Adjustable Tray Rack

Abstract

A machine to sort documents includes a stacker having a tier of the plurality of pockets and a magazine positioned at one end of the stacker. A first transport and a second transport operably associated with the magazine are configured to carry the documents through the stacker. Once the sorted documents are at the end of the machine, there is a tray system operably associated with the machine to allow the user to store the resulting sorted documents from the machine.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No. 13/098,064, filed 29 Apr. 2011, titled “Document Sorting Machine,” and is a continuation-in-part of U.S. application Ser. No. 13/245,970, filed 27 Sep. 2011, titled “Document Sorting Machine,” and both are hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

1. Field of the Invention

The present invention relates generally to machines utilized to sort documents, i.e., mail pieces such as letters, and more particularly, to a sorting machine having dual magazines located at one end for increasing sorting capacity. Specifically, a motorized Tray Rack System, hereafter referred to as the tray system, which features multiple, motorized shelves that hold multiple removable document containers (bins, tubs, or trays), hereafter referred to as removable trays. When located in proximity of an automated sorting system for the sorting of documents (e.g. letters, postcards, checks, flats, and parcels) into groups having common identifying criteria (e.g. ZIP codes, mail boxes, and so forth), the shelves in the tray system facilitate the efficient transfer documents from numbered destination pockets in the sorter to corresponding numbered removable trays. Furthermore, when a sort scheme change is made at the automated sorting system, the tray system features a motor that when activated by a worker, ergonomically moves the shelves holding the removable trays for the first sort scheme to a subordinate position and moves shelves holding the removable trays for the second sort scheme to a dominant position.

2. Description of Related Art

Automated sorting machines are well known in the art for sorting large volumes of documents (e.g. letters, postcards, checks, flats, and the like) into groups having a common identifying criteria (e.g. Zip Codes, mail boxes, and so forth). A sorting machine typically comprises a front end or feeder section and one or more stacker sections, wherein the front end feeds the documents, one-by-one, past a reader (e.g. optical character reader (“OCR”), bar code reader (“BCR”), or the like) to a transport that carries it to a designated sort pocket in one or more stacker sections.

As the document passes the reader, the desired criteria on the document is read and a signal is generated that, in turn, is processed to generate a designation signal for that particular document. This designation signal, in turn, triggers a diverter or gate at the designated pocket in the stacker section as the document approaches to divert the piece from the transport into the designated pocket where it is stacked with other pieces having the same identifying criteria. Such machines are well known and are commercially available e.g., Vsort® Flat Sorting machine, NP8000™ Sorting machine, Crossfire SE, and OMEGA® Mail Sorters all manufactured and distributed by National Presort, Inc., Dallas, Tex.

Many present sorting machines are comprised of a plurality of vertically stacked tiers of sort pockets which increase the number of pockets available during the sorting operation without substantially increasing the machine's foot print (floor area required for the machine). With these types of sorting machines, the letters are read and directed by a Level Distribution Unit or elevator system to the particular tier on which its respective sort pocket is located. For example, if the sorting machine has four tiers, only approximately 25% of the letters being fed will go to each tier. This means that approximately 75% of the sort capacity of each tier goes unutilized. It can be seen that if the unused capacity on each tier can be reduced, the throughput of the machine can be significantly increased.

Machines for automatically sorting documents, such as mail, into one of an array of selected pockets or compartments, are common. The pockets or compartments in the sorter are mapped to a first sort scheme. Removable document container trays are staged to match with the pockets or compartments in the first sort scheme.

Typically, as removable trays are filled, they are manually moved to pallets or other conveyances placed in close proximity to the sorter or are manually moved onto conveyor systems, which automatically transport them to a distant staging area.

In most sorting scenarios, a scheme change is required to achieve the desired level of sort saturation. The pockets or compartments in the sorter are mapped to a second sort scheme. Empty removable trays are staged to match with the pockets or compartments in the second sort scheme. Therefore, all removable trays for the first sort scheme must be moved to accommodate the empty removable trays for the second sort scheme.

Furthermore, the mail sorted in the second sort scheme may need to be merged with mail in the first sort scheme, which requires the worker to locate the removable trays on pallets or in the distant staging area. This process is very time consuming and greatly increases the possibility that mail will be merged incorrectly, potentially resulting in costly fines.

In another sorting scenario, a scheme change is required to accommodate the sorting of documents having different process and pricing requirements. The processing of standard mail, first class mail, and non-profit mail each have specific rules, pricing, and scheme requirements.

