Abstract: A bi-directional belt sorter for unloading items into a selected bin located along a travel path of a conveyor system includes a carrier and a support frame secured to the carrier. The carrier has a plurality of orientations with respect to the support frame. The carrier includes a conveyor belt for unloading items into the selected bin located to the side of or in-line with the travel path of the conveyor system. The conveyor system includes a host computer for controlling the distribution of items to selected bins.

Abstract: A package and bundle singulator having a cone shaped housing with an input receiving opening and an outlet discharge opening. A helix or spiral is formed on an inner surface of the housing to engage and separate packages and bundles entering the input receiving opening. A support frame rotatably supports and maintains the housing in an orientation where the input receiving opening is at a higher level than the output discharge opening. The housing is rotated by a drive assembly engaging the housing.

Abstract: An automated method for filling orders using an automated ordering system having a product conveyor, a computer controller, and a plurality of dispensers for dispensing products arrayed in a matrix in rows and columns, wherein the method of filling orders comprises the steps of: coupling each dispenser in a row to a first common control element in the controller; coupling each dispenser in a column to a second common control element in the controller, where the column of dispensers shares a common dispenser with the row of dispensers; and actuating the first and the second control elements simultaneously to dispense a product from the common dispenser onto the conveyor.

Abstract: The present invention comprises apparatus for identifying, intercepting and forwarding incorrectly addressed mailpieces having either a machine readable or non-machine readable address. The apparatus reads (either mechanically or manually) the addressee name and the mailpiece destination marking address for processing in a database and comparison to a list of names and former addresses in the USPS National Change of Address database of persons who have requested mail forwarding service. If the read name and address match a name and former address in the database, then the mailpiece is identified as having an incorrect address and intercepted from the mail stream. The apparatus then searches the NCOA database for a forwarding address and delivery point ZIP code corresponding to the address. The forwarding address and delivery point ZIP marking number are printed on the mailpiece in place of the incorrect address and the mailpiece is returned to the mail stream for delivery to the addressee.

Abstract: Apparatus and method for detection of leading and trailing edges of objects moving along a defined path. A light radiation source directs a light beam toward a beamspot on the path. Light reflected from the beamspot is received by two light sensors. An edge of an object moving along the defined path substantially blocks the light from being received by one light sensor. Circuitry is provided for distinguishing the difference in reflected light received at each light sensor and determining whether the leading edge or trailing edge of the object is blocking the reflected light. Length of detections (leading and trailing edges) and time interval between the detections of the leading and trailing edge are processed to provide information about the object such as height of the leading and trailing edges of the object and length of the object. Further processing of leading and trailing edge detections can detect overlapped objects having relatively uniform surfaces.

Abstract: An apparatus for unfolding a bifolded mailpiece comprises a pair of pivotable receiving wall for receiving a bifolded mailpiece, a pair of receiving wall cylinders for pivotally moving the receiving walls and a pair of spreader walls for spreading the bifolded mailpiece received between said receiving walls, the spreader walls being pivotally mounted and actuated by a pair of spreader wall cylinders, a ram being provided for moving the spreader walls along a vertical axis to cooperate with the receiving walls to unfold the mailpiece.

Abstract: A method and apparatus for separating, feeding and sorting stacked products utilizes a computer controlled conveyor transport path. The transport path includes infeed, separating and output sections. The infeed section includes an infeed conveyor and feed roller to regulate downstream movement into the separating section. The separating section includes a plurality of individually and selectively controlled friction feeder rolls arranged on a laterally tilted incline plane. The method and apparatus includes sensors along the separating section for determining position and relative movement of products. Through computer control, individual feeder rolls or sets of feeder rolls on the inclined plane are selectively energized to separate underlying products from stacked overlying or overlapping products. The foregoing process is repeated until all products in a stack have been separated into individual units.

