Method and Apparatus for Jogging and Feeding Sortable Articles

Abstract

An apparatus includes a vibrating jogging tray with rotatable rods having longitudinal edges. The apparatus can further include a transfer assembly comprising a transfer belt and a first vacuum system positioned opposite to a separation assembly comprising a separation belt and, optionally, a second vacuum system. In operation, the rods rotate a plurality of articles toward the transfer assembly. The first vacuum system can draw a first article onto the transfer belt and transports it to a processing station. If a second article overlaps the first article on the transfer belt, the second vacuum system can draw the second article off of the first article and onto the separation belt. If the first article traveling on the transfer assembly is thicker than a distance between the transfer belt and the separation belt, a retractable roller can retract the separation belt and/or the transfer belt to increase the distance therebetween.

Description

FIELD OF THE INVENTION

The present invention relates to the automated handling of documents, envelopes and other sortable articles, particularly to an improved method and apparatus for jogging and feeding.

BACKGROUND INFORMATION

Mail and check processing centers, such as post offices, inter-office mail rooms and banks often use a vibrating jogging machine to align and justify a group of documents, envelopes or similar articles. The jogging machine described in U.S. Pat. No. 6,497,406 is one such example.

Commonly, after the group of articles are aligned and justified, a feeding machine is used to transport the jogged articles to another automated device (e.g. a scanner, labeler or sorter) for further processing.

Most jogging and feeding machines are separate stand-alone units, which means an operator must first empty a bin full of articles into a jogger to have them jogged, and then manually remove the aligned articles from the jogger and load them into a feeding machine.

In addition, most of today's feeders are usually designed to process articles with a uniform thickness (such as single sheets of paper with a standard thickness). However, real world articles vary in size and thickness, ranging from small checks, postcards and coupons to ledger size forms, and announcement sized to inter-office sized envelops.

SUMMARY OF THE INVENTION

In one embodiment, a jogging and feeding apparatus has a jogging tray coupled to a motor. A plurality of rods are rotatably coupled within the jogging tray. The plurality of rods are adapted to rotate at a synchronized rate with one another and have a spiral thread and a longitudinal edge.

In another embodiment, a jogging and feeding apparatus includes a transfer assembly comprising a transfer belt and a first vacuum system. The first vacuum system is adapted to suction air through a plurality of openings in the transfer belt. The apparatus further includes a separation assembly having a separation belt and a second vacuum system. The second vacuum system is adapted to suction air through a plurality of openings in the separation belt. A portion of the transfer belt is positioned opposite to a portion of the separation belt. The transfer belt is adapted to rotate around a plurality of first rollers in a first direction and the separation belt is adapted to rotate around a plurality of second rollers in the same first direction.

In yet another embodiment, a first portion of a transfer assembly is secured opposite to a second portion of a separation assembly. A first belt in the transfer assembly is adapted to rotate in a first direction and a second belt in the separation assembly is adapted to rotate in the same first direction. A first suction fan disposed within the transfer assembly is adapted to suction air from a plurality of holes in the first belt and a second suction fan disposed within the separation assembly is adapted to suction air from a plurality of holes in the second belt.

These and other aspects of the present invention will be apparent from the following detailed description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic isometric view of a jogging and feeding apparatus provided in accordance with one embodiment of the present invention.

FIG. 2 is a schematic partial top orthogonal view of FIG. I to detail a jogging tray, and includes a plurality of sortable articles in the jogging tray.

FIG. 3 is a schematic isometric view of a rod provided in accordance with one embodiment of the present invention.

FIG. 4 is a schematic cross-sectional view taken along line 4-4 of the rod of FIG. 3.

FIG. 5 is a schematic side view of a motor and jogging tray provided in accordance with one embodiment of the present invention.

FIG. 6 is a schematic partial cross-sectional view taken along line 6-6 of the jogging and feeding apparatus of FIG. 2 to show a pulley system for rotating a plurality of rods. To detail the possible effects of a suction force generated by a vacuum system when the jogging and feeding apparatus is in operation, FIG. 6 further depicts a second article overlapping a first article on a transfer belt.

FIGS. 7A and 7B show a schematic top view of a transfer belt positioned opposite to a separation belt, with the separation belt in a first and a second position in accordance with the embodiment of FIG. 1.

