Dual mode stacking system and method of use

Abstract

An apparatus and method for orienting a container. The apparatus includes a frame moveable between a lowered position and a raised, substantially vertical position. A container cradle is pivotably connected to the frame and selectively positionable to a substantially vertical stacking position or a substantially horizontal stacking position when the frame is in the raised, substantially vertical position. The method includes, amongst other features, orienting the container into a horizontal stacking position or maintaining the container in a same orientation as the frame when in the raised vertical position. In the latter orientation, product or other objects can be stacked in a vertical orientation.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application Ser. No. 60/552,747 and U.S. Provisional Application Ser. No. 60/552,748, both filed Mar. 15, 2004, which are now incorporated by reference in their entirety herein.

FIELD OF THE INVENTION

The invention generally relates to a dual mode stacking system and method of use and, more particularly, to a system and method for stacking products in either a horizontal or vertical position within a container using a single system.

BACKGROUND DESCRIPTION

The sorting of mail is a very complex, time consuming task. In general, the sorting of mail is processed though many stages, including back end processes, which sort or sequence the mail in delivery order sequence. These processes can either be manual or automated, depending on the mail sorting facility, the type of mail being sorted such as packages, flats, letter and the like. A host of other factors may also contribute to the automation of the mail sorting, from budgetary concerns to modernization initiatives to access to appropriate technologies to a host of other factors.

In general, however, most modern facilities have taken major steps toward automation by the implementation of a number of technologies. These technologies include, amongst others, letter sorters, parcel sorters, advanced container conveyors, flat sorters and the like. As a result of these developments, postal facilities have become quite automated over the years, considerably reducing overhead costs.

Although automation has provided many benefits, there are still requirements that cannot be met by currently known systems. For example, recently the United States Postal Service (USPS) has requested a single machine with both vertical stacking and horizontal stacking capabilities. However, such systems are not currently available which are capable of stacking mail in a horizontal orientation and a vertical orientation within a container using a single machine. Thus, currently known systems do not meet some of the current requirements of the postal system (e.g., United States Postal System) and thus cannot provide the required designed flexibility to enhance the productivity and overall evolving efficiencies demanded by such postal system and other customers.

The invention is designed to overcome one or more of the above problems.

SUMMARY OF THE INVENTION

In a first aspect of the invention, an apparatus for orienting a container includes a frame moveable between a lowered position and a raised position. A cradle is pivotably connected to the frame and is selectively positionable to a substantially vertical stacking position when the frame is moved to the raised position.

In another aspect of the invention, the apparatus for stacking product includes a conveyor support structure and a conveyor tilt frame moveable between a lowered position and a raised position. A conveyor actuator is coupled to the conveyor support structure and the conveyor tilt frame to move the conveyor tilt frame between the lowered position and the raised position. A container cradle is pivotably coupled to the conveyor tilt frame, and a system extends between the container cradle and the conveyor support structure to position the container cradle in a substantially vertical stacking orientation when the conveyor tilt frame is in the raised position.

In yet another aspect of the invention, an apparatus for orienting a container includes a frame moveable between a lowered position and a raised, substantially vertical position. The apparatus also includes a container cradle pivotably connected to the frame and selectively positionable to a substantially vertical stacking position or a substantially horizontal stacking position when the frame is in the raised, substantially vertical position.

In another aspect of the invention, the apparatus includes a conveyor tilt frame moveable between a lowered position and a raised, substantially vertical position. A conveyor actuator is coupled to the conveyor tilt frame to move the conveyor tilt frame between the lowered position and the raised, vertical position. A container cradle is pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation within the container. A linkage system extends between the container cradle and the conveyor support structure to position the container cradle to a substantially horizontal stacking orientation or maintain the container cradle in a substantially same orientation as the conveyor tilt frame when in the raised, substantially vertical position.

In another aspect of the invention, the apparatus includes a conveyor tilt frame moveable from approximately 0° to approximately 70° in a vertical position. A conveyor actuator is coupled to the conveyor tilt frame to move the conveyor tilt frame from approximately 0° to approximately 70° in the vertical position. A container cradle is pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation when the conveyor tilt frame is positioned to approximately 70°. A mode selector includes (i) a first position to selectively orient the container cradle in the horizontal stacking orientation, and (ii) a second position to selectively maintain the container cradle and the conveyor tilt frame at substantially a same orientation when the conveyor tilt frame is positioned to approximately 70°.

In this embodiment, a four bar linkage rotates the container cradle to the horizontal stacking orientation when the mode selector is in the first position and the conveyor tilt frame is positioned to approximately 70°. The four bar linkage also maintains the container cradle in the substantially same orientation when the conveyor tilt frame is positioned to approximately 70° and the mode selector is in the second position for vertical stacking. A product stop mechanism and a synchronizer are also provided. The synchronizer is selectively controlled by the mode selector and is capable of moving the product stop mechanism to an extended position when the container cradle is moved to the substantially vertical stacking orientation.

In a further aspect of the invention, a method of stacking mail includes inserting an empty container into a pivotably mounted cradle and raising the cradle from a first height to a raised height. The cradle is rotated to a substantially vertical stacking position and mail is inducted into the container. The cradle is lowered to the first height and rotated into a substantially horizontal orientation after a predetermined amount of mail has been inducted into the container.