Abstract: A method and apparatus for separating, feeding and sorting stacked products utilizes a computer controlled conveyor transport path. The transport path comprises infeed, separating and output sections. The infeed section includes an infeed conveyor and feed roller to regulate downstream movement into the separating section. The separating section includes a plurality of individually and selectively controlled friction feeder rolls arranged on a laterally tilted incline plane. The method and apparatus includes sensors along the separating section for determining position and relative movement of products. Through computer control, individual feeder rolls or sets of feeder rolls on the inclined plane are selectively energized to separate underlying products from stacked overlying or overlapping products. The foregoing process is repeated until all products in a stack have been separated into individual units.

Abstract: Apparatus and method are disclosed for detection of overlapped objects moving along a defined path. A light radiation source directs a light beam toward the path. As an object moves into the light beam, reflected light is received by two light sensors. An edge of an overlapping object moving along the defined path substantially blocks the light reflected from the underlying object from being received by one light sensor. The edges of an overlapping object are detected when a there is a difference in the amount of reflected light received by the light sensors and there exists a substantial rate of change in the amount of reflected light (indicative of a true edge of an overlapping object as opposed to warps, wrinkles, creases, etc. on the surface of an object) received by either light sensor due to the substantial blockage of reflected light by the edge.

Abstract: A modular power roller conveyor is described having a conveyor section for transporting a product unit. The conveyor section comprises a number of active zones, each active zone containing means for sensing the entry of a product unit into the active zone. A programmable controller generates activation signals to a drive roller in response to the means for sensing. A plurality of carrier rollers are slaved to the drive roller within the active zone such that activation of the drive roller actuates all of the carrier rollers to drive the product unit through the active zone and into the next active zone. The programmable controller also generates a deactuation signal to deactivate the active zone as a product unit exits the zone.

Abstract: An automated ordering system has a gathering conveyor belt and a plurality of product dispenser onto the gathering conveyor belt, the plurality of product dispensers arrayed in a matrix in rows and columns wherein each row of product dispensers and each column of product dispensers share common control elements. The product dispensers are of cartridge type utilizing gravity to eject products from a cartridge suspended above the gathering conveyor belt onto the gathering conveyor belt. A universal product dispenser platform accepts a wide range of different sizes and shapes of cartridges storing products to be dispensed. The universal product platform provides support for an actuator for singulating products mounted to the cartridge.

Abstract: A method and apparatus for separating, feeding and sorting stacked products utilizes a computer controlled conveyor transport path. The transport path comprises infeed, separating and output sections. The infeed section includes an infeed conveyor and feed roller to regulate downstream movement into the separating section. The separating section includes a plurality of individually and selectively controlled friction feeder rolls arranged on a laterally tilted incline plane. The method and apparatus includes sensors along the separating section for determining position and relative movement of products. Through computer control, individual feeder rolls or sets of feeder rolls on the inclined plane are selectively energized to separate underlying products from stacked overlying or overlapping products. The foregoing process is repeated until all products in a stack have been separated into individual units.

Abstract: An automated ordering system has a gathering conveyor belt and a plurality of product dispensers for dispensing products onto the gathering conveyor belt, the plurality of product dispensers arrayed in a matrix in rows and columns wherein each row of product dispensers and each column of product dispensers share common control elements. The product dispensers are of cartridge type utilizing gravity to eject products from a cartridge suspended above the gathering conveyor belt onto the gathering conveyor belt. A universal product dispenser platform accepts a wide range of different sizes and shapes of cartridges storing products to be dispensed. The universal product platform provides support for an actuator for singulating products mounted to the cartridge.

Abstract: An apparatus for unfolding a bifolded mailpiece comprises a pair of pivotable receiving walls for receiving a bifolded mailpiece, a pair of receiving wall cylinders for pivotally moving the receiving walls and a pair of spreader walls for spreading the bifolded mailpiece received between said receiving walls, the spreader walls being pivotally mounted and actuated by a pair of spreader wall cylinders, a ram being provided for moving the spreader walls along a vertical axis to cooperate with the receiving walls to unfold the mailpiece.

Abstract: An automated order system (AOS) having an arrayed matrix of product dispensers oriented at a compound angle with respect to an underlying gathering conveyor belt. Each dispenser includes a flexible belt ejector mechanism for dispensing products stored therein. The flexible ejector mechanism includes an L-shaped guide track that is mounted adjacent to the dispenser to minimize the amount of space required for each dispenser in the matrix. Thus, more product dispensers may be installed in the AOS over a given fixed conveyor length. Furthermore, the compound angle facilitates resupply of the dispensers and minimizes the likelihood of damage to an ejected product upon impact with the conveyor. A cartridge is also included in each dispenser having a trough and adjustable product shelf for aligning the product stack and properly positioning the bottom-most product for positioning.

Abstract: The present invention comprises apparatus for identifying, intercepting and forwarding incorrectly addressed mailpieces having either a machine readable or non-machine readable address. The apparatus reads (either mechanically or manually) the addressee name and the mailpiece destination marking address for processing in a database and comparison to a list of names and former addresses in the USPS National Change of Address database of persons who have requested mail forwarding service. If the read name and address match a name and former address in the database, then the mailpiece is identified as having an incorrect address and intercepted from the mail stream. The apparatus then searches the NCOA database for a forwarding address and delivery point ZIP code corresponding to the address. The forwarding address and delivery point ZIP marking number are printed on the mailpiece in place of the incorrect address and the mailpiece is returned to the mail stream for delivery to the addressee.

Abstract: A vacuum beam product dispenser and singulator to dispense and singulate "soft" products in an automated order dispensing system (AOS) includes a product cartridge and an inclined conveyor belt. The conveyor belt picks the products from the bottom of the cartridge using a vacuum control element and carries it up the conveyor until it reaches a pinch roller that holds the product ready to be dispensed to a central conveyor of the AOS. Products are picked from the product cartridge by the inclined conveyor in a position such that a product will fall off the conveyor unless held by a vacuum generated by the vacuum control element. Thus, random multiples removed from the cartridge with the picked product fall off the conveyor. The product stream from the hopper is thereby singulated.

Abstract: A bar code reader for reading picket and ladder oriented bar codes from products a singulated product stream transported through a scanning zone. The bar code reader is comprised of a pair of raster scanners to scan for ladder oriented bar codes on the top surface of each product and a pair of line scanners to scan the top and bottom surface of each product for picket oriented bar codes. In a second embodiment, a second pair of raster scanners is provided in addition to the top raster scanners and the line scanners to scan the bottom surface of each product for ladder oriented bar codes. The scanned optical bar code information is decoded and transmitted to a computer for analysis to identify, count and determine the disposition, according to the scanned code, of each product in the stream.

Abstract: A singulated stream of products comprised of both single and overlapping products is transported through a scanning zone along a transport path. Each single or overlapping product defines a shadow on the transport path that is analyzed to determine the presence of product multiples in the product shadow by measuring the width and length of the product shadow. If the length of the product shadow exceeds by more than a predetermined amount the average length of previously measured shadows having a similar width, the shadow likely contains two or more overlapping products. As the product shadow moves through the scanning zone, each product included therein is scanned for affixed bar codes by a plurality of bar code scanners. If two different bar codes or two identical bar codes from mutually exclusive scanners are recorded for a single product shadow, then the shadow likely contains two or more overlapping products.

Abstract: A vacuum beam product dispenser and singulator to dispense and singulate "soft" products in an automated order dispensing system (AOS) includes a product cartridge and an inclined conveyor belt. The conveyor belt picks the products from the bottom of the cartridge using a vacuum control element and carries it up the conveyor until it reaches a pinch roller that holds the product ready to be dispensed to a central conveyor of the AOS. Products are picked from the product cartridge by the inclined conveyor in a position such that a product will fall off the conveyor unless held by a vacuum generated by the vacuum control element. Thus, random multiples removed from the cartridge with the picked product fall off the conveyor. The product stream from the hopper is thereby singulated.