FIG. 8 is a schematic front view of a transfer belt in accordance with another embodiment of the present invention.

FIGS. 9A and 9B show a schematic top view of a transfer belt positioned opposite to a separation belt, with the transfer belt in a first and a second position in accordance with another embodiment of the present invention.

FIG. 10 is a schematic of a system comprising a jogging and feeding apparatus provided in accordance with one embodiment of the present invention and a processing station adapted to receive an article from the jogging and feeding apparatus.

DETAILED DESCRIPTION

Briefly, the present invention provides an apparatus that can both jog and feed a plurality of sortable articles; including articles of the same thickness and articles of varying thickness, such as paper, mail, cards, booklets, inter-office sized envelopes, and the like.

In one embodiment, the apparatus includes a vibrating jogging tray with rotatable rods coupled to a transfer assembly. The transfer assembly has a transfer belt and a first vacuum system. Positioned opposite to the transfer assembly is a separation assembly comprising a separation belt and second vacuum system. In operation, the rods rotate the plurality of articles toward the transfer assembly. The first vacuum system can draw and retain a first article from the plurality of articles onto the transfer belt and the transfer belt can transport the first article past the opposing separation assembly to another station for further processing. In the event that a second article overlaps the first article on the transfer belt, the second vacuum system can draw the second article off of the first article and onto the separation belt. In the event that an article traveling on the transfer assembly and past the separation assembly is thicker than a distance between the transfer belt and the separation belt, a retractable roller is adapted to retract the separation belt and/or the transfer belt to increase the distance therebetween.

FIGS. 1 and 2 show a jogging and feeding apparatus provided in accordance with one embodiment of the present invention. The jogging and feeding apparatus 10 includes a jogging tray 12 adapted to vibrate and thereby separate a plurality of sortable articles 14 (shown in FIG. 2) in the jogging tray 12 from one another and align a bottom edge 16 of each of the plurality of articles 14. The jogging tray 12 comprises a guide rail 18 having a flat vertical surface 19 and a movable guide plate 20. The jogging tray 12 includes a plurality of rods 22 rotatably coupled within the jogging tray 12. The rods 22 partially protrude above a top surface 24 of the jogging tray 12, are positioned substantially parallel to one another and are adapted to rotate at a synchronized rate with one another in the direction of the guide rail 18. The movable guide plate 20 is selectively coupled to at least one of the plurality of rods 22. The rods 22 have spiral grooves 26 adapted to move the guide plate 20 and the plurality of articles 14 in the jogging tray 12 to a forward end 28 of the jogging tray 12 when the rods 22 rotate. As the rods 22 rotate toward the guide rail 18, a side edge 30 of each of the plurality of articles 14 is driven toward the guide plate 20 to justify the side edges 30 against the guide plate 20. As shown in FIG. 3, to further assist the jogging function of the apparatus 10, in one embodiment, the rods 22 have a longitudinal edge 32. As the rods 22 rotate at a synchronized rate, the longitudinal edge 32 on each rod 22 protrudes above the top surface 24 of the jogging tray 12 at a cyclical interval to slightly lift the articles 14 being jogged. This lifting action helps to further separate one article from another, and assists the bottom edge 16 of each article being jogged to fall within the grooves 26 in the rods 22.

In the embodiment shown in FIG. 4, the rod 22 has four longitudinal edges 32 that were achieved by manufacturing the rod 22 with a substantially rectangular or square cross section 34 (shown in FIG. 4). As can be appreciated, a number of other cross sections may be used to yield a rod 22 with at least one longitudinal edge 32. For example, the rod 22 can be made with a substantially octagonal cross section to yield a rod 22 having eight longitudinal edges. Hexagonal, pentagonal, or triangular cross sections can also be employed to yield a rod 22 having either six, five or three longitudinal edges. The number of cross sections that the rod 22 can have to yield at least one longitudinal edge is not to be limited and can further include a tear-drop or cam-like cross-sectional shape to yield one longitudinal edge.

To vibrate the jogging tray 12 and rotate the rods 22 at a synchronized rate, any number of motorized configurations may be used. In the example shown in FIG. 5, to vibrate the jogging tray 12, a bottom surface of the jogging tray 36 is coupled to a first motor 38 having an off-set shaft 40 and a crank arm 42. In the example shown in FIG. 6, to rotate the plurality of rods 22 at a synchronized rate with one another, the rods 22 are coupled to a second motor 44 via a number of pulleys 46 and a pulley belt 48.

