Abstract: A method and apparatus for sorting articles to a delivery point sequence includes at least one article sorter adapted to sort articles and a conveying system operable to arrange and convey containers of articles sorted in a first sort pass to an induct of the article sorter for a second sort pass or process of the articles. The system or method automatically sorts and conveys trays containing sorted articles from a discharge of at least one sorting assembly to an induct of the at least one sorting assembly. The conveying assembly may have a generally continuous conveying track and is operable to automatically provide the trays to the induct of the at least one sorting assembly in a sequenced manner.

Abstract: A method and apparatus for sorting articles to a delivery point sequence includes at least one article sorter adapted to sort articles and a conveying system operable to arrange and convey containers of articles sorted in a first sort pass to an induct of the article sorter for a second sort pass or process of the articles. The system or method automatically sorts and conveys trays containing sorted articles from a discharge of at least one sorting assembly to an induct of the at least one sorting assembly. The conveying assembly may have a generally continuous conveying track and is operable to automatically provide the trays to the induct of the at least one sorting assembly in a sequenced manner.

Abstract: A method and apparatus for sorting articles to a delivery point sequence includes at least one article sorter adapted to sort articles and a conveying system operable to arrange and convey containers of articles sorted in a first sort pass to an induct of the article sorter for a second sort pass or process of the articles. The conveying system may include at least one transport conveyor and a plurality of zone conveyors or staging zones. The transport conveyor conveys trays from the discharge of the article sorter to the induct of the article sorter, and the zone conveyors are positioned along the transport conveyor. The conveying system is operable to arrange and accumulate trays in a sequenced manner on the transport conveyor. The transport conveyor is operable to discharge the sequenced trays to the induct of the article sorter.

Abstract: A method for handling trays for use with an article sorter includes providing a conveying surface along a plurality of sorter units and conveying empty trays along the conveying surface. The empty trays that are being conveyed along the conveying surface are stopped with a tray stopping device that is positioned at least partially below the conveying surface and operable to project a portion of the tray stopping device above the conveying surface to engage and stop an empty tray. The stopped empty trays are moved from the conveying surface to the tray support areas in a direction generally transverse to the conveying surface. The empty trays are at least partially filled at the tray support areas, and the partially filled trays are moved from the tray support area onto the conveying surface.

Abstract: A method and apparatus for sorting articles to a delivery point sequence includes at least one sortation assembly adapted to sort articles and a buffer. The buffer is operable to arrange and convey containers of articles sorted in a first sort pass to an induct of the at least one sortation assembly for a second sort pass or process of the articles. The buffer automatically arranges the containers in an arranged manner prior to conveying the containers and articles to the induct of the at least one sortation assembly for the second sort process. The second sort process is then performed to sort the articles to a delivery point sequence or carrier walk sequence depth of sort. A conveyor assembly may be operable to convey containers to an appropriate one of multiple sortation assemblies and/or buffers to increase the sequencing matrix capability of the apparatus.

Abstract: An automatic tray handling system for use with an article or mail sortation system, such as a flats mail sortation system, is operable to automatically remove filled or partially filled trays from individual sorter units and to replenish the sorter units with empty trays. The empty trays and/or filled trays are moved along at least one conveying surface adjacent to the sorter units. The automatic tray handling system includes a plurality of tray moving devices, which are operable to move the empty trays from the conveying surface to the sorter units, whereby the trays are at least partially filled by the sorter units. The tray moving devices are then further operable to move the at least partially filled trays from the sorter units to a conveying surface, whereby the filled trays may be conveyed to downstream operations, such as an automatic labeling station. Preferably, the empty trays are movable in a continuous loop about the mail sortation system.

Abstract: An automatic tray handling system for use with an article or mail sortation system, such as a flats mail sortation system, is operable to automatically remove filled or partially filled trays from individual sorter units and to replenish the sorter units with empty trays. The empty trays and/or filled trays are moved along at least one conveying surface adjacent to the sorter units. The automatic tray handling system includes a plurality of tray moving devices, which are operable to move the empty trays from the conveying surface to the sorter units, whereby the trays are at least partially filled by the sorter units. The tray moving devices are then further operable to move the at least partially filled trays from the sorter units to a conveying surface, whereby the filled trays may be conveyed to downstream operations, such as an automatic labeling station. Preferably, the empty trays are movable in a continuous loop about the mail sortation system.

Abstract: An article separation conveyor system includes a plurality of conveyors which are independently and/or collectively operable to destack, separate and/or align articles being conveyed along the article separation conveyor. The conveyor system includes a destacking conveyor, a side by side eliminating conveyor and/or an aligning conveyor. The destacking conveyor includes a plurality of conveying portions, which are inclined to convey articles up and then drop or guide them onto the next adjacent conveyor. The side-by-side eliminating conveyor includes a pair of diverting members and is operable to redirect articles from one side of the conveyor to the other to destack and separate articles as they are continuously conveyed along the conveyor. The aligning conveyor is operable to align articles along one side of the discharge conveyor so the articles are arranged for identification at a downstream scanning device and induction onto a sortation system.

Abstract: An automatic tray-handling system for use with a mail sorter (26) having a plurality of tray supporters, comprises a transporter (50) having a conveying surface (56) and an insertion/extraction assembly (58); and respective feed (44a, 44b) and discharge conveyors (46a, 46b) adapted to feed empty trays (38) to the transporter conveying surface (56) and receiving at least partially full trays (38) from the transporter conveying surface. The insertion/extraction assembly (58) is adapted to insert empty trays (38) to tray support areas and remove at least partially full trays (38) from tray support areas. The conveying surface operational is adapted to receive empty trays (38) from the feed conveyor (44a, 44b) and at least partially full trays (38) from the insertion/extraction assembly (58). Moreover from the conveying surface empty trays are dischargeable to the insertion/extraction assembly (58) and to the discharge conveyor (46a, 46b).

Abstract: An automatic tray handling system for use with an article or mail sortation system, such as a flats mail sortation system, is operable to automatically remove filled or partially filled trays from individual sorter units and to replenish the sorter units with empty trays. The empty trays and/or filled trays are moved along at least one conveying surface adjacent to the sorter units. The automatic tray handling system includes a plurality of tray moving devices, which are operable to move the empty trays from the conveying surface to the sorter units, whereby the trays are at least partially filled by the sorter units. The tray moving devices are then further operable to move the at least partially filled trays from the sorter units to a conveying surface, whereby the filled trays may be conveyed to downstream operations, such as an automatic labeling station. Preferably, the empty trays are movable in a continuous loop about the mail sortation system.

Abstract: A method and apparatus for sorting mail to delivery point sequence includes providing a first sortation assembly adapted to performing a first sort pass to mail articles supplied to it and a second sortation assembly adapted to performing a second sort pass to mail articles supplied to it. Mail articles are supplied to the first sortation assembly which identifies the mail articles and performs a first sort pass to sort the mail articles. The mail sorted by the first sortation assembly is conveyed to the second sortation assembly which performs a second sort pass to sort the mail articles to delivery point sequence depth of sort.

Abstract: A method and apparatus for sorting articles to a delivery point sequence includes at least one sortation assembly adapted to sort articles and a buffer. The buffer is operable to arrange and convey containers of articles sorted in a first sort pass to an induct of the at least one sortation assembly for a second sort pass or process of the articles. The buffer automatically arranges the containers in an arranged manner prior to conveying the containers and articles to the induct of the at least one sortation assembly for the second sort process. The second sort process is then performed to sort the articles to a delivery point sequence or carrier walk sequence depth of sort. A conveyor assembly may be operable to convey containers to an appropriate one of multiple sortation assemblies and/or buffers to increase the sequencing matrix capability of the apparatus.

Abstract: An article separation conveyor system includes a plurality of conveyors which are independently and/or collectively operable to destack, separate and/or align articles being conveyed along the article separation conveyor. The conveyor system includes a destacking conveyor, a side by side eliminating conveyor and/or an aligning conveyor. The destacking conveyor includes a plurality of conveying portions, which are inclined to convey articles up and then drop or guide them onto the next adjacent conveyor. The side-by-side eliminating conveyor includes a pair of diverting members and is operable to redirect articles from one side of the conveyor to the other to destack and separate articles as they are continuously conveyed along the conveyor. The aligning conveyor is operable to align articles along one side of the discharge conveyor so the articles are arranged for identification at a downstream scanning device and induction onto a sortation system.