In yet another aspect of the invention, a method is provided for stacking product in either a horizontal orientation or a vertical orientation. The method includes placing a container on a container cradle and determining whether product is to be stacked in a vertical stacking orientation or a horizontal stacking orientation in the container. If the product is to be stacked in the vertical stacking orientation, the method includes rotating a conveyor frame to a substantially vertical orientation while maintaining the container cradle in a substantially same orientation as the conveying frame. If the product is to be stacked in the horizontal stacking orientation, the method includes rotating the conveyor to the substantially vertical position and rotating the container cradle to a substantially, raised horizontal orientation. The method also inducts product into the container, and when the product has reached a predetermined height or weight in the container or no further product is available then:

• • (i) if the product was stacked in the vertical stacking orientation, rotating the conveyor frame into a substantially horizontal position while maintaining the maintaining the container cradle in a same orientation as the conveying frame; and
  • (ii) if the product was stacked in the horizontal stacking orientation, rotating the conveyor frame to the substantially vertical position and rotating the container cradle to an original, lowered horizontal orientation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a schematic of the system of the invention;

FIG. 2 shows a cross sectional view of system along line 1-1 of FIG. 1 according to the invention;

FIG. 3 shows the system in a horizontal loading position according to the invention;

FIG. 4 shows the system in a vertical loading position according to the invention;

FIG. 5 shows a vertical stacking container support and stop system in a retracted position according to the invention;

FIG. 6 shows the vertical stacking container support and stop system in an extended position according to the invention;

FIG. 7 shows steps implementing the system in a vertical loading position in accordance with the invention;

FIG. 8 shows steps implementing the system in a horizontal loading position in accordance with the invention; and

FIG. 9 shows a dual step flow for implementing either a vertical or horizontal loading position.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The invention is directed to a system and method for stacking product in either a vertical orientation or a horizontal orientation using a single machine. The product may be, for example, flats and other mail items (i.e., letters), for future delivery or warehousing or the like. The invention significantly reduces machine costs by allowing a single machine to stack flats and mail pieces or other disparate products in delivery point sequence, in embodiments, in either a vertical orientation or a horizontal orientation. Other applications such as warehousing and storage applications are also contemplated for use with the invention.

In one aspect of the invention, the system is capable of sequencing and stacking flats in both a vertical and horizontal orientation into a container from a single design. The flats being fed from a base flats processing machine may successfully sort into a container in the same exact sequence as the base machine presents the product to the system of the invention. That is, the flats may be properly sequenced in the container using the system and method of the invention in either a horizontal or vertical orientation, depending on the particular requirements.

The design of the invention provides the ability to present a container located in a “cradle” type device, to a sorting machine for either horizontal or vertical sequencing into a container. In one aspect of the invention, the system contains two degrees of freedom in the motion system design:

• (i) pivoting a conveyor frame, which sets a vertical height of the container to either transfer a container (lower position of frame) or position the container for sequencing (upper position of frame). Both horizontal and vertical stacking may require this motion; and
• (ii) a rotational feature of a cradle within the conveyor frame. In this mode, the system of the invention can rotate the cradle to an angle in order to allowing stacking in a vertical orientation, for example.

For horizontal stacking of the product, the cradle (with the container) remains in a horizontal orientation as the frame is rotated up (as per the first degree of freedom). For vertical stacking of the product, the cradle (with the container) remains at the same angle as the frame (e.g., the container as remains at the angle of the frame) as the frame is rotated up (as per the first degree of freedom). Additional features, as described below, are designed to ensure that the container remains substantially stationary, will not topple or rotate, and that the mail or other articles or product, more generally, remain within the container during processing. The dual mode system contains built-in safety features as described below.

Dual Mode Stacking System of the Invention

Referring now to FIG. 1, a diagram of the system of the invention is shown. In the embodiment of FIG. 1, the dual mode sequencing system is generally depicted as reference numeral 100 and includes a conveyor tilt frame 102. The conveyor tilt frame 102 is a structural component of the dual sequencing system providing the guidance and orientation for the container. In one implementation, the conveyor tilt frame 102 includes two opposing side walls 102a and a bottom surface 102b. The conveyor tilt frame 102, in one example, is of sufficient strength to properly position a container “T” weighing up to 70 pounds, for example, and move this container “T” through a 70-degree arc in approximately 2 seconds. It should be recognized by those of ordinary skill in the art that the system of the invention can also accommodate different weights and move through different arcs, as would be modified for a particular application and configuration.

In one implementation, the conveyor tilt frame 102 has three pivot joints including, for example,

• (i) The first pivot joint is for proper container orientation depending upon whether the container is being transferred into or out of the dual mode sequencing system;
• (ii) The second pivot joint provides the mounting strength feature for the container cradle and the ability to properly position the cradle for either horizontal or vertical sequencing mode; and
• (iii) The third pivot joint provides a mounting point for the system actuator.

Still referring to FIG. 1, the conveyor tilt frame 102 is mounted to a conveyor support structure 104 which is a structural member of sufficient strength to support the conveyor tilt frame 102, in addition to a container cradle 106 and the container “T” (fully loaded). The conveyor tilt frame 102 or conveyor support structure 104 also provides an anchor and/or pivot point for a system actuator 108. The support structure 104 may be mounted to the sorting machine, itself, or self-standing and braced to the sorting machine.

The conveyor actuator 108 provides the drive force to move the conveyor tilt frame 102 with the container cradle 106 and container from a horizontal orientation to a vertical orientation of approximately 70-degrees. It should be recognized that other orientations are also contemplated for use by the invention, and that the use of 70 degrees is provided as one illustration. Accordingly, the invention should not be limited to a 70 degree orientation.

The conveyor actuator 108 can be any powered device capable of linear or angular motion of sufficient strength for the dual mode sequencing system. This may be, for example, a linear actuator, rack and pinion gear, pneumatic or hydraulic drive and be configured as any linear or rotary motion device, including servo-amplifier controlled, capable of handling loads and speeds associated with the dual mode sequencing system. The mounting of the actuator can be through bearings, flanges, shafts and the like as shown generally at reference numeral 108a. A fail-safe mode, e.g., stop, 108b is also provided to immediately stop motion of the conveyor tilt frame upon loss of power.

