path 106 through
a parallel plane contact. This is further depicted via inset 270 of FIG. 2, where
a two dimensional top view of the guide mechanism 200 is shown, illustrating the general
orientation of the stack plane 272 (i.e., the frontal face of the mail item) relative
to the guide mechanism 200 at rest position 214. It will be understood by one skilled
in the art that the contact plane of the guide mechanism 200 is not generally parallel
to the stack plane 272 until the guide mechanism is offset or rotated α degrees to
the drive position 216. Consequently, the guide motor drive 202 remains inactive for
any angular displacement of the guide mechanism 200 less than α degrees.
[0027] When the angular displacement of the guide mechanism 200 is greater than or equal
to α degrees and the presence detector 155 determines the presence of mail items proximate
to the point of entry 104, the guide motor drive 202 is activated. Prior to these
conditions being met, the gripper belts 206 need not be active while the stack is
steadily advancing forward. Hence, the contact plane of the guide mechanism at this
point and the drive portion of the gripper belts 206 become parallel to the stack
plane 272, thereby enabling a substantial frictional force to be applied onto the
mail item at the point of entry 104 versus the static counter force of the singulator
210. From this point on, the belts 206 and the guide motor drive 202 remain active
as the guide mechanism 200 is further rotated due to an increase in the stack pressure
proximate to the point of entry 104.
[0028] The angular displacement 218 of θ degrees represents the maximum allowable rotational
movement of the guide mechanism 200 beyond its rest position 214 before further adaptation
of feeder system 100 is required. Rotation beyond the angular displacement 218 is
limited due to the restriction of an extension arm 222 of the guide mechanism 200
by a buffer 224. The extension arm 222 is connected to a spring 226 that exerts a
tensional force suitable for enabling controlled rotational movement and return of
the guide mechanism to its rest position 214. As further depicted in FIG. 2, a magnet
232 is disposed at one end of the extension arm 222 at a small distance above a magnetic
field variance sensor 230. The magnetic field variance sensor 230, also known commonly
as a Hall Effect sensor, is a transducer that varies its output voltage in response
to changes in the magnetic field intensity as the magnet 232 is rotated in accordance
with the guide mechanism 200. Hence, as the position of the magnet 232 changes due
to rotation of the guide mechanism 200 to an angle ranging from α degrees and θ' degrees,
where θ' may be equal to or slightly greater than θ depending on the configuration
of the extension arm 222, so too does the magnetic field intensity.
[0029] Upon detecting that the magnetic field intensity has diminished with respect to a
position of the magnet 232 corresponding to an angle greater than θ degrees (e.g.,
an angular displacement beyond the reverse position 218 of the guide mechanism 200
up to θ' due to the accumulated density of mail items), the sensor 230 generates a
signal to the feeder control system 170 indicating an excessive stack pressure condition
resulting from an accumulation of mail items near the guide mechanism 200. To account
for this, the feeder control system 170 responds by reversing the forward advancing
direction Y of the belt motor drive 130 and hence belts 120 and 122, thereby reversing
the direction of advancement 212 of the mail stack and reducing the stack pressure.
This allows the guide mechanism 200 to retract in a controlled manner towards its
natural rest position 214 as the force exerted upon it in direction 212 by the mail
stack 102 is subsequently decreased. Alternatively, rather than reverse the drive
direction of belts 120 and 122, the feeder system 100 may ramp down the speed of the
belt motor 130 controlling belts 120 and 122, said speed being adjusted in proportion
to the extent of angular displacement of the guide mechanism 200 as detected by the
magnetic field variance sensor 230. Once positioned again between the drive position
216 and the reverse position 218, the belts 120 and 122 may resume their drive in
direction 212 (i.e., direction Y as depicted in FIG. 1).