For example, on a daily basis, standard mail may be processed before and/or after more time sensitive first class mail processing is complete. The pockets or compartments in the sorter are mapped to the appropriate standard class or first class mail sort scheme. Empty removable trays are staged to match with the pockets or compartments in the sort scheme. All removable trays for the appropriate standard class or first class mail sort scheme must be moved accordingly to accommodate the switch in mail class to be processed.

Accordingly, there exists a need for a tray system that facilitates the ergonomic movement of motorized shelves holding removable document container trays from a dominant position to a subordinate position or from a subordinate position to a dominant position that will greatly increase the efficiency of movement, reduce the possibility of errors, and greatly reduce labor costs associated with unnecessary movement of removable trays.

Although the foregoing developments represent strides in the area of sorting machines, many shortcomings remain.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the invention are set forth in the appended claims. However, the invention itself, as well as a preferred mode of use, and further objectives and advantages thereof, will best be understood by reference to the following detailed description when read in conjunction with the accompanying drawings, wherein:

FIG. 1 is a simplified side view of the dual front end sorting machine of the present invention can be incorporated;

FIG. 2 is a top view of the sorting machine shown in FIG. 1;

FIG. 3 is an enlarged view of one end of the sorting machine of FIG. 1;

FIG. 4 is an enlarged, top view of the buffer unit at each end of each tier of the sorting machine of FIG. 1;

FIG. 5 is an enlarged, top view of the serpentine “piggy-backing” section at each end of the sorting machine of FIG. 1;

FIG. 6 is a top view of an alternative embodiment of a sorting machine of the sorting machine of FIG. 1;

FIG. 7 is side view of the sorting machine of FIG. 6;

FIGS. 8 and 9 are side views of the sorting machine of FIG. 6 with a purge system;

FIG. 10A is a top view of a buffer unit and the purge system of the sorting machine of FIG. 6;

FIG. 10B is a top view of an alternative embodiment of the buffer unit and the purge unit of the sorting machine of FIG. 10A;

FIG. 11 is a flow chart depicting a preferred method to sort documents;

FIGS. 12 and 13 are oblique view of a tray system operably associated with the sorting machine of FIG. 6;

FIG. 14 is an oblique view of an alternative embodiment of a magazine of the sorting machine of FIG. 6;

FIG. 15 is a top view of the magazine of FIG. 14; and

FIG. 16 is an oblique view of a tray system operably associated with the sorting machine of FIG. 6.

While the sorting machine and method of the present application is susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and are herein described in detail. It should be understood, however, that the description herein of specific embodiments is not intended to limit the invention to the particular embodiment disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the process of the present application as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The document sorting machine of the present application overcomes common disadvantages associated with conventional machines and method for sorting documents. Illustrative embodiments are described below. It will of course be appreciated that in the development of any actual embodiment, numerous implementation-specific decisions will be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.

Referring more particularly to the drawings, FIG. 1 is a plan view of a multi-tiered, dual front end document sorting machine 10 in accordance with the present invention. As seen in FIG. 1, machine 10 comprises of two halves A and B which are substantially identical in form and function. For the sake of clarity, only one half will be described in detail. Each half (A and B) is comprised of a feeder section 11, a transport 12, a serpentine piggy-backing section 13, and elevator or Level Distribution Unit (LDU) 14, and multi-tiered stacker section 15.

Each half (A and B) comprises of a feeder section 11 having a magazine 16 (see FIG. 2) onto which a batch of documents (e.g., letters or pieces 17) are positioned (see FIG. 2). Conveyor 18 (e.g., motor driven chain-link belts) feeds documents 17 forward onto a pickoff which picks off one document at a time and delivers it onto transport 12. As the document passes by optical character reader and/or bar code reader (not shown), identifying mark (e.g. a sort code such as a Zip Code or bar code, respectively) on the document 17 is read by the appropriate reader which, in turn, generates a signal representative of the mark as is well known in the art. These signals are then processed to direct the document through LDU 14 to its pre-assigned sort pocket on one of tiers 22 in stacker section 15.

Stacker section 15 is shown as being comprised of a plurality (e-g. four) of vertically stacked tiers 22, each tier being substantially identical to the others. Each tier 22 has a plurality of horizontal stacker bins or “pockets” 20 (only some shown and numbered for clarity) arranged in pairs having one pocket on either side of the looped transport 12. As best seen in FIGS. 2 and 3, transport 12 on each tier 22 forms a continuous path or “carousel” which extend through both the adjacent stacker sections 15 of both A and B. That is, transport 12 passes around a “turn around” pulleys 23 at the opposite ends of the respective stacker sections so that a document may be carried along one side of the sort pockets, turned around, and then carried back along the other side of the sort pockets until the document reaches its designated pocket. While only two stacker sections are shown, it should be recognized that there may be more than two section aligned with each other or the two sections shown may be combined into a single stacker section without departing from the present invention.

Each pocket 20 has a diverter means (see 21a in FIG. 4; not shown in other Figures for the sake of clarity) which is actuated as a designated document 17 approaches its pocket. The diverter, when activated, temporarily intersects the centerline of transport 12 to thereby divert document 17 from transport 12 into its designated pocket 20. This type of operation is well known in commercially-available sorting machines; e.g., Models NP8000, Vsort®, and OMEGA® Mail Sorters, manufactured and distributed by National Presort, Inc., Dallas, Tex.

While the machine 10 will be shown and described as having four tiers 22, it should be recognized that more or less tiers (i.e., at least one) can be used without departing from the present invention. It will also be recognized, in most operations using multi-tiered sorting machines, the sorting of the mail will be programmed to arrange the sort pockets so that each tier will receive approximately an equal amount of the documents. For example, in a four-tier machine, the designated pockets for a particular batch of documents will be assigned so that approximately 25% of the documents will be fed to each tier, leaving appropriate 75% of the available transport capacity of that tier unused.

In accordance with one embodiment, dual feeders 11 feed documents onto transport 12 from opposite ends of the sorting machine 10. That is, one feeder 11A reads and feeds documents from one end of the sorter 10 through its respective LDU 14 to each of the four tiers 22 while, at the same time, feeder 11B reads and feeds documents from the other end of the elongated sorting machine 10.

As described above, documents 17 are fed from either feeder 11A or 11B and may have to travel almost all of the way around the looped transport 12 of a respective tier 22 in order to reach a designated pocket 20 which lies on the other side of the stacker section from which the document it entered the transport. In order to do this, that document must completely travel through both stacker sections 15 along one side of the tier and then reverse directions at “turn around” pulley 23 in a respective buffer unit 30 before it can travel along the other side of the tier to reach its designated pocket.

Since documents 17 are being fed simultaneously from both feeders 11A and 11B onto respective ends of the respective common looped transport 12 of each respective tier 22, there is a real possibility that a document from one of the feeders and already in the transport may collide with a document being fed onto the transport by the other feeder; thereby causing a collision between the two documents. Any such collisions can result in a shut-down of sort operations. To prevent this from happening, a buffer unit 30 is provided at each end of each tier 22. Since the buffer units 30 are identical, only the unit at one end (i.e. 30B) will be described in detail.

As best seen in FIG. 4, buffer unit 30B includes transport 12B that feeds document 17C from feeder 11B into the looped or carousel transport 12 at one end of a respective tier 22. To prevent document 17C from colliding with document 17B already on transport 12 (e.g., one which has been fed from feeder 11A), a sensor(s) (not shown) along transport 12 determines whether document 17B is likely to arrive at the merge point 35 at the same time as document 17C will enter transport 12. If the possibility of collision is imminent, document 17B is held in buffer unit 30 until document 17C enters transport 12 at point 35, at which time, document 17B is released to resume normal operation.

If a following document 17A is positioned on transport 12 so that it might run up onto document 17B as it is being delayed in unit 30, gate G is actuated to divert document 17A into a “purge” pocket 20P. Any documents in purge pocket 20P are later removed and run back through sorting machine 10 to sort them into their proper packets. This allows both feeders to continue to feed documents without interruption.

Another feature of the present invention is serpentine piggy-back unit 13 (FIG. 5). The function of this unit is to stack, or “piggy-back” consecutive documents going to the same designated pocket whose combined thicknesses are equal to or less than a predetermined thickness. Stacking such documents is highly beneficial since it reduces the number of times a gate at a particular pocket has to be actuated during the sort operation. Also, the piggy-backing of these documents leaves a gap on the transport which is also beneficial in merging the documents from the dual feeders.

In the operation of serpentine, piggy-back unit 13, the thickness and length of each document 17D (FIG. 5) is measured by any known thickness and length measuring device 40 as it passes through serpentine unit 13. Such devices are well known in the art and are available from several commercial sources. If the thickness of document 17D equals or exceeds a predetermined thickness or the length of document 17D₁ exceeds the length of document 17D₂, it passes on through unit 13 to its designated pocket in the stacker section. However, if the combined thicknesses of any two consecutive, adjacent documents 17D (i.e., documents going to the same sort pocket) is equal to or less than the predetermined thickness and the length of document 17D₁ does not exceed the length of document 17D₂, the first document 17D₁ is diverted into by-pass transport 12T by gate 31 and is temporarily held at that point.

When the following document 17D₂ (which is going to the same pocket as document 17D₁) approaches the exit of bypass transport 12T, document 17D₁ is fed (i.e., piggy-backed) onto document 17D₂ without stopping document 17D₂. The two stacked documents will now travel along transport 12 as if a single document until it reaches its designated pocket 2nd is sorted accordingly. It should be appreciated that the unit 13 could easily be adapted to piggy-back multiple documents together, i.e., three or more documents traveling to the same designated pocket.

Referring now to FIGS. 6 and 7 in the drawings, respective top and side views of an alternative embodiment of sorting machine 10 is shown. Sorting machine 601 is substantially similar in function to sorting machine 10. In particular, sorting machine 601 is utilized to sort documents in a plurality of sorting pockets. Sorting machine 601 comprises one or more of the various systems discussed above, i.e., a feeder section, transport, level distribution unit, stacker section, and other required systems, to effectively and rapidly sort documents. It will be appreciated that sorting machine 601 could include one or more of the features of sorting machine 10, and likewise, sorting machine 10 could easily be adapted with the features of sorting machine 601.

Sorting machine 601 includes a first magazine 603 and a second magazine 605, both magazines being located at the same end section 607 of sorting machine 601, and both magazines being substantially similar in form and function to magazine 16, discussed above. Magazine 603 and magazine 605 include a conveyor 609 for feeding documents onto a pickoff (not shown), which in turn, picks off one document at a time and delivers the document to a transport. In the preferred embodiment, a first transport 611 is operably associated with magazine 603 and a second transport 613 is operably associated with magazine 605. During operation, a worker places documents 615 on magazine 603 and documents 617 on magazine 605, which in turn are fed to and subsequently carried by respective transport 611 and transport 613. For clarity, movement of both transport 611 and transport 613 are depicted with arrows on sorting machine 601. The selectively positioning of both magazine 603 and magazine 605 at the same end section 607 allows a single worker to feed both transports simultaneously, thus reducing costs associated with employing multiple workers to perform the same job.

Sorting machine 601 preferably includes an elevator 621 utilized to elevate transport 611 at a height above a first level distribution unit 623 such that uninterrupted travel of documents 615 is achieved between feeder section 619 and a second level distribution unit 625. During operation, documents 615 from magazine 603 are fed through feeder section 619 and are carried by transport 611 above first level distribution unit 623 via elevator 621 to second level distribution unit 625. Thereafter, documents 615 are placed in the stream of partially sorted documents 617 from magazine 605. This feature greatly increases sorting efficiency, as is further discussed below.

Like sorting machine 10, sorting machine 601 comprises a stacker section 627 comprising a first section 629, or called a rear section, having a plurality of pockets 631 and a second section 633, or called a front section, having a plurality of pockets 631. In the preferred embodiment, stacker section 627 comprises two or more tiers 635, preferably four tiers, to increase sorting capacity. However, it will be appreciated that alternative embodiments could include more or less tiers than the preferred embodiment.

It should be understood that a designated pocket for some of documents 617 could be positioned on section 629, thus requiring documents 617 to travel the entire length of section 629 then reverse direction at a first buffer unit 637 prior to documents 617 traveling along section 629 to the designated pocket. Sorting machine 601 further comprises a second buffer unit 639 utilized to maintain continuous travel of both documents 615 and documents 617 around section 629 and section 633, thus forming a continuous “loop” around stacker 627. As documents 617 travel around first buffer unit 637, documents 615 from magazine 605 are added thereto via transport 611. This feature increases the efficiency of sorting machine 601 by placing documents 615 in a stream of documents 617 already sorted in section 633. It should be understood that the remaining unsorted documents 617 have designated pockets located on section 629 of stacker 627, thereby requiring the unsorted documents to travel the entire length of section 633 and reverse direction at first buffer unit 637. Sorting documents 617 prior to merging documents 615 creates additional openings on transport 613 for receiving documents 615, which in turn increases the sorting capacity of the documents and overall efficiency of sorting machine 601.

Referring to FIGS. 8 and 9 in the drawings, side views of sorting machine 601 are shown with a purge system 801. Purge system 801 is utilized to remove documents 615 and documents 617 from their respective transports in one or more scenarios, including, but not limited to, the documents that risk colliding with one another, the documents that have an unknown pocket designation, and/or a jam occurs, which requires the tier to shut down for repair. With a tier shutdown, additional mail from the LDU must be purged until the jam is cleared and the tier is restarted. Purge system 801 comprises one or more of a purge pocket 803 for storing the documents removed from the transport and an associated control system 805, i.e., a sorter/supervisor board adapted to direct documents to pocket 803 during one or more of the foregoing scenarios.

Purge pocket 803 is preferably operably associated with turn around buffer unit 639; wherein, as one or the foregoing purge scenarios described above occurs, control system 805 activates a diverter means 1001 (see FIG. 10), i.e., a gate, which in turn diverts documents 615 and documents 617 from transport 613 to pocket 803 for storing. After the jammed tier is fixed, control system 805 deactivates diverter means 1001 and the documents from the LDU continue to their designated pocket. Thereafter, a worker collects the documents from pocket 803 and returns the unsorted documents to the magazine for resorting. In the preferred embodiment, pocket 803 is positioned next to turn around buffer unit 639. However, it will be appreciated that alternative embodiments could include one or more purge pockets 803 selectively positioned at various locations on sorting machine 601. For example, a purge pocket 803 could be position alongside pockets 631 of stacker 627 and/or one or more pockets 631 could be reserved as purge pockets.

Control system 805 is operably associated with a plurality of sensors 807 utilized to determine whether a jam 901 on the tier has occurred. If a jam does occur, control system 805 shuts down all sorting on the jammed tier. Control system 805 is adapted to activate controls, lever, motors, buffers, diverters, and other associated equipment utilized to direct the documents from the LDU to purge pocket 803. FIG. 9 provides illustration of a jammed tier 635, which is shut down and the documents diverted to purge pocket 803. It will be appreciated that while the jammed tier is shut down, the other remaining 7 tiers (4 tiers on section 629 and 3 tiers on section 633) remain operable.

Purge system 801 greatly increases sorting efficiency of sorting machine 601, in particular, purge system 801 enables sorting machine 601 to shut down a single tier in lieu of shutting down all tiers, thus allowing sorting machine 601 to remain operable. In the preferred embodiment, a single tier is shut down; however, it should be appreciated that alternative embodiments could include a purge system adapted to shut down one or more jammed pockets on a tier in lieu of shutting down the entire tier. This alternative embodiment enables the remaining pockets on the tier to operate while the jammed pocket(s) are undergoing maintenance. Furthermore, the preferred embodiment includes a purge pocket for each tier; however, it should be appreciated that alternative embodiments could include a single purge pocket adapted to store documents for all tiers and/or a designated tier utilized as a purge pocket. For example, section 633 could include a fifth tier having a plurality of pockets and being utilized as designated purge tier in lieu of a single purge pocket 803.

Referring now to FIG. 10A in the drawing, a top view of buffer unit 639 and purge system 801 are shown. Buffer unit 639 includes a pulley 1003 utilized to turn around transport 613 such that continuous travel of transport 613 is achieved between buffer unit 637 and a pulley (not shown) of buffer unit 639. Buffer unit 639 is further optionally provided with a first buffer 1005 and a second buffer 1007, both buffers being utilized to prevent documents on the transport from colliding with each other. In the preferred embodiment, both buffer 1005 and buffer 1007 utilize one or more servomotors adapted to hold the documents in position. However, it should be appreciated that alternative embodiments could include solenoids and/or other suitable stopping means, i.e., suction devices, in lieu of the preferred embodiment. Solenoids are particularly desirable because they reduce the amount of starting and stopping of the transport belt. Also, it should be appreciated that alternative embodiments could include a buffer unit adapted to provide controlled collision of the documents.

During operation, one or more sensors (not shown) along transport 613 determines whether a document 1009 is likely to arrive at a merge point 1011 at the same time as an entering document 1013. If the possibility of collision is imminent, document 1009 will be held in position with buffer 1005 until document 1013 passes merge point 1011, at which time, document 1009 is released to resume travel to the designated sorting pocket 631. Likewise, second buffer 1007 is utilized in a similar manner, namely, one or more sensors determine whether collision of a document 1015 is imminent with document 1009, and if so, buffer 1007 holds document 1015 in position until document 1009 is released. The dual buffer configuration reduces collision between two or more documents on the transport, which increases the overall efficiency of the sorting operation. It should be appreciated that additional buffers could be utilized in alternative embodiments. For example, a buffer could be selectively position between first buffer 1005 and second buffer 1007, thereby allowing an additional document to be held in position if collision is imminent.

Referring now to FIG. 10B in the drawing, a top view of an alternative embodiment of buffer unit 639 is shown operably associated with purge system 801. Buffer unit 1000 is substantially similar in form and function to buffer unit 639 with additional significant features, as will be discussed below. Like unit 639, buffer unit 1000 is also configured to retain one or more documents in a holding position when collision between documents is eminent. In the exemplary embodiment, buffer unit 1000 comprises a single buffer 1002 positioned upstream of a merge point 1004 and purge pocket 803 to prevent collision between entering documents and documents already traveling on transport 613. It should be appreciated that the features of buffer unit 639 could be incorporated in buffer unit 1000, and likewise the features of buffer unit 1000 could easily be used in one or more of the buffer units discussed herein.

Buffer unit 1000 further comprises a pulley 1006 adapted to rotatably turn directional movement of the document traveling along transport 613. In the preferred embodiment, buffer 1002 utilizes one or more servomotors as means for retaining the documents in a holding position. However, it should be appreciated that alternative embodiments could include solenoids, suction devices, and/or other suitable stopping means in lieu of the preferred embodiment. Solenoids are particularly desirable because the solenoids are configured to reduce the amount of starting and stopping of the transport belt.

During operation, one or more sensors (not shown) operably associated with transport 613 senses whether a document 1008 traveling on transport 613 is likely to arrive at a merge point 1004 at the same time as an entering document 1010. If the possibility of collision is imminent, document 1010 will be held in position with buffer 1002 until document 1008 passes merge point 1004, at which time, document 1010 is released to resume travel to the designated sorting pocket 631.

It will be appreciated that buffer unit 1000 can be operably associated with purge pocket 803. For example, if a third document 1012 enters transport 613 while document 1010 is being retained in a holding position, diverter means 1001 is activated and the buffer releases document 1010, which in turn is purged into purge pocket 803 via diverter means 1001. This feature allows continuous travel of document 1012, and subsequent documents, on transport 613 without colliding with document 1010.

The buffer configuration reduces collision between two or more documents on the transport, which increases the overall efficiency of the sorting operation. It should be appreciated that additional buffers could be utilized in alternative embodiments. For example, the buffers of buffer unit 639 along with a buffer selectively position between first buffer 1005 and second buffer 1007 could be utilized with buffer 1002, thereby allowing multiple documents being retained in a holding position for preventing collision.

Referring next to FIG. 11 in the drawings, a flow chart 1101 illustrating the preferred method of sorting documents is shown. Box 1103 depicts the first step, which includes separating the documents into a first portion and a second portion. Thereafter, the first portion is carried to a first end of a tier of pocket and subsequently sorted, as depicted in boxes 1105 and 1107. The second portion is simultaneously carried to a second end of the tier of pockets and then merged into the stream of already partially sorted documents from the first portion, as depicted in boxes 1109 and 1111. The preferred embodiment also includes the process of removing the documents from the first transport with a purge system, as described above, and as depicted in box 1113. Also, the preferred embodiment includes the process of stacking the document on one another with a stacking unit, as described above, and as depicted in box 1115.

Referring now to FIGS. 12 and 13 in the drawings, oblique view of a tray system 1201 is shown. Tray system 1201 is utilized to store documents that are removed from stacker section 627 as pockets 631 become full and/or during changing of schemes, as is further discussed below. In operation, a worker collects documents from the pockets and places the documents in a corresponding removable tray 1203 carried by tray system 1201. Thereafter, the worker removes tray 1203 as tray 1203 becomes full and replaces tray 1203 with an empty tray. It should be understood that each tray 1203 carried by tray system 1201 corresponds to a pocket on stacker section 627. For example, tray system 1201 could include twenty trays 1203, each tray being designated to store documents from twenty different pockets of stacker section 627.

Tray system 1201 preferably comprises a framed structure 1205 for supporting the plurality of trays 1203 and for supporting associated subsystems operably associated with tray system 1201. In the preferred embodiment, tray system 1201 comprises eight rows or shelves 1207 for holding five trays 1203; however, alternative embodiments could include more or less rows 1207 and rows adapted to hold more or less trays than the preferred embodiment. Tray system 1201 includes four rows 1207 designated for a first scheme section 1209 and four rows 1207 designated for a second scheme section 1211. It should be understood that sorting machine 601 could easily be adapted to operate with multiple schemes. Schemes are defined as operating scenarios, in particular, a first scheme occurs when sorting machine 601 sorts international documents, and a second scheme occurs when the documents are nationally sorted. For example, a first collection of documents could include designations to a plurality of countries, thereby designating a pocket 631 to individual countries; whereas, in the second scheme, each pocket could be designated for each state within the United States. Of course, it should be understood that these two exemplary schemes are one example of many different types of schemes operably associated with sorting machine 601. It should be appreciated that alternative embodiments could include more or less schemes than the preferred embodiment. Schemes are defined as sort destinations within varying operating scenarios. As an example, a first scheme occurs when the automated sorting machine is tasked to sort documents locally, and a second scheme occurs when the automated sorting machine is tasked to sort documents nationally. In this example, the first collection of documents could include Zone Improvement Plan (ZIP) code destinations within a state, whereas, in the second scheme, the collection of documents could include ZIP code destinations in multiple states of the United States. Providing a tray system with multiple scheme sections greatly increases the overall efficiency of tray system 1201, namely, the worker is no longer required to remove removeable trays from the tray system as the sorting machine switches between schemes.

Tray system 1201 further comprises a lift subsystem 1213 operably associated with a drive system 1215. Lift subsystem 1213 is utilized to lower and raise rows 1207 relative to the floor. For example, FIG. 12 shows rows 1207 at a lower position, while FIG. 13 shows rows 1207 at an elevated position. During operation, a worker manipulates a switch 1217, which in turn activates drive subsystem 1215 and lift subsystem 1213. Switch 1217 is part of a control subsystem that allows the sorter to control the tray system so that the accessible rows coordinate with the current sorting scheme. Switch 1217 can subsequently be manipulated by the worker to lower rows 1207 to the lower position. An alternate embodiment of the present application features an automated switching mechanism connected to a computer or other control electronics that activates drive subsystem 1215 and lift subsystem 1213 to lift or lower the shelves 1207 when a sort scheme change occurs. This feature of raising and lowering the rows provides ergonomic advantageous, specifically, a worker is no longer required to bend over to reach and stack documents near the floor. In the preferred embodiment, the worker simply manipulates switch 1217 to elevate the bottom rows or shelves for stacking.

Lift subsystem 1213 preferably comprises one or more of a chain 1219 rotatably coupled to a top gear 1221 and a bottom gear 1223. Rows 1207 are securely held in position with a rigid sidewall 1225, which includes one or more brackets 1227 adapted to fasten to chain 1219. Drive subsystem 1215 preferably includes a motor 1229 rotatably coupled to a drive shaft 1231, which in turn is rotatably coupled to gear 1221. During operation, drive subsystem 1215 rotates gear 1221, which in turn causes rows 1207 to raise or lower via movement of chain 1219. Of course, it will be appreciated that alternative embodiments could include different means for lifting the rows. For example, the tray system could easily be adapted with a worm gear system, a hydraulic system, gear system, and/or other suitable systems adapted to lower and raise an object.

Referring next to FIGS. 14 and 15, respective oblique and top views of an alternative embodiment of magazine 603 are shown. Magazine 1401 is substantially similar in form and function to magazine 603 and could include all the features of found therein, and likewise, the features of magazine 1401 could easily be incorporated in one or more of the magazines discussed above. Like magazine 603, magazine 1401 provides means for feeding documents to the stacker section. It will be appreciated that magazine 1401 provides significant advantages over other magazine embodiments. Specifically, magazine 1401 feeds documents to both transport 611 and 613 simultaneously. For example, during operation a worker places the documents onto the two conveyors, each conveyor being operably associated with one of the two transports passing through the stacker section. This embodiment allows a single worker to perform a job generally designated for two workers, thus greatly reducing the cost of operation.

For ease of description, not all of the required subsystems and devices operably associated with magazine 1401 are shown. For example, the necessary sensors, connectors, power sources, mounting supports, circuitry, software, control systems, and so forth are not all shown in order to clearly depict the novel features of the magazine. However, it should be understood that the magazine is operably associated with these and other required systems and devices for operation, as conventionally known in the art, although not discussed and depicted in the drawings.

Magazine 1401 comprises one or more of a structure 1403 for supporting the various components and systems of magazine 1401 thereon. A first conveyor 1405 and a second conveyor 1407 are supported by structure 1403 and are configured to receive the unsorted documents. Structure 1403 is further optionally provided with a working area 1409 for placing the documents thereon prior to positioning the documents on the conveyors.

Conveyor 1405 includes a track 1411 operably associated with a slider 1413, and likewise, conveyor 1407 includes a track 1415 operably associated with a slider 1417. In the preferred embodiment, both track 1411 and track 1415 are oriented relatively parallel to each other to facilitate easily loading of the documents thereon. In addition, track 1411 is positioned at a height relative to track 1415 for further ease of use. In the preferred embodiment, magazine 1401 includes two tracks at a height relative to each other. However, it will be appreciated that alternative embodiments could include three or more tracks and having the same or a height elevation relative to each other. During operation, the tracks are configured to move the sliders in direction D1, which in turn push the documents to feeders 1419 and 1421. It should be appreciated that feeders 1419 and 1421 are substantially similar in form and function to one or more of the feeders discussed above. Feeder 1419 is configured to feed the documents to transport 611, while feeder 1421 is configured to feed the documents to transport 613.

It should be appreciated that the sliders are either operated in a locked position or an unlocked position. In particular, during operation a worker slidingly moves the slider along the conveyor in an unlocked position to place the documents on the conveyor. Thereafter, the worker slides the slider along the track to abut the slider against the documents, and then locks the slider to the moveable track with a locking mechanism (not shown). The worker repeats this process as additional documents are placed on the conveyors.

Magazine 1401 is further provided with a control system 1423 for controlling the various systems and devices associated with sorting machine 601. In the preferred embodiment, control system 1423 includes a control panel 1425 conductively coupled to a monitor 1427. During operation, a worker manipulates control panel 1425 for activating/deactivating the various systems of sorting machine 601, while monitor 1427 provides viewing access to the operation of the systems associated with sorting machine 601.

Referring now also to FIG. 16 in the drawings, an oblique view of a tray system 1301 is shown. This example of an alternative embodiment of the present application features four odd-numbered shelves 1303, four even-numbered shelves 1305, and five blockout panels 1307. The four odd-numbered shelves 1303 are designated for first scheme staging. The four even-numbered shelves 1305 are designated for second scheme staging. In the default condition of the present application the four odd-numbered shelves 1303 are exposed for use and the trays 1203 placed thereon are readily accessible and the four even-numbered shelves 1305 are nested behind the four blockout panels 1307, which block access to the trays 1203 thereon. Blockout panel 1307a is similar to the other blockout panels 1307, however blockout panel 1307a is shown partially cut out in FIG. 16 so that the normally hidden trays 1203 are visible.

Continuing to Refer to FIG. 16, during operation, a worker manipulates a switch 1317, which in turn activates drive subsystem 1315 and lift subsystem 1313 only to the extent necessary to move the even-numbered shelves 1305 from the nested position behind the blockout panels 1307 to the exposed position, and move the odd-numbered shelves 1303 from the exposed position to behind the blockout panels 1307. Switch 1317 can subsequently be manipulated by the worker to reverse the positions whenever necessary. While this embodiment is shown with a total number of eight shelves it should be apparent that the number of shelves could be changed to reflect changing conditions such as the number of schemes, the number of trays, and the type of schemes. For example if there were three schemes, then there would be an odd number of shelves with a number of blockout panels to match. There would be 9 shelves and enough blockout panels so that only 3 shelves are visible to the user.

It is apparent that a sorting machine with significant advantages has been described and illustrated. In particular, the sorting machine effectively and rapidly sorts documents by providing two transports, the first transport utilized to carry documents through a plurality of sorting bins and a second transport utilized to merge documents into the stream of documents already partially sorted with the first transport. This features enables both a first magazine operably associated with the first transport and a second magazine operably associated with the second transport to be position at the same end section of the sorting machine, thus enable a single worker to feed both magazines simultaneously, which in turn allows a single worker to feed documents into the sorting machine in lieu of multiple workers performing the same job. In addition, the sorting machine is adapted with a purge system, which allows documents to be removed from the machine, thus enabling the sorting machine to continue operation while the jammed tier is being repaired. Further, the sorting machine could include a magazine configured to feed both transports simultaneously.

The particular embodiments disclosed above are illustrative only, as the embodiments may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. It is therefore evident that the particular embodiments disclosed above may be altered or modified, and all such variations are considered within the scope and spirit of the invention. Accordingly, the protection sought herein is as set forth in the description. Although the present embodiments are shown above, they are not limited to just these embodiments, but are amenable to various changes and modifications without departing from the spirit thereof.

Claims

1. A tray system to store documents, the tray system comprising:

a first row of a plurality of removable trays associated with a first scheme;

a second row of a plurality of removable trays associated with a second scheme;

a lift subsystem operably associated with the first row and the second row, the lift subsystem being adapted to raise and lower the first row and the second row; and

a drive subsystem operably associated with the lift subsystem, the drive subsystem being adapted to drive the lift subsystem;

wherein the tray system allows switching between the first row and the second row.

2. The tray system of claim 1, the lift subsystem comprising:

a first gear;

a second gear; and

a chain rotatably coupled to the first gear and the second gear.

3. The tray system of claim 1, further comprising:

a manual switch.

4. The tray system of claim 1, further comprising:

a switch configured to be remotely controlled by a computer.

5. The tray system of claim 1, further comprising:

a first position; and

a second position;

wherein the first row and second row are moved between the first position and the second position to limit access.

6. