Abstract: A hold-and-release singulator includes a conveyor having a transport mechanism for carrying a group of items such as parcels, packages, containers or the like from an entry end towards an exit end of the singulator, a hold and release system that can hold items that have entered the singulator on the conveyor so that such items are not transported by the conveyor while causing one item to be transported by the conveyor, and a control system that controls operation of the conveyor and the hold-and-release system in a manner effective to remove the group of items from the exit end of the conveyor one at a time according to a removal scheme, preferably with a predetermined minimum spacing.

Abstract: A sorter conveyor system according to the invention includes at least one endless conveyor loop including a rail. One or more conveyor segments are mounted on the rail. Each segment is a series of cart units each having wheel structures mounted for rolling movement along the rail, a carrier for carrying one or more items thereon, a selectively actuable mechanism for actuating the carrier laterally in at least one direction to unload an item from the carrier to an unloading station adjacent the conveyor loop, and a coupling mechanism for joining each cart unit in each series in a head to tail relationship. One or more drive elements are connected to one or more of the cart units and configured to permit the conveyor segment to be driven by a linear drive unit.

Abstract: In one embodiment, an article sorting system includes successive coarse and fine singulators and a recirculating loop for processing a disordered stream of items including three-dimensional non-flat articles. A coarse singulator includes cascaded ramped conveyors, preferably operating at progressively greater speeds. A detection system, such as a vision system, for monitoring the stream of articles and identifying and/or tracking individual items passing through the system is used in conjunction with a fine singulator such as a chevron, hold-and-release or strip conveyor downstream from the coarse singulator. A control system is utilized in connection with the vision system to regulate the flow of articles through the system by, for example, diverting doubles or clusters for separations.

Abstract: A passive discharge mechanism for discharging articles from a trolley at selected locations is disclosed. The trolley may be equipped with on-board intelligence for communicating with an external controller, monitoring the trolley's location, and signaling actuation of a moveable member for engaging the passive discharge mechanism as the trolley reaches a selected destination for an article conveyed by the trolley. In one aspect the passive discharge mechanism comprises a transverse conveyor; in another aspect the passive discharge mechanism includes a tilt-type tray. A trolley for conveying articles along a monorail having arcuate portions includes a rigid frame having a longitudinal axis and opposed ends is also disclosed.

Abstract: In a process for sorting mail pieces according to the invention using a priori or first sort pass derived information, a sorting machine is used having a first array of pockets and a second array of pockets physically separate from the first array of pockets. The first and second arrays are swept of mail pieces by separate sweepers. The number of mail pieces sorted to each array are equalized in order to equalize the volume of mail pieces swept by each sweeper. In particular, where each pocket corresponds to a destination code and a total number of mail pieces per destination code is known in advance for each sort scheme to be carried out on the sorting machine, the equalizing step involves assigning destination codes to specific pockets to different sweeper zones in a manner that equalizes the volume of mail pieces swept by each sweeper. Mail is then swept from the pockets to trays stored on a vertically and horizontally extending rack having rows and columns of compartments containing trays.

Abstract: A trolley car for conveying articles along a monorail having arcuate portions includes a rigid frame having a longitudinal axis and opposed ends.

Abstract: An apparatus and method for measuring the weight of a moving object is disclosed. In one embodiment, the apparatus includes a platform for supporting the moving object to be weighed, means for permitting the object to move smoothly over the platform, a weight sensor for measuring a force applied to the platform by the moving object and generating a weight sample that reflects the measured force value, a detection sensor that generates a signal upon detecting the moving object on the platform, a processor having a memory, which processor receives samples from the weight sensor and stores weight values based on the samples; and means for calculating the weight of the object using a succession of the stored values when the detection sensor generates its signal.

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: A sorter conveyor system according to the invention includes at least one endless conveyor loop including a rail. One or more conveyor segments are mounted on the rail. Each segment is a series of cart units each having wheel structures mounted for rolling movement along the rail, a tray for carrying one or more items thereon, a selectively actuable mechanism for tilting the tray laterally in at least one direction to unload an item from the tray to an unloading station adjacent the conveyor loop, and a coupling mechanism for joining each cart unit in each series in a head to tail relationship. One or more drive elements are connected to one or more of the cart units and configured to permit the conveyor segment to be driven by a linear drive unit.

Abstract: An apparatus for handling and transferring letter mail from and to different sized mail receptacles or containers such as cartridges and mail trays includes a support frame rotatably supporting a platform and intermediate transfer pan. The platform is adapted to receive a letter mail receptacle, and a clamp apparatus is provided to secure the container to the platform. A motor and coaxial shafts, coupled with a clutch, are drivingly engaged with the platform and the intermediate transfer pan. An elevator is provided to move the platform along a longitudinal axis and the platform is rotatable around an axis perpendicular to the longitudinal axis through the operation of the motor, coaxial shafts and clutch, the clutch selectively coupling the coaxial shafts. The platform and the intermediate transfer pan are rotated such that the letter mail originally located in a receptacle clamped on the platform is transferred to the intermediate transfer pan.

Abstract: A flat article turntable for use in a flat article sorting system having a flat article holding cartridge, a cartridge handling mechanism and an automatic flat article feeder is provided with an empty cartridge presentation mechanism for presenting empty cartridges to a cartridge handling system. A full cartridge acceptor mechanism for receiving full cartridges from the cartridge handler system. A rotary mechanism is provided for rotating a full cartridge 90°. An index mechanism is provided to matingly index the cartridges with the automatic feeder of the sorting system. An extraction mechanism is provide including a cartridge opener for opening the cartridge. A pushing mechanism is operatively connected for pushing stacked articles from the cartridge. A pause mechanism is interconnected to allow a finger on the automatic feeder to take the stacked articles, and a closing mechanism is attached to close the cartridge.

Abstract: A method and apparatus for automatically transferring and handling cartridges containing flat articles. The method and apparatus robotically transfers filled cartridges from the output compartments of a sorting machine to a buffer shelf; and from the buffer shelf to a docking station of a cartridge unloader and automatic feeder to the input of the sorting machine, and for transferring empty cartridges from the docking station to either the buffer or the output compartments of the sorter, is provided.

Abstract: A product dispensing apparatus includes a gathering conveyor and a plurality of product dispensers for dispensing items onto the gathering conveyor, the plurality of product dispensers including a first subset of product dispensers and a second subset of product dispensers, the first subset and the second subset have at least one common product dispenser. First and second relays are coupled to the first and second subset of product dispensers, respectively; simultaneously energizing the first and second relay actuates at least one of the product dispensers. The product dispensers are arrayed in a matrix for dispensing products, the matrix of product dispensers having a plurality of rows and a plurality of columns, corresponding the first and second subset.

Abstract: A method and apparatus for transferring a stack of flat articles from a cartridge. The method and apparatus are adapted for use in connection with a method and apparatus for automatically stacking mail into cartridges in output compartments of a sorting machine, robotically transferring filled cartridges from the output compartments to a buffer shelf; and from the buffer shelf to a docking station of a cartridge unloader and automatic feeder to the input of the sorting machine, and for transferring empty cartridges from the docking station to either the buffer or the output compartments of the sorter, is provided.

Abstract: An improved device for edging flat products is provided having a plurality of spaced apart generally upstanding fingers, the fingers being forwardly translatable with a group of flat products between them. Each of the fingers is rockable back and forth across a vertical centerline as the fingers are forwardly translated to jostle the flat products, thereby to align the bottom edges of the flat products.

Abstract: A sensor roller and method for detecting the presence of a tray located thereon, where the tray is traveling along a conveyor system, includes a housing having an interior chamber and a plurality of apertures. The apertures are in one-to-one correspondence with actuators, where the actuators each have an exposed portion protruding through the apertures. The sensor roller further includes a piston slidable in the interior chamber of the housing and engaging the actuators. The piston slides between a non-actuated position to an actuated position in response to a tray travelling along the conveyor system depressing an actuator into the interior chamber of the housing. A sensor detects the presence of the piston in the actuated position and generates a detection signal in response thereto.

Abstract: A mail sorting process used with a sorting machine where the next successive sort is performed during the sweeping operation of the previous sort. In a first sort, a batch of mailpieces are sorted and directed to a selected first array or group of destination pockets or bins. After the first sort is completed, the mailpieces are swept from the pockets in a sweeping operation. A second sort for sorting a second batch of mailpieces to a selected second array or group of destination pockets is begun during the sweeping operation of the first sort. As such, the sorting process sorts a batch of mailpieces to a group of destination pockets while another group of destination pockets used during a previous sort are being swept.

Abstract: A method and apparatus for stacking flat articles into a cartridge. The method and apparatus are adapted for use in connection with output compartments of a sorting machine, robotically transferring filled cartridges from the output compartments to a buffer shelf; and from the buffer shelf to a docking station of a cartridge unloader and automatic feeder to the input of the sorting machine, and for transferring empty cartridges from the docking station to either the buffer or the output compartments of the sorter.

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: A cartridge for containing mail. The cartridge is specially adapted for use in a method and apparatus for automatically stacking mail into cartridges in output compartments of a sorting machine, robotically transferring filled cartridges from the output compartments to a buffer shelf; and from the buffer shelf to a docking station of a cartridge unloader and automatic feeder to the input of the sorting machine, and for transferring empty cartridges from the docking station to either the buffer or the output compartments of the sorter, is provided.