[0030] The twin axis motion controller 204 may be employed as a means for coordinating the
control action of drive belts 120 and 122 in response to a given stimulus. Specifically,
as the angular displacement of the guide mechanism 200 increases from drive position
216 to reverse position 218 due to build up of the stack pressure; such variation
is continuously monitored by the sensor 230. The sensor 230 generates and transmits
a signal to the feeder control system 170, indicating the extent of motion of the
guide mechanism 200. In responding to the received signal, the feeder control system
170 generates a control signal for adjusting the behavior of the feeder system 100.
For example, the feeder control system 170 may continuously or in a stepwise fashion
reduce the speed of stack advancement in direction Y in response to the signal, thereby
reducing the stack in proximity to the point of entry 104 and the guide mechanism
200.
[0031] As another example, the feeder control system 170 may increase the rotational speed
(i.e., IPS 208) of motor drive 202 of the guide mechanism 200 in response to the signal,
thereby increasing the speed of the drive belts 206 and the rate of feeding the mail
items into the transport path 106. As the speed of removing the mail items from the
mail stack 102 is increased, the stack pressure exerted onto the guide mechanism 200
is gradually reduced.
[0032] According to another embodiment, a touch sensor may be disposed on the side surface
of buffer 224 for detecting the excessive stack pressure. Specifically, as the guide
mechanism 200 is rotated to the position corresponding to the angle of θ' degrees
due to the excessive stack pressure, the extension arm 222 comes into contact with
the side surface of the buffer 224, thereby triggering the touch sensor to generate
a signal indicating that the stack pressure exerted onto the guide mechanism 200 has
exceed a safety limit (i.e. a threshold). In receiving the signal, the feeder control
system 170 may adjust the behaviors of the feeder system 200. For example, the feeder
control system 170 may reverse the direction of stack advancement, stop or ramp down
the speed of the belt motor 130 with respect to the extent of angular displacement
of the guide mechanism 200 or deactivate guide motor drive 202 responsive to reduced
angular displacement of the guide mechanism 200 resulting from reversing of belt motor
130-i.e., when displacement is less than drive position 216,.
[0033] As another alternative embodiment, a pressure sensor may be disposed on the side
surface of buffer 224 for monitoring the stack pressure exerted onto the guide mechanism
200. Specifically, as the guide mechanism 200 is rotated to the position corresponding
to the angle of θ' degrees due to the accumulation of the mail items in front of the
entry point 104, the extension arm 222 comes into contact with the side surface of
the buffer 224, thereby exerting pressure onto the pressure sensor. As the mail items
accumulate and the stack pressure continuously increases so does the pressure exerted
onto the pressure sensor by the extension arm. At the same time, the pressure sensor
generates and transmits a signal to the feeder control system 170 indicating the pressure
detected by the pressure sensor at the contact point between the buffer 224 and the
extension arm 222. Upon determining that the detected pressure indicated by the signal
exceeds a pre-determined threshold, the feeder control system 170 adjusts the behaviors
of the feeder system 100 as described earlier in this application. In addition, the
pre-determined threshold may be adjusted by a user for setting the maximum allowable
stack pressure exerted onto the guide mechanism 200 before the feeder control system
170 starts to execute the adjustment.
[0034] Regardless of the chosen approach, skilled artisans will recognize that modifying
the behavior of the feeder system 100 in response to the degree of positional displacement
of the guide mechanism 200 provides a means of compensatory feedback to thwart common
feeding problems. Furthermore, it will be recognized by those skilled in the art that
measuring pressure may be performed using a pressure transducer, force control monitoring
device or other pressure detection means other than as a function of an extent of
displacement. In this way, the sensor output produced by such pressure detection means
would be suitable for indicating pressure exertion near the point of entry to the
transport path and could directly replace a measurement of angular displacement as
an indicator of stack pressure variation. Still further, as the behavior of the feeder
system varies depending on the positional displacement, the range or threshold of
displacement may be tempered to the requirements of a given sorter system accordingly.