FIG. 1 further shows the container cradle 106, which is the second degree of freedom motion of the system. The container cradle 106 includes a container power transfer assembly 110 which is in the flow stream of a load conveyor 112 and a remove conveyor 114. The load conveyor 112 is designed to transport the containers “T” onto the container cradle 106 and the remove conveyor 114 is designed to transport the containers “T” from the system of the invention. The container power transfer assembly 110 may be a belt driven transport or a roller driven transport, known in the art of conveying systems. For example, the power roller bed 110 may be a set of rollers capable of transferring a container. The conveyor rollers are spaced to provide support and friction drive to an empty or full container and also to provide sufficient clearance for other mechanical features such as sensors, pop-up stops and the like. The power roller bed is inherently safe due to minimal torque of the power roller and typical o-ring drive belts that can slip when the rollers are subjected to outside forces.

The container cradle 106 also includes a bottom portion 106a and side members 106b. These structural members 106a and 106b provide support for the container transfer power assembly 110, as well as stops 116a and 116b and accompanying sensors 116a₁, 116a₂, 116b₁ and 116b₂. Pivot joints 118 are fitted into this structure and provide a mounting pivot point for the container cradle 106 via a four bar linkage mechanism 120 or alternatively a sprocket and belt or chain assembly. This container cradle 106 will pivot about a container cradle pivot 122, which may be used to determine the common relationship between the vertical and horizontal container positions.

The pop-up stops 116a and 116b are located at the trailing edge and leading edge of the container cradle 106, respectively. The stops 116a and 116b may be electrical, pneumatic or hydraulic actuated and provide registration and support for the container while in the container cradle 106. The stops 116a and 116b are moveable in both an upward and downward direction. In one implementation, the stop 116b, in the upright position, provides for positioning and supporting the container “T” at the leading edge while in the container cradle 106, and may be used for both horizontal and vertical stacking. That is, as an empty container is transferred onto the container cradle 106, this leading edge stop 116b pops up in front of the container to stop the container and register it for proper position.

For horizontal stacking of product, the stop 116a makes certain that the container cannot transfer off the cradle, out of sequence. That is, after an empty container has entered the cradle, this stop 116a pops up to confine or limit the movement of the container intended for horizontal sequencing. Now, as product is transferred into the container during horizontal sequencing, the impact of the product in the container forces the container back away from the product insertion point, but trailing edge pop-up stop 116a limits the amount of travel of the container due to this impact and maintains proper container position for horizontal sequencing. For vertical stacking, the stop 116b provides the leading edge registration point for the container and supports the container while rotating up to the sequencing angle of 70 degrees, maintaining this support as the container fills with products.

In the vertical stacking position, a container support and stop system, schematically represented at reference numeral 200, is provided (as discussed in more detail with reference to FIGS. 4-6). It should be recognized by those of ordinary skill in the art that the stacking container support and stop system 200 (system) may be used in conjunction with the system 100; however, the system 200 may equally be a stand alone system or be used in conjunction with other systems that provide only vertical stacking positions for the containers.

Still referring to FIG. 1, the sensors 116a₁, 116a₂, 116b₁ and 116b₂ may be item present sensors. For example, these sensors may be a photodiode, reflective type sensor, transmitter and receiver sensor, or the like. In operation, the sensors will determine the position of the respective stops 116a and 116b; that is, the sensors 116a₁, 116a₂, 116b₁ and 116b₂ will sense when the stops are in the fully extended or retracted position by for example, the stops blocking or interrupting the transmission or reflection emitted by the sensors. By way of example:

• (i) Leading edge pop-up stop position sensor 116b: When the leading edge pop-up stop is required to actuate up, this sensor assures that the stop has reached its fully up position. The sensor is an item present type sensor mounted on the pop-up stop assembly, for example.
• (ii) Leading edge pop-up stop retract position sensor 1116b₂: When the leading edge pop-up stop is required to drop down, this sensor assures that the stop has reached its fully down position. The sensor is an item present type sensor mounted on the pop-up stop assembly, for example.
• (iii) Trailing edge pop-up stop up position sensor 116a₁: When the trailing edge pop-up stop is required to actuate up, this sensor assures that the stop has reached its fully up position. The sensor is an item present type sensor mounted on the pop-up stop assembly, for example.
• (iv) Trailing edge pop-up stop, retract position sensor 116a₂: When the trailing edge pop-up stop is required to drop down, this sensor assures that the stop has reached its fully down position. The sensor is an item present type sensor mounted on the pop-up stop assembly, for example.

In one embodiment, a photodiode detects the presence or absence of an object by the interruption of an energy source, e.g., a light beam. The digital or analog output of the sensors 116a₁, 116a₂, 116b₁ and 116b₂ may be linked to the operation of the pop-up stops 116a, 116b, and/or the operation of the actuator 108, or other components which should be well understood by those of skill in the art.

In one embodiment, an optional pressure sensor or photodiode may be positioned to detect the product in the container. The output of the sensor may be linked to the operation of the actuator 108 such that detection of an empty product container causes the actuator 108 to raise the tilt frame 102 to the vertical stacking position, and the detection of a full or other predetermined height or weight of the product container causes the actuator 108 to lower the tilt frame 102 to its starting position. Other sensors known in the art can be implemented to determine whether the container transfer power assembly 110 is properly aligned with the load conveyor 112 and the remove conveyor 114, all communicating with controller “C”.

The four-bar linkage mechanism 120 comprises two four-bar linkages pivotally mounted on opposing sides of the container cradle 106. More specifically, each of the four-bar linkages are mounted on side walls 106b of the container cradle 106, at the pivots 118, and extend to respective sides of the mode selector 126. The pivot connection at the mode selector 120 may be referred to as a four bar link pivot and conveyor tilt frame pivot 124 (e.g., structure), which is mounted to the conveyor support structure 104. The four bar linkage 120 may provide the rotational control of the cradle. Depending upon a mode selector position 126, the four-bar linkage pivot feature will maintain its relationship with the support structure for vertical stacking.

The “mode selector” 126 is used to determine which orientation the container is at for stacking. For example, the mode selector may be a pin or clutch for engaging certain (for horizontal or vertical type of stacking) structures of the system. In one illustration, the mode selector 126 may engage the conveyor tilt frame 102 and the four bar linkage 120 to select the vertical stacking orientation. Thus, for horizontal stacking, the cradle (with the container) remains in a horizontal orientation as the frame is rotated to the substantially vertical position. However, for vertical stacking, the cradle (with the container) remains at substantially or the same angle as the frame as the frame is rotated to the substantial vertical position.

FIG. 1 shows various additional sensors contemplated for use with the invention. As should be understood, the sensors, as well as the components, can be controlled and coordinated by the controller “C”. Also, as should be understood by those of skill in the art, the types of sensors used with various embodiments of the invention include any known appropriate sensor, such as a photodiode, photoelectric, or pressure sensor. This list is not intended to be exhaustive, and persons of ordinary skill in the art will appreciate that other types of sensing devices may be used with the invention. These sensors may include, for example:

• • Container-in-position sensor mounted in the cradle, 126
  • Horizontal sequencing mode selector position sensor, 128
  • Vertical sequencing mode selector position sensor, 130
  • Conveyor up position sensor, 132
  • Conveyor down position sensor, 134
  • Conveyor slow down sensor, 136a and 136b
  • Product jam sensor, 138

Other sensors known in the art can be implemented to determine whether the container transfer power assembly 110 is properly aligned with the load conveyor 112 and the remove conveyor 114, and the mail stop device 200 is properly extended or retracted.

Container-In-Position Sensor

The container-in-position sensor may be an item present type sensor, mounted in the cradle. This sensor may monitor the presence of a container on the container cradle 106 to assure proper container transfer into and out of the cradle by the interruption of an energy source, e.g., a light beam.

In one implementation of the invention, when this sensor detects that a container is present, the trailing edge pop-up stop then moves to the up position (in the horizontal position). Then, if all other required conditions are met, the dual mode system is now ready to rotate the conveyor frame up into sort position. After the product sorting is complete in the container, the container tilt conveyor rotates to the down position and the container transfers off the cradle to a buffer location. The container-in-position sensor also detects when a filled container is transferred off the cradle successfully. Accordingly, the output of the sensor may be linked to the operation of the actuator 108 such that detection of an empty container causes the actuator 108 to raise the tilt frame 102 to the vertical position, and the detection of a full or other predetermined level of product within the container causes the actuator 108 to lower the tilt frame 102 to its starting position.

Horizontal Sequencing Mode Selector Position Sensor

This sensor may be an item present type sensor and assures that the horizontal sequencing mode selector is properly positioned. When horizontal sequencing is called for, this sensor confirms (feeds back to the control system) that the correct selection has taken place. This sensor may be mounted on the mode selector assembly, and may detect the presence of an object by the interruption of an energy source, e.g., a light beam.

Vertical Sequencing Mode Selector Position Sensor

This sensor may be an item present type sensor and assures that the vertical sequencing mode selector is properly positioned. When vertical sequencing is called for, this sensor confirms (feeds back to the control system) that the correct selection has taken place. This sensor may be mounted on the mode selector assembly, and may detect the presence of an object by the interruption of an energy source, e.g., a light beam.

Conveyor Up Position Sensor

This sensor may be an item present type sensor and determines when the conveyor has reached its fully up position, ready to sort product to the container. This sensor may be mounted on the conveyor actuator, and may detect the presence of an object by the interruption of an energy source, e.g., a light beam.

Conveyor Down Position Sensor

This sensor may be an item present type sensor and determines when the conveyor has reached its fully down position, ready to transfer the filled container off from the cradle to a buffer location. This sensor may be mounted on the conveyor actuator, and may detect the presence of an object by the interruption of an energy source, e.g., a light beam.

Conveyor Actuator Slow-Down Sensors

The system may contain slow-down sensors near the end of stroke at both ends to control deceleration of the conveyor frame. These sensors would provide input to the actuator control circuitry (electrical, pneumatic or hydraulic) to slow-down the end-of-stroke movement of the conveyor actuator. This would enable the system to rotate as quickly as possible to position and minimize impact at the end of travel. These sensors may be located within the actuator, and may be, for example, an encoder or detect the velocity of the conveyor frame by detecting emitted energy reflected from a reflector.

Product Jam Sensor

The product jam sensor may be a motion sensing unit for detecting the movement of product across the gap (“G” as shown in FIG. 3) between a cross belt “B” and the product container “T”, e.g., by the interruption of an energy source, e.g., a light beam. The control monitors activity at this sensor and determines if there is a product jam at this point in the system. The control should detect movement of product while sorting is in progress. A jam is detected when sorting to a specific container is in progress but the sensor is not detecting motion of product across the gap between the cross belt and the container. FIG. 2 is a cross sectional view of the system along line 1-1 of FIG. 1. This view shows the side walls of the container cradle as well as the conveyor tilt frame. It is seen in this view that the container cradle is “cradled” or within the side walls of the conveyor tilt frame. Also, the four bar linkage is coupled to both of the side walls of the container cradle.

FIG. 3 shows the system in an upright position, with the container cradle in a horizontal orientation. For illustration purposes many of the features as described in FIG. 1 are not shown; however, it should be understood that all or a combination of these features may be present in the embodiment of FIG. 3. For example, all or none or a combination of the sensors, as described above, may be provided in this embodiment. In this view, the actuator is extended to an upright position. The horizontal mode is selected such that the four bar link pivot and conveyor title frame pivot remains in a same position as that shown in FIG. 1.

FIG. 4 shows the system in a substantial vertical upright position, with the container cradle 106 in a vertical stacking orientation. For illustration purposes, many of the features as described in FIG. 1 are not shown; however, it should be understood that all or a combination of these features may be present in the embodiment of FIG. 4. As shown in FIG. 4, the actuator 108 is in the extended position and the vertical mode is selected such that the four bar link pivot and conveyor title frame pivot 124 may pivot about the support structure. In this position, the system 200 is also in the extended position to stabilize the container and prevent product, generally, from dropping from the container during loading. In this embodiment, the system 200 is synchronized with the vertical movement of the container cradle 106, for example, via the synchronizer bar 150.

With the container oriented at 70 degrees from the horizon during vertical stacking, two conditions may exist:

• • (i) The first condition is that the center of gravity of the container (with or without product) in the 70-degree stacking position shifts to cause the container to rotate out of sorting position on the conveyor.
  • (ii) The second condition is that product being propelled into the container may react and bounce back out of the container.
    To address the first issue, a container support 202 is provided which, in the extended position, supports an upper rim of the container. To address the second issue, a product stop 204 makes certain that the product placed in the container “T” remains in the container during the stacking process. These features are discussed in greater detail below.

The synchronizer bar 150 may be used to synchronize the motion of the container support 202 and the product stop 204 with the conveyor tilt frame 102. By using the synchronizer bar 150, the system 200 may be extended at the same time the container is oriented into the vertical loading position. Likewise, after the vertical product stacking is completed, the conveyor tilt frame 102 can move to the horizontal position and at the same time, the product stop 204 and container support 202 can rotate out of the way for the container transfer.

Referring to FIGS. 5 and 6, the system 200 includes the container support 202 and the product stop 204, coupled to the cross belt assembly “B” via a four bar linkage 208. The synchronizer bar 150 pivotably extends between the product stop 204, for example, and the structure 124 via a bell crank 206a. The bell crank 206a includes two pivot points associated with the drive point for the vertical stacking mechanism and the four bar link pivot 124.

The product stop 204, in one implementation, is pivotally mounted from the cross belt roller axle “A”, e.g., product stop pivot, and is actuated by a separate power source or the synchronizer bar 150 via the stacking mode selector 126. A cross belt roller axle pivot 210 provides the point at which the product stop 204 may pivot. In one aspect of the invention, the product stop 204 acts as a barrier to product wanting to bounce or recoil back out of the container during vertical stacking, i.e., the product stop will prevent the product from coming out of sequence in the vertical stacking mode. The product stop 204 may also prevent jamming or stopping of the system by preventing the product from being ejected from the container.

The product stop 204 includes a hinged pivot “E” for the container support 202, and is of sufficient strength to provide structural support for the container support 202. The movement of the product stop 204 is automated by the use of either an external power source or combined into the stacking mode selector 126 and driven as a result of the movement of the synchronizer bar 150. Thus, in one aspect, the product stop actuator, e.g., synchronizer bar 150, controls the two positions of the product stop 204 during product stacking and processing.

As shown in FIGS. 5 and 6, the four-bar linkage 208 controls the two positions of the container support 202 and product stop 204 during product processing, and is of sufficient strength to push and pull the system. the first position of the product stop 204 is the up/retracted position where it is tucked up underneath the cross belt assembly. This position is required in order to allow the product container to pass under the cross belt with the minimum required vertical distance. The second position is the lowered or extended position where the product stop 204 is positioned substantially parallel to or at a substantially same angle as the product container top (FIG. 6).

The container support 202 supports the container during vertical stacking when the conveyor is oriented at 70-degrees from the horizon (FIG. 4). By supporting the upper rim of the container, the container support 202 ensures that the container “T” will not tip during vertical product stacking. This function may be required due to the center of gravity of the container shifting and possibly rolling down the conveyor oriented at 70-degrees to the horizon. The container support 202 may also counteract the shifting center of gravity and keep the container properly positioned on the conveyor during vertical stacking. The movement of the container support 202 may be automated by the use of either an external power source or combined into the product stop assembly and driven as a result of the movement of the synchronizer bar 206.

The four-bar linkage 208 is provided on both sides of the system, each including two actuator bars 208b₁ and 208b₂, a fixed link 208a and remaining moveable link 208b₃. The actuator bars 208b₁ and 208b₂ are also moveable links. The fixed link 208a provides the pivot points from which the actuator bars 208₁ and 208₂ rotate. The fixed link 208a is also fixed to the cross belt assembly “B” or any structure nearby. The moveable links 208b₁ and 208b₂ and 208b₃, attach to the container support and pivot about the hinge part of the container support. The synchronizer bar 150 may also be in communication with the mode selector 126 in order to selectively control the movement of the four-bar linkage 208 and, in turn, the system 200.

As the synchronizer bar 150 moves from the position of FIG. 5 to the position of FIG. 6, the four bar linkage pivots to the extended position. As the linkage pivots, the system 200 also pivots about points “D” and “E”, into the extended position. Thus, when the four bar linkage 208 is in the extended position, the container support 202 and the product stop 204 will automatically pivot, as well. Instead of using the four bar linkage, an external power source can be used such as an actuator or the like. In one implementation, during the horizontal stacking mode of the dual mode stacking 100, the mode selector 126 remains in a default position and therefore does not actuate the system 200. This will allow the container cradle to remain in a horizontal position for horizontal stacking.

FIG. 7 shows steps implementing the system in a horizontal loading position in accordance with the invention. The flow of FIG. 7 (and FIGS. 8 and 9) may equally represent a high level block diagram, representing the system of the invention. The steps of FIG. 5 (and FIGS. 8 and 9) may be implemented on computer program code in combination with the appropriate hardware. This computer program code may be stored on storage media such as a diskette, hard disk, CD-ROM, DVD-ROM or tape, as well as a memory storage device or collection of memory storage devices such as read-only memory (ROM) or random access memory (RAM). Additionally, the computer program code can be transferred to a workstation over the Internet or some other type of network. The steps of these figures are not limited to the sequence provided herein.

Referring to FIG. 7, in step 500, an empty container is transferred toward the cradle by way of the external container management system. The mode selector is set for horizontal and confirmed via its sensor. In step 502, the leading edge pop-up stop is actuated to the up position and confirmed via its sensor when the container is placed on the cradle. In step 504, the container triggers the container-in-position sensor on the cradle. The trailing edge pop-up stop moves to the up position and is confirmed by its sensor. In step 506, the conveyor actuator rotates the conveyor frame to the 70-degree position for sequencing and its position confirmed by the sensor. The cradle and container are in the horizontal orientation, via a rotation of the container cradle. In step 508, product sequencing can begin to this container.

In step 510, the container fill is complete, and the conveyor actuator moves the conveyor tilt frame to the down position and is confirmed via sensor. This step may also be provided after a determination that the container has reached a predetermined fill height or weight of product or no further product is available, as should be understood by those of skill in the art. The pop-up stops move to the down position and are confirmed by their sensors. In step 512, the filled container moves off the cradle to the buffer location. At the same time or soon thereafter, the new empty container is on its way into the cradle. The process may repeat itself (as represented in step 514). It should be understood that the steps shown above may be combined into more or less steps than illustrated. Thus, for example, the steps shown in step 510 may be separated, as one example.

FIG. 8 shows the process steps for vertical loading. This process may begin with the conveyor tilt frame in the down position and the machine programmed for vertical sequencing. In step 600, the empty container is transferred toward the cradle by way of the external container management system. The mode selector is set for vertical and confirmed via its sensor. In step 602, the leading edge pop-up stop is actuated to the up position and confirmed via its sensor. In step 604, the container triggers the container-in-position sensor on the cradle. The trailing edge pop-up stop may be moved to the up position which may be confirmed by its sensor; however, the trailing edge stop may not be required in this operation.

In step 606, the conveyor actuator rotates the conveyor frame to the 70-degree position for sequencing and its position is confirmed by the sensor. In this operation, the cradle and container are also at the 70-degree position; that is, they rotate in the same orientation as the conveyor. In step 608, product sequencing can begin to the container. In step 610, after the container fill is complete (or when the container has reached the predetermined height or weight of product or no further product is available), the conveyor actuator moves the conveyor tilt frame to the down position and is confirmed via a sensor. In this step, the pop-up stops move to the down position and are confirmed by their sensors. The filled container moves off the cradle to the buffer location, in step 612. At the same time or soon thereafter, the new empty container is on its way into the cradle. The process may repeat itself (as represented in step 614).

FIG. 9 is a flow combining steps of FIGS. 5 and 6. For example, as seen in step 700, an operator picks a mode: vertical or horizontal mode. The system will then actuate the mode in either steps 702a or 702b. In step 704, the leading edge stop will be activated. In step 706, the container will move into the cradle. In step 706, the trailing edge stop will be raised if the horizontal mode was selected. This will prevent the container from moving backwards during the stacking process. In step 710, the system will be raised via the actuator. In step 712, the processing of the product will begin in the container. This can be performed in either the vertical or horizontal mode, depending on the selection. In the vertical mode, the system will pivot. In step 714, after the container is filled, there may be a delay until the container is removed and a new container is loaded into the system. In step 716, the conveyor will lower and, in step 718, the stops will lower. Of course, depending on the mode selection only the leading edge stop may need to be retracted or lowered. In step 720 there is a transfer of the containers. The system steps may repeat, as represented in step 722. In step 724, there is a return to the selection mode, which may be a mechanical, electrical or software control.

While the invention has been described in terms of embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.

Claims

1. An apparatus for orienting a container, comprising:

a frame moveable between a lowered position and a raised position; and

a cradle pivotably connected to the frame, the cradle selectively positionable to a substantially vertical stacking position when the frame is moved to the raised position.

2. The apparatus of claim 1, further comprising an actuator mounted to the frame for moving the frame between the lowered position and the raised position.

3. The apparatus of claim 1, further comprising a stop positioned proximate a leading edge of the cradle, the stop selectively provides a stopping position of the cradle.

4. The apparatus of claim 1, wherein the cradle includes a pivot joint on opposing sides thereof, and partly forms a four bar linkage pivotably mounted to the frame which selectively rotates the cradle as the frame is moved between the lowered position and the raised position.

5. The apparatus of claim 1, further comprising an intake conveyor and an exit conveyor at opposing ends of the frame for moving a container towards and away, respectively, the frame.

6. The apparatus of claim 1, further comprising a fail safe stop which stops motion of the frame upon a loss of power.

7. The apparatus of claim 1, further comprising a vertical edge stop which supports a position of a container when the cradle is in the substantially vertical stacking position.

8. The apparatus of claim 1, further comprising:

a synchronizer bar actuated by movement of the frame; and

a stop system which is actuated by the synchronizer bar to an extended position and a retracted position by movement of the frame into the raised position and lowered position, respectively.

9. The apparatus of claim 8, wherein the stop system comprises a backstop to retain product in a container during vertical stacking of product when the cradle is in the substantially vertical stacking position.

10. The apparatus of claim 8, wherein the product stop system comprises a container support to support a container when the frame is in the raised position and the cradle is in the substantially vertical stacking position.

11. The apparatus of claim 1, wherein the cradle holds a container having mail pieces stacked therein.

12. An apparatus for stacking product, comprising:

a conveyor support structure;

a conveyor tilt frame moveable between a lowered position and a raised position;

a conveyor actuator coupled to the conveyor support structure and the conveyor tilt frame, the conveyor actuator moving the conveyor tilt frame between the lowered position and the raised position;

a container cradle pivotably coupled to the conveyor tilt frame; and

a system extending between the container cradle and the conveyor support structure to position the container cradle in a substantially vertical stacking orientation when the conveyor tilt frame is in the raised position.

13. The apparatus of claim 12, further comprising a synchronizer and a stop mechanism, the synchronizer moving the stop mechanism to an extended position when the container cradle is moved to the substantially vertical stacking orientation and the conveyor tilt frame is moved to the raised position.

14. The apparatus of claim 13, wherein the stop mechanism comprising:

a four-bar linkage controllable by movement of the synchronizer;

a container support; and

a product stop,

the container support and the product stop are opened to the extended position in synchronization by movement of the four-bar linkage.

15. The apparatus of claim 14, wherein the container support and the product stop are opened to the extended position when the container cradle is moved to the substantially vertical stacking orientation position, and retracted when the container cradle is moved to a lowered position.

16. The apparatus of claim 12, wherein the system is a four-bar linkage system mounted between the conveyor support frame and the container cradle.

17. The apparatus of claim 12, wherein the container cradle supports a container for stacking mail pieces therein.

18. The apparatus of claim 12, wherein the conveyor tilt frame further comprises:

a first pivot joint to provide container orientation depending on whether a container is being transferred into or out of the container cradle;

a second pivot joint positioning the container cradle in either a horizontal stacking position or the substantially vertical stacking orientation; and

a third pivot joint providing a mounting point for the conveyor actuator.

19. An apparatus for orienting a container, comprising:

a frame moveable between a lowered position and a raised, substantially vertical position; and

a container cradle pivotably connected to the frame and selectively positionable to a vertical stacking position or a horizontal stacking position when the frame is in the raised, substantially vertical position.

20. The apparatus of claim 19, further comprising an actuator mounted to the frame for moving the frame between the lowered position and the raised, substantially vertical position.

21. The apparatus of claim 19, wherein the frame is a first degree of freedom motion and the container cradle is a second degree of freedom motion.

22. The apparatus of claim 19, wherein the container cradle includes a container power transfer assembly which is in a flow stream of a load conveyor and a remove conveyor.

23. The apparatus of claim 19, further comprising stops located at the trailing edge and leading edge of the container cradle, respectively.

24. The apparatus of claim 23, wherein:

the stops are moveable in both an upward direction and downward direction; and

in the upright position, one of the stops positions and supports the container at the leading edge when the container cradle is in either the vertical stacking position or the horizontal stacking position.

25. The apparatus of claim 23, wherein:

the stops are a leading edge pop-up stop and a trailing edge pop-up stop; and

at least one sensor includes at least one of: (i) a leading edge pop-up stop position sensor which senses when the leading edge pop-up stop has reached its up position; (ii) a leading edge pop-up stop retract position sensor which senses when the leading edge pop-up stop is required to drop down, and senses that the leading edge pop-up stop has reached its down position; (iii) a trailing edge pop-up stop, up position sensor which senses when the trailing edge pop-up stop is required to actuate up and senses that the trailing edge pop-up stop has reached its up position; and (iv) a trailing edge pop-up stop, retract position sensor which senses when the trailing edge pop-up stop is required to drop down and senses when the trailing edge pop-up stop has reached its down position.

26. The apparatus of claim 19, further comprising at least one of:

(i) a container-in-position sensor which monitors the presence of a container on the container cradle;

(ii) an orientation sequencing mode selector position sensor which determines that a predetermined sequencing mode has been selected;

(iii) a frame position sensor which determines when the frame has reached the lowered position and the raised, substantially vertical position;

(iv) a frame actuator sensor which controls a speed of the frame to minimize impact at an end of travel position; and

(v) a product jam sensor for detecting the movement of product.

27. The apparatus of claim 26, wherein the container-in-position sensor controls a stop to register the container in the container cradle.

28. The apparatus of claim 19, wherein the container cradle includes a pivot joint to provide a mounting pivot point for a linkage mechanism, the linkage mechanism selectively positions the container cradle between the vertical stacking position and the horizontal stacking position when the frame is moved to the raised, substantially vertical position.

29. The apparatus of claim 28, wherein the linkage mechanism is a four bar linkage mechanism including two parallel bars, a portion of the container cradle and a portion of a mode selector.

30. The apparatus of claim 19, further comprising a mode selector to selectively provide an orientation of the container cradle to either the vertical stacking position or the horizontal stacking position.

31. The apparatus of claim 19, wherein the container cradle holds a container having product stacked therein.

32. An apparatus for stacking product, comprising:

a conveyor tilt frame moveable between a lowered position and a raised, substantially vertical position;

a conveyor actuator coupled to the conveyor tilt frame to move the conveyor tilt frame between the lowered position and the raised, substantially vertical position;

a container cradle pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation within the container; and

a linkage system extending between the container cradle and a support structure of the conveyor tilt frame to position the container cradle to a substantially horizontal stacking orientation or maintain the container cradle in a substantially same orientation as the conveyor tilt frame is moved in the raised, substantially vertical position for vertical stacking.

33. The apparatus of claim 32, further comprising a mode selector selectively engaging the linkage system to provide a stacking orientation of the container.

34. The apparatus of claim 32, wherein the linkage system is a four-bar linkage system.

35. The apparatus of claim 32, wherein the conveyor tilt frame further comprises:

a first pivot joint to provide container orientation depending on whether the container is being transferred into or out of the container cradle;

a second pivot joint positioning the container cradle for stacking product in the horizontal stacking orientation; and

a third pivot joint providing a mounting point for the conveyor actuator.

36. The apparatus of claim 32, wherein the product is mail pieces.

37. The apparatus of claim 32, further comprising:

a mode selector mounted to the conveyor tilt frame, the mode selector including: a first position to selectively orient the container cradle in the horizontal stacking orientation when the conveyor tilt frame is in the raised, substantially vertical position, and a second position to selectively maintain the container cradle at the vertical stacking orientation when the conveyor tilt frame is in the raised, substantially vertical position;

wherein the linkage system is a a four bar linkage which: rotates the container cradle to the horizontal stacking orientation when the mode selector is in the first position and the conveyor tilt frame is the raised, substantially vertical position, and maintains the container cradle in a same orientation as the conveyor tilt frame for vertical stacking when the conveyor tilt frame is in the raised, substantially vertical position and the mode selector is in the second position;

a product stop mechanism; and

a synchronizer mounted between the product stop mechanism and the mode selector, the synchronizer moving the product stop mechanism to an extended position when the container cradle is moved to the vertical stacking orientation and the conveyor tilt frame is in the raised, substantially vertical position.

38. An apparatus for stacking product in a horizontal orientation or a vertical orientation, comprising:

a conveyor tilt frame moveable from approximately a horizontal position to a vertical position;

a conveyor actuator coupled to the conveyor tilt frame to move the conveyor tilt frame from the approximately the horizontal position to the vertical position;

a container cradle pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation when the conveyor tilt frame is positioned to approximately the vertical position;

a mode selector including: a first position to selectively orient the container cradle in the horizontal stacking orientation, and a second position to selectively maintain the container cradle and the conveyor tilt frame at substantially a same orientation when the conveyor tilt frame is positioned to approximately the vertical position;

a four bar linkage which: rotates the container cradle to the horizontal stacking orientation when the mode selector is in the first position and the conveyor tilt frame is positioned to approximately the vertical position; and maintains the container cradle in the substantially same orientation when the conveyor tilt frame is positioned to approximately the vertical position and the mode selector is in the second position for vertical stacking;

a product stop mechanism; and

a synchronizer selectively controlled by the mode selector, the synchronizer moving the product stop mechanism to an extended position when the container cradle is moved to the substantially vertical stacking orientation.

39. The apparatus of claim 38, wherein the product stop mechanism comprises:

a four-bar linkage controllable by movement of the synchronizer;

a container support; and

a product stop,

the container support and the product stop are opened to the extended position in synchronization by movement of the four-bar linkage.

40. The apparatus of claim 38, wherein the substantially horizontal position to the vertical position is approximately 0° to 70°.

41. A method of stacking mail, comprising:

inserting an empty container into a pivotably mounted cradle;

raising the cradle from a first height to a raised height;

rotating the cradle to a substantially vertical stacking position;

inducting mail into the container when the cradle is in the substantially vertical position; and

lowering the cradle to the first height and rotating the cradle into a substantially horizontal orientation after a predetermined amount of mail has been inducted into the container.

42. The method of claim 41, further comprising transporting a non-empty container out of the cradle and transporting an empty container out of the cradle.

43. A method of stacking mail in either a horizontal orientation or a vertical orientation, comprising:

placing a container on a container cradle;

if the mail is to be stacked in the vertical stacking orientation, rotating a conveyor frame to a substantially vertical orientation while maintaining the container cradle in a substantially same orientation as the conveying frame; and

if the mail is to be stacked in the horizontal stacking orientation, rotating the conveyor to the substantially vertical position and rotating the container cradle to a substantially, raised horizontal orientation;

inducting mail into the container; and

when the mail has reached a predetermined height or weight in the container or no further mail is available then: if the mail was stacked in the vertical stacking orientation, rotating the conveyor frame into a substantially horizontal position while maintaining the maintaining the container cradle in a same orientation as the conveying frame; and if the mail was stacked in the horizontal stacking orientation, rotating the conveyor frame to the substantially vertical position and rotating the container cradle to an original, lowered horizontal orientation.

44. The method of claim 43, further comprising determining when the container has reached the predetermined height or weight of mail or no further mail is available.

45. The method of claim 43, further comprising actuating a leading edge pop-up stop when the container is placed on the container cradle.

46. The method of claim 43, further comprising triggering a container-in-position sensor when the container is positioned on the container cradle.

47. The method of claim 46, further comprising, in response to the triggering step, beginning the induction of the mail.

48. The method of claim 43, further comprising sensing the position of the container in the container cradle.

49. The method of claim 43, further comprising moving a stop into an up position after the container has been placed on the container cradle and lowering the stop after the container cradle has been moved to its original, lowered horizontal orientation such that the container can be ejected therefrom.

50. The method of claim 43, further comprising sensing whether the is being stacked in the vertical stacking orientation or the horizontal stacking orientation in the container.