In another embodiment, also depicted in FIGS. 1 and 2, a transfer assembly 50 is positioned adjacent to the forward end 28 of the jogging tray 16. The transfer assembly 50 includes a transfer belt 52 with a plurality of first-sized openings 54 and a plurality of second-sized openings 56 (shown in FIG. 1). The plurality of first-sized openings 54 in the transfer belt 52 are positioned on the belt 52 at intervals, with a distance 58 therebetween. The transfer belt 52 is adapted to rotate at a fixed speed around a plurality of first rollers 60 in a clockwise direction. A third motor 61 (shown in FIG. 2) is used to rotate the transfer belt 52.

The transfer assembly 50 further includes a first vacuum system 62 comprised of a group of vertically positioned suction fans 64. It is to be understood that other configurations and devices for providing a suction on the belt can also be used. The first vacuum system 62 is adapted to suction air from the plurality of first and second-sized openings 54, 56 in the transfer belt 52 to generate a first and a second suction force 66, 68 (shown in FIG. 1), respectively. The term “vacuum system” as used herein means commercially available systems employed to apply a continuous vacuum.

The first suction force 66 is one that is at least sufficient enough to draw, from the plurality of articles 14 on the jogging tray 12, a first article 70 (shown in FIG. 2) from the forward end 28 of the tray 12 onto the transfer belt 52. The second suction force 68 is one that is at least sufficient enough to retain the first article 70 onto the transfer belt 52 once it has been drawn thereto. Because more force is required to draw an article onto the transfer belt 52 than is required to retain the article onto a belt, the first suction force 66 is typically higher than the second suction force 68.

As one of ordinary skill in the mechanical art can appreciate, determining the threshold amount of force needed to accomplish each of these tasks will depend on a number of design factors, such as the distance between the transfer belt 52 and the jogging tray 12, the power level of the first vacuum system 60, the size and number of each of the plurality of first and second-sized openings 54, 56 on the transfer belt 52.

In one embodiment, the distance 58 between the first-sized openings 54 is designed to reduce the likelihood the first suction force 66 will draw more than one article from the forward end 28 of the tray 12 onto the transfer belt 52 at the same time. Considerations for determining the interval distance 58 between each set of first-sized openings 54 includes the overall length of the transfer belt 52, the typical length of the articles 14 being transported, and the speed at which transfer the belt 52 travels. In another embodiment, a metal plate (not shown) mounted behind the transfer belt 52 is used to control the timing of the application of the first suction force 66. The metal plate is positionable in a first position to restrict the flow of air through the first-sized openings 54 and in a second position to allow the flow of air through the first-sized openings 54.

In one example, the transfer assembly has a transfer belt with 75 to 125 first-sized openings appearing on the transfer belt at an interval of every 12.7 millimeters (0.5 inches), with each first-sized opening being 4 to 6 millimeters (0.16 to 0.24 inches) in diameter. The transfer belt further has two to four second-sized openings per 645 square millimeters (per one square inch), with each second-sized opening being 4 to 8 millimeters (0.16 to 0.32 inches) in diameter, and a first vacuum system with a power rating that can range from 367 to 1,471 watts (0.5 to 2 horsepower) to generate a first suction force through the first-sized openings that varies between 2.7 and 4.0 kPa (20 and 30 mmHg) and a second suction force through the second-sized openings that varies between 2.7 and 4.0 kPa (20 and 30 mmHg).

In another embodiment, positioned opposite to a portion of the transfer assembly 50 is a separation assembly 72. The separation assembly 72 includes a separation belt 74 with, optionally, a plurality of third-sized openings 76. The separation belt 74 is adapted to rotate around a plurality of second rollers 78 and, as shown in FIGS. 7A and 7B, to move from a first position to a second position. To rotate the separation belt 74, a motor 63 (shown in FIG. 1) is used. The separation belt 74 is adapted to rotate in a direction that is the same as that in which the transfer belt 52 rotates. For example, if the transfer belt 52 is adapted to rotate in a clockwise direction (as is the case in the embodiment described above), the separation belt 74 is also adapted to rotated in a clockwise direction. As a result, because the separation assembly 72 is positioned opposite to a portion of the transfer assembly 50, when the jogging and feeding apparatus 10 is in use, the transfer belt 52 travels in a direction that is opposite to the direction in which the separation belt 74 travels.

To move the separation belt 74, a number 78a of the plurality of second rollers 78 are retractable. The retractable rollers 78a reside on a moveable base plate 80 coupled to a spring 82. When the spring 82 is in a natural position, there is a distance 84 between the separation belt 74 and the transfer belt 52. When the spring 82 is in a biased position, the spring 82 biases the base plate 80 and the retractable rollers 80a on the base plate 80. This, in turn, biases the separation belt 74 in the second position and increases the distance 84 between the separation belt 74 and the transfer belt 52. The distance 84 between the two belts 52, 74 is a design choice that depends, in part, on the average thickness of the majority of articles that the jogging and feeding apparatus 10 is likely to jog and feed. The amount of distance by which the distance will vary depending on the thickness of the article being transported on the transfer belt 52 and the spring rate. In one example, the range is between 0.25 and 12.7 millimeters (0.01 and 0.5 inches).

In another embodiment, if openings 76 in the separation belt 74 are present (as shown in FIG. 1), the separation assembly 72 includes a second vacuum system 86 comprised of a horizontally positioned suction fan 88. The second vacuum system 86 is adapted to suction air from the plurality of third-sized openings 76 in the separation belt 74 to generate a third suction force 90. The third suction force 90 is one that, in the event that a second article 92 overlaps the first article 70 on the transfer belt 52 (as shown in FIG. 6), is high enough to pull the second article 92 off of the transfer belt 52 and onto the separation belt 74 and yet low enough so as to not pull the first article 70 off of the transfer belt 52. As a result, the third suction force 90 is typically lower than each of the first and the second suction forces 66, 68. Factors for determining the third suction force 90 include: the size and number of the plurality of third-sized openings 76 in the separation belt 74, the distance between the transfer belt 52 and the separation belt 74, and the strength level of the first and the second suction force 66, 68.

In one example, the separation assembly has a separation belt with 30 to 50 third-sized openings appearing on the separation belt at an interval of every 12.7 millimeters (0.5 inches), with each opening being 4 to 6 millimeters (0.16 to 0.24 inches) in diameter, and a second vacuum system with a power rating that can range from 367 to 1,471 watts (0.5 to 2 horsepower) to generate a third suction force through the third-sized openings that varies between 2.7 and 4.0 kPa (20 and 30 mmHg).

It is to be understood that the various embodiments described herein can be utilized singularly or in various combinations. In operation, in one embodiment, the first motor 38 gently vibrates the jogging tray 12 while the second motor 44 rotates the plurality of rods 22 at a synchronized rate in the direction of the guide rail 18. An operator places a plurality of articles 14 that are to be jogged and fed (e.g. fed in the jogger and feeder apparatus 10 for purposes of being transported to a scanner, labeler, sorter or the like) in the jogging tray 12 in a vertical position against the guide plate 20. When the jogger and feeder apparatus 10 is turned on, the first motor 38 vibrates the jogging tray 12 and the second motor 44 rotates the rods. The vibration from the tray 12 and the rotation of the rods 22 jostle the plurality of articles 14 and cause the bottom edges 16 of the plurality of articles 14 to align against the top surface 24 of the jogging tray 12. The rotation of the rods 22 further causes the side edges 30 of each of the plurality of articles 14 to justify against the vertical surface 19 of the guide plate 20. The lifting motion from the longitudinal edges 32 on the rods 22 cyclically lifts the plurality of articles 14. On their downward fall, the articles 14 fall within the grooves 26 in the rods 22. Because the articles 14 are positioned within the spiral grooves 26, as the rods 22 rotate, the rods move the articles 14 toward the forward end 28 of the tray 12 and the guide plate 20 also moves therewith.

In embodiments where a transfer assembly is positioned adjacent to the forward end 28 of the jogging tray 16, when the first article 70 has been moved sufficiently close to the rotating transfer belt 52 of the transfer assembly 50, the first suction force 66 (generated by the air suctioned through the plurality of first-sized openings 54 in the transfer belt 52 by the first vacuum system 62) suctions the first article 70 onto the transfer belt 52. The second suction force 68 (generated by the air suctioned through the plurality of second-sized openings 56 in the transfer belt 52 by the first vacuum system 62) maintains the first article 70 on the transfer belt 52. In this way, the first article 70 travels on the transfer belt 52 to a processing station 94 (e.g. a scanner, labeler or sorter) adapted to receive the article 70 from the apparatus 10, shown in FIG. 10.

If a separation assembly 72 with retractable rollers 78a is positioned opposite to the transfer assembly 50 and the first article 70 traveling on the transfer belt 52 is thicker than the distance 84 between the transfer belt 52 and the separation belt 74, then, when the first article 70 reaches the separation assembly 72, the moving article 70 generates a lateral force causing the resultant vector to bias the spring 82 and retract the separation belt 42. This increases the distance 84 between the two belts 52, 74 to allow the first article 70 to continue to travel on the transfer belt 52, past the separation assembly 72 and toward the processing station 94.

If the plurality of third-sized openings 76 are present in the separation belt 74 and the first suction force 66 suctions both a first article 70 and a second article 92 onto the transfer belt in a manner that causes the second article 92 to overlap the first article 70 (as shown in FIG. 6), the third suction force 90 (generated by the air suctioned through the plurality of third-sized openings 74 in the separation belt 74 by the second vacuum system 86) suctions the second article 92 off of the transfer belt 52 and onto the separation belt 74. In operation (best seen in FIGS. 1 and 6), because the suction force generated by the air suctioned through the plurality of first and/or second-sized openings 54, 56 in the transfer belt 52 by the first vacuum system is greater than the third suction force 90, the first article 70 remains on the transfer belt 52, travels past the separation assembly 72 and proceeds on to the processing station 94. As the first article 70 travels past the separation assembly 72, the separation belt 74 drives the second article 92 backward (in a direction that is opposite to that in which the transfer belt 52 is traveling) toward the plurality of rods 22. As soon as the portion of the transfer belt 52 that is opposite to the separation belt 74 is free of any articles, the greater suction force generated by the air suctioned through the plurality of first and/or second-sized openings 54, 56 in the transfer belt 52 causes the second article 92 traveling on the separation belt 74 to be suctioned back onto the transfer belt 52. In this way, the second article 92 proceeds, as did the first article 70 earlier, to travel on the transfer belt 52, past the separation assembly 72 and toward the processing station 94.

Because a force that is high enough to draw the first article 70 onto the transfer belt 52 will also be high enough to retain the article 70 thereto, it can be appreciated that the transfer belt 52 does not have to have two different sized openings. In another embodiment, shown in FIG. 8, a transfer belt 152 has only a plurality of first-sized openings 154 and a first vacuum system 162 is adapted to suction air from the plurality of first-sized openings 154 to generate a first suction force 166 that is at least sufficient enough to both draw and retain a first article 170 onto the transfer belt 152.

In another embodiment, shown in FIGS. 9A and 9B, to increase a distance 284 between a separation belt 272 and a transfer belt 252, the transfer belt 252 (instead of the separation belt 76 discussed in reference to FIGS. 7A and 7B) is adapted to rotate around a plurality of first rollers 260. A number 260a of the plurality of first rollers 260 are retractable rollers and reside on a moveable base plate 280 coupled to a spring 282. When the spring 282 is in a biased position, the spring 282 biases the base plate 280 and the retractable rollers 260a on the base plate 280. This, in turn, biases the transfer belt 252 in a second position and increases the distance 284 between the separation belt 272 and the transfer belt 252.

It is to be understood that while the invention has been described above in conjunction with preferred specific embodiments, the description is intended to illustrate and not to limit the scope of the invention, as defined by the appended claims. Indeed, various modifications of the invention in addition to those described herein will become apparent to those skilled in the art from the foregoing description and the accompanying figures. Such modifications are intended to fall within the scope of the appended claims.

It is further to be understood that all values are to some degree approximate, and are provided for purposes of description.

The disclosures of any patents, patent applications, and publications that may be cited throughout this application are incorporated herein by reference in their entireties.

Claims

1. An apparatus for jogging and feeding sortable articles, the apparatus comprising:

a first motor;

a jogging tray coupled to the first motor; and

a plurality of rods rotatably coupled within the jogging tray, the plurality of rods being adapted to rotate at a synchronized rate with one another and comprising a spiral thread and a longitudinal edge.

2. The apparatus according to claim 1 further comprising a pulley belt coupled to a second motor adapted to rotate the plurality of rods at the synchronized rate.

3. The apparatus according to claim 1 wherein the cross section of each of the plurality of rods is rectangular.

4. A system comprising the apparatus of claim 1, the system further comprising a processing station configured to receive a sortable article from the apparatus.

5. The apparatus according to claim 1 further comprising a transfer assembly positioned adjacent to the jogging tray, the transfer assembly comprising a transfer belt and a first vacuum system, the transfer belt defining a plurality of first openings and the first vacuum system being adapted to suction air through the plurality of first openings.

6. The apparatus according to claim 5 wherein the plurality of first openings in the transfer belt comprises a plurality of openings having a first size and a plurality of openings having a second size.

7. The apparatus according to claim 5 further comprising a separation assembly positioned opposite to the transfer assembly, the separation assembly comprising a separation belt and a second vacuum system, the separation belt defining a plurality of second openings and the second vacuum system being adapted to suction air through the plurality of second openings.

8. An apparatus for jogging and feeding sortable articles, the apparatus comprising:

a transfer assembly comprising a transfer belt, a plurality of first rollers and a first vacuum system, the transfer belt defining a plurality of first openings and the first vacuum system being adapted to suction air through the plurality of first openings;

a separation assembly comprising a separation belt, a plurality of second rollers and a second vacuum system, the separation belt defining a plurality of second openings and the second vacuum system being adapted to suction air through the plurality of second openings;

wherein a portion the transfer belt is positioned opposite to a portion of the separation belt; and

wherein the transfer belt is adapted to rotate around the plurality of first rollers in a first direction and the separation belt is adapted to rotate around the plurality of second rollers in the first direction.

9. The apparatus according to claim 8 wherein the portion of the transfer belt and the portion of the separation belt are separated by a distance and at least one of the plurality of first rollers in the transfer assembly is adapted to vary the distance between the transfer belt and the separation belt.

10. The apparatus according to claim 9 further comprising a spring adapted to bias the at least one of the plurality of first rollers in the transfer assembly in a first position.

11. The apparatus according to claim 8 wherein the portion of the transfer belt and the portion of the separation belt are separated by a distance and at least one of the plurality of second rollers in the separation assembly is adapted to vary the distance between the transfer belt and the separation belt.

12. The apparatus according to claim 11 further comprising a spring adapted to bias the at least one of the plurality of second rollers in the separation assembly in a first position.

13. The apparatus according to claim 8 wherein the plurality of first openings in the transfer belt comprises a plurality of openings having a first size and a plurality of openings having a second size.

14. The apparatus according to claim 13 wherein the first size is selected to yield a first suction force and the second size is selected to yield a second suction force when the first vacuum system suctions air through the plurality of openings in the transfer belt.

15. The apparatus according to claim 14 wherein the amount of the first suction force is greater than the amount of the second suction force.

16. The apparatus according to claim 14 wherein the plurality of second openings in the separation belt have a third size and the third size is selected to yield a third suction force when the second vacuum system suctions air through the plurality of second openings.

17. The apparatus according to claim 16 wherein the amount of the first suction force is greater than the amount of the third suction force and the amount of the second suction force is greater than the amount of the third suction force.

18. A system comprising the apparatus of claim 8, the system further comprising a processing station configured to receive a sortable article from the apparatus.

19. A method of making an apparatus for jogging and feeding sortable articles, the method comprising:

securing a first portion of a transfer assembly opposite to a second portion of the transfer assembly;

adapting a first belt in the transfer assembly to rotate in a first direction and adapting a second belt in the separation assembly to rotate in the first direction; and

disposing a first suction fan within the transfer assembly to suction air from a plurality of holes in the first belt and disposing a second suction fan within the separation assembly to suction air from a plurality of holes in the second belt.

20. The method according to claim 18 further comprising:

securing a forward end of a jogging tray adjacent to a second portion of the transfer assembly;

rotatably coupling a plurality of rods within the jogging tray; and

adapting the plurality of rods to rotate at a synchronized rate.