For example, while the generalized behavior of the feeder system 100 in response to
varying stack pressure conditions as described above is indicated in TABLE 1 below,
skilled practitioners may adjust the extent of α or θ, the speed of the belt motor
drive 130, the proportional control settings of the twin axis motor controllers with
respect to motor drives 130 and 202, etc, and other profile data.
TABLE 1: Response of feeder system to varying stack pressure conditions
Position; Displacement |
Belts 120 and 122 |
Gripper Belts 206 |
Upon start-up and between rest position 214 and drive position 216; 0 to α degrees |
Active; driven in direction 212 at a variable speed, proportional to extent of θ |
Inactive |
Beyond drive position 216 up to reverse position 218; Greater than α up to θ degrees |
Active; driven in direction 212 at a decreasing variable speed, proportional to extent
of θ |
Active |
Beyond reverse position 218; Greater than 0 degrees |
Active; driven in reverse at an increasing variable speed, proportional to extent
of θ |
Active |
[0035] As depicted in the table, when the guide mechanism is positioned between rest position
214 up to a pre-determined angular displacement (i.e., drive position 216), the feeder
control system 170 enables belts 120/122 to drive toward the point of entry 104 at
a proportionally decreasing speed; hence regulating the rate of stack pressure accumulation
near the point of entry 104. Also, as depicted, when the guide mechanism is positioned
well beyond the pre-determined angular displacement (i.e., greater than reverse position
218), the feeder control system 170 enables belts 120/122 to drive away from the point
of entry 104 at a proportionally increasing speed; hence regulating the rate of stack
pressure accumulation near the point of entry 104. Therefore, the speed and direction
of the drive belts 120/122 is persistently regulated to maintain as consistent a rate
of stack pressure for affecting the rate of mail item feeding within the feeder system
100. Of course, this dynamic regulatory behavior of the feeder system 100 will vary
relative to differing profile variables (e.g., α, θ, the speed of the belt motor drive
130, job characteristics).
[0036] Once a mail item is singled out and forced by the guide mechanism 200 through the
point of entry 104 in the direction of the transport path 106, one or more edge detection
sensors 220a-b placed adjacent to the transport path 106 may detect the presence of
a leading or lagging edge of a mail item as it moves towards the transport belt. Various
sensor configurations may be employed accordingly, including those wherein the receiver
and transmitter sensor components are integrated or separated by a given distance.
Immediately following the first fed mail item, the next mail item is advanced such
that a gap between the first mail item and the second mail item exists. Variations
in gap between respective mail items may be persistently monitored via analysis of
the data yielded by the edge detection sensors 220a-b. While some variation is typically
expected when processing mail items having common dimensional characteristics (e.g.,
length) to within a threshold of variance, excessive or progressively increasing gap
is usually a result of ineffective feeding by the feeder system. Progressively decreasing
gap between mail items is usually an indicator of doubles being passed through the
transport path. Lack of consistent gap, therefore affects the overall throughput and
efficiency of the sorter device. Furthermore, lack of consistent gap may result from
excessive stack pressure.
[0037] In responding to gap variations, and given known conditions that affect the gaps
between consecutive mail items (e.g., distance between edge detection sensors, the
speed 208 of the mail item in inches per second, expected mail item length or doubles
resulting from improper mail item feeds), the feeder system 100 may alter its behavior
to compensate for variations in gap-i.e., variation from a pre-set mail item gap length.
For example, the feeder control system 170 may reduce or increase the speed of the
guide mechanism motor drive 202 and hence the speed of the gripper belts 206. Furthermore,
the feeder control system 170 may alter the function of motor drives 130 and 202 relative
to each other with regard to a determined gap variance breach, etc., as a means of
compensating for detected error conditions. Exemplary behavior of the feeding device
responsive to the monitored gap between the first and second mail item is shown in
the Table 2 below:
TABLE 2: Response of feeder system to varying gap conditions
Status of sensor 220(a) |
Status of sensor 220(b) |
Status of Gripper Belts 206 |
Not blocked by passing mail item (mail item not present) |
Not blocked by passing mail item (mail item not present) |
Active in high speed mode |
Blocked by passing mail item (mail item is present) |
Not blocked by passing mail item (mail item not present) |
Active in high speed mode |
Not blocked by passing mail item (mail item not present) |
Blocked by passing mail item (mail item is present) |
Active in high speed mode |
Blocked by passing mail item (mail item is present) |
Blocked by passing mail item (mail item is present) |
Active in low speed mode |
[0038] Of course the rate (as measured in IPS)-high speed or low speed-of the gripper belts
206 will vary depending upon the intended or desired gap length or pitch to be maintained
or accounted for. For instance, at a gap length of 2-3" between mail items, a high
speed mode may correspond to a rate of 160 IPS while a low speed mode is at a rate
of 105 IPS. For a gap length of 4-5" between mail items, high speed mode may be 90
IPS while low speed is 50 IPS. Those skilled in the art will recognize that the progressive
ramping up or down of the gripper belts 206 in response to detected gap or pitch variations
enables more continuity and enhanced processing of mail items along the transport
path 106. Mail items may be appropriately sped up (e.g., from 0 IPS and up) or slowed
down (to 0 IPS) in response to monitored gap length and/or pitch, and with respect
to a known speed of the transport path 106 itself, as a means of maintaining gap continuity
upon entry to the transport path 106.
[0039] As a further means of maintaining gap or pitch continuity between successive mail
items entered onto the transport path 106, the feeder control system 170 may dynamically
switch between gap-based feeding and pitch-based feeding respective to a comparison
between an actual monitored pitch and a specified minimum pitch. Specifically, when
the actual measured pitch (length of a first mail item + gap length between the second
mail item) is determined to be greater than a specified minimum pitch threshold (e.g.,
definable profile data), the guide mechanism 200 of feeder system 100 may operate
as a gap-based feeder. When the actual measured pitch is determined to be less than
the specified minimum pitch, a determination is made as to the extent of gap needed
to meet the specified minimum pitch. Once determined, the the feeder control system
170 may adapt the guide motor drive 202 speed accordingly to accommodate, meet or
maintain the fixed minimum pitch constraint.
[0040] According to one embodiment as depicted in FIG. 3(a), a method 300 is provided for
adjusting a mail feeding system based on a stack pressure exerted onto a guide mechanism
substantially similar to that depicted in FIG. 2. As depicted in FIG. 3(a), the method
300 includes (1) advancing a plurality of mail items in a first direction toward the
guide mechanism 200 (block 302), wherein the guide mechanism 200 is configured to
guide the plurality of mail items 102 to a transport path 106, and wherein the guide
mechanism 200 has a variable angular displacement indicative of a stack pressure against
the guide mechanism. The method 300 further includes a step of comparing the variable
angular position of the guide mechanism 200 with a pre-determined angular displacement
216 (block 304) and a step of adjusting the stack pressure in response to the comparison
(block 306).
[0041] According to another embodiment as depicted in FIG. 3(b), a method 310 is provided
for guiding mail items to the transport path 106 in a mail feeding system 100 substantially
similar to that depicted in FIG. 1. As depicted in FIG. 3(b), method 310 includes
(1) advancing a first mail item and a second mail item in a first direction of a feeding
device (block 312), wherein the feeding device 100 is configured to guide the first
and the second items to the transport path 106, (2) monitoring on the transport path
106 a gap between the first mail item and the second mail item (block 314) and (3)
adjusting at least one behavior of the feeding device in response to the gap between
the first mail item and the second mail item (block 316). According to this embodiment,
the feeding device may be substantially similar to the guide mechanism 200 as depicted
in FIG. 2.
[0042] In the previous description, numerous specific details are set forth, such as specific
materials, structures, processes, etc., in order to provide a better understanding
of the present subject matter. However, the present subject matter can be practiced
without resorting to the details specifically set forth herein. In other instances,
well-known processing techniques and structures have not been described in order not
to unnecessarily obscure the present subject matter.
[0043] Those skilled in the art will recognize that the methodologies presented herein may
be controlled or implemented by one or more processors/controllers, such as one or
more computers (ref. numeral 170 in FIG. 1). Typically, each such processor/controller
is implemented by one or more programmable data processing devices. The hardware elements,
operating systems and programming languages of such devices are conventional in nature
and it is presumed that those skilled in the art are adequately familiar therewith.
[0044] FIGS. 4 and 5 provide functional block diagram illustrations of general purpose computer
hardware platforms. FIG. 4 illustrates a network or host computer platform, as may
typically be used to implement a server. FIG. 5 depicts a computer with user interface
elements, as may be used to implement a personal computer or other type of work station
or terminal device, although the computer of FIG. 5 may also act as a server if appropriately
programmed. It is believed that those skilled in the art are familiar with the structure,
programming and general operation of such computer equipment and, as a result, the
drawings should be self-explanatory.
[0045] For example, sorter server 114 may be a PC based implementation of a central control
processing system like that of FIG. 5, or may be implemented on a platform configured
as a central or host computer or server like that of FIG. 4. Such a system typically
contains a central processing unit (CPU), memories and an interconnect bus. The CPU
may contain a single microprocessor (e.g. a Pentium microprocessor), or it may contain
a plurality of microprocessors for configuring the CPU as a multi-processor system.
The memories include a main memory, such as a dynamic random access memory (DRAM)
and cache, as well as a read only memory, such as a PROM, an EPROM, a FLASH-EPROM,
or the like. The system memories also include one or more mass storage devices such
as various disk drives, tape drives, etc.
[0046] In operation, the main memory stores at least portions of instructions for execution
by the CPU and data for processing in accord with the executed instructions, for example,
as uploaded from mass storage. The mass storage may include one or more magnetic disk
or tape drives or optical disk drives, for storing data and instructions for use by
CPU. For example, at least one mass storage system in the form of a disk drive or
tape drive, stores the operating system and various application software as well as
data, such as sort scheme instructions and image data. The mass storage within the
computer system may also include one or more drives for various portable media, such
as a floppy disk, a compact disc read only memory (CD-ROM), or an integrated circuit
non-volatile memory adapter (i.e. PC-MCIA adapter) to input and output data and code
to and from the computer system.
[0047] The system also includes one or more input/output interfaces for communications,
shown by way of example as an interface for data communications with one or more other
processing systems. Although not shown, one or more such interfaces may enable communications
via a network, e.g., to enable sending and receiving instructions electronically.
The physical communication links may be optical, wired, or wireless.
[0048] The computer system may further include appropriate input/output ports for interconnection
with a display and a keyboard serving as the respective user interface for the processor/controller.
For example, a printer control computer in a document factory may include a graphics
subsystem to drive the output display. The output display, for example, may include
a cathode ray tube (CRT) display, or a liquid crystal display (LCD) or other type
of display device. The input control devices for such an implementation of the system
would include the keyboard for inputting alphanumeric and other key information. The
input control devices for the system may further include a cursor control device (not
shown), such as a mouse, a touchpad, a trackball, stylus, or cursor direction keys.
The links of the peripherals to the system may be wired connections or use wireless
communications.
[0049] The computer system runs a variety of applications programs and stores data, enabling
one or more interactions via the user interface provided, and/or over a network to
implement the desired processing, in this case, including those for processing document
data as discussed above.
[0050] The components contained in the computer system are those typically found in general
purpose computer systems. Although summarized in the discussion above mainly as a
PC type implementation, those skilled in the art will recognize that the class of
applicable computer systems also encompasses systems used as host computers, servers,
workstations, network terminals, and the like. In fact, these components are intended
to represent a broad category of such computer components that are well known in the
art. The present examples are not limited to any one network or computing infrastructure
model-i.e., peer-to-peer, client server, distributed, etc.
[0051] Hence aspects of the techniques discussed herein encompass hardware and programmed
equipment for controlling the relevant document processing as well as software programming,
for controlling the relevant functions. A software or program product, which may be
referred to as an "article of manufacture" may take the form of code or executable
instructions for causing a computer or other programmable equipment to perform the
relevant data processing steps regarding document printing and associated imaging
and print quality verification, where the code or instructions are carried by or otherwise
embodied in a medium readable by a computer or other machine. Instructions or code
for implementing such operations may be in the form of computer instruction in any
form (e.g., source code, object code, interpreted code, etc.) stored in or carried
by any readable medium.
[0052] Such a program article or product therefore takes the form of executable code and/or
associated data that is carried on or embodied in a type of machine readable medium.
"Storage" type media include any or all of the memory of the computers, processors
or the like, or associated modules thereof, such as various semiconductor memories,
tape drives, disk drives and the like, which may provide storage at any time for the
software programming. All or portions of the software may at times be communicated
through the Internet or various other telecommunication networks. Such communications,
for example, may enable loading of the relevant software from one computer or processor
into another, for example, from a management server or host computer into the image
processor and comparator. Thus, another type of media that may bear the software elements
includes optical, electrical and electromagnetic waves, such as used across physical
interfaces between local devices, through wired and optical landline networks and
over various air-links. The physical elements that carry such waves, such as wired
or wireless links, optical links or the like, also may be considered as media bearing
the software. As used herein, unless restricted to tangible "storage" media, terms
such as computer or machine "readable medium" refer to any medium that participates
in providing instructions to a processor for execution.
[0053] Hence, a machine readable medium may take many forms, including but not limited to,
a tangible storage medium, a carrier wave medium or physical transmission medium.
Non-volatile storage media include, for example, optical or magnetic disks, such as
any of the storage devices in any computer(s) or the like, such as may be used to
implement the sorting control and attendant mail item tracking based on unique mail
item identifier. Volatile storage media include dynamic memory, such as main memory
of such a computer platform. Tangible transmission media include coaxial cables; copper
wire and fiber optics, including the wires that comprise a bus within a computer system.
Carrier-wave transmission media can take the form of electric or electromagnetic signals,
or acoustic or light waves such as those generated during radio frequency (RF) and
infrared (IR) data communications. Common forms of computer-readable media therefore
include for example: a floppy disk, a flexible disk, hard disk, magnetic tape, any
other magnetic medium, a CD-ROM, DVD or DVD-ROM, any other optical medium, punch cards
paper tape, any other physical storage medium with patterns of holes, a RAM, a PROM
and EPROM, a FLASH-EPROM, any other memory chip or cartridge, a carrier wave transporting
data or instructions, cables or links transporting such a carrier wave, or any other
medium from which a computer can read programming code and/or data. Many of these
forms of computer readable media may be involved in carrying one or more sequences
of one or more instructions to a processor for execution.
[0054] While the foregoing has described what are considered to be the best mode and/or
other examples, it is understood that various modifications may be made therein and
that the subject matter disclosed herein may be implemented in various forms and examples,
and that the teachings may be applied in numerous applications, only some of which
have been described herein. It is intended by the following claims to claim any and
all applications, modifications and variations that fall within the true scope of
the present teachings.
1. A method for operating a mail feeding system, the method comprising steps of:
advancing (302, 312) a plurality of mail items (102) in a first direction toward a
guide mechanism (200), the guide mechanism (200) configured to guide the plurality
of mail items (102) to a transport path (106), wherein the guide mechanism (200) has
a variable angular displacement indicative of a stack pressure against the guide mechanism
(200);
comparing (304) the variable angular displacement of the guide mechanism (200) with
a pre-determined angular displacement (218); and
adjusting (306) the stack pressure in response to the comparing step by advancing
one or more of the plurality of mail items (102) in a second direction opposite to
the first direction or by reducing a speed for advancing the plurality of mail items
(102) in the first direction.
2. The method of claim 1, wherein the adjusting step is performed during active operation
of the transport path (106).
3. The method of claim 1, further comprising the steps of:
determining whether the variable angular displacement of the guide mechanism (200)
is greater or equal to the pre-determined angular displacement (218);
generating a first control signal in response to a result of the determination; and
adjusting the stack pressure in response to the first control signal.
4. The method of claim 3, wherein the guide mechanism (200) has one or more belts (206)
driven by a guide motor (202) and the one or more belts (206) drive the plurality
of mail items (102) to the transport path (106).
5. The method of claim 4, further comprising:
deactivating the guide motor (202) in response to the first control signal.
6. The method of claim 4, further comprising:
increasing a rotational speed of the guide motor (202) in response to the first control
signal and the presence of mail items (102) proximate to the guide mechanism (200).
7. The method of claim 1, further comprising the steps of:
monitoring (314), prior to entry to the transport path (106), a distance between a
first mail item and a second mail item of the plurality of mail items (102) guided
by the guide mechanism (200) to the transport path (106);
adjusting (316) the guide mechanism (200) from a first to a second feed rate in response
to the distance between the first mail item and the second mail item and profile data
associated with the first and second mail item; and
feeding the second mail item at the second feed rate onto the transport path (106)
based on the adjusting step.
8. The method of claim 7, wherein the profile data includes one or more of: a magazine
belt speed profile, stack pressure sensor thresholds, gripper belt speed profile,
sensor status, gap or pitch threshold and job characteristic data.
9. The method of claim 7, wherein the monitoring step further comprises:
detecting a first edge of the first mail item and a second edge of the second mail
item; and
calculating pitch as the time duration between the first edge of the first mail item
and the second edge of the second mail item.
10. The method of claim 7, wherein the monitoring step further comprises:
detecting a second edge of the first mail item and a first edge of the second mail
item; and
calculating the gap as the time duration between the first edge of the first mail
item and the second edge of the second mail item.
11. The method of claim 7, wherein the step of adjusting further comprises:
detecting a subsequent mail item proximate to the guide mechanism (200); and
adjusting a rotational speed of a belt motor (130) which is configured to advance
the plurality of mail items (102) to the guide mechanism (200).
12. The method of claim 9, wherein the step of adjusting further comprises:
comparing the calculated pitch to a specified minimum pitch threshold;
determining a difference between the specified minimum pitch threshold and the calculated
pitch; and
adjusting the guide mechanism (200) from a first feed rate to a second feed rate respective
to the determined difference in order to meet the specified minimum pitch threshold.
13. A feeder system comprising:
a variable speed magazine (107) for driving a plurality of mail items (102) in a direction
toward or away from a transport path (106) of a sorter;
a guide mechanism (200) for guiding each of the plurality of mail items (102) onto
the transport path (106);
one or more guide mechanism sensors (230) for continuously measuring a variable angular
displacement indicative of a stack pressure against the guide mechanism (200); and
a feeder control system (170) for maintaining a consistent rate at which mail items
(102) are guided from the magazine (107) onto the transport path (106) by the guide
mechanism (200),
wherein in response to an indicated stack pressure the feeder control system (170)
drives the magazine (107) in the direction toward or away from the transport path
(106).
14. The system of claim 13, wherein the feeder system responds to profile data including
one or more of: magazine belt speed profile, stack pressure sensor thresholds, gripper
belt speed profile, sensor status, gap or pitch threshold and job characteristic data..
15. The system of claim 13, further comprising:
one or more gripper belts (206) associated with the guide mechanism (200) capable
of being driven in at least two speeds, the gripper belts (206) suitably contacting
at least one of the plurality of mail items (102) as it is driven by the magazine
(107); and
one or more sensors (220a, 220b) for monitoring a distance between successive mail
items (102) fed onto the transport path (106) by said guide mechanism (200);
wherein in response to the monitored distance the feeder control system (170) adjusts
the speed of the gripper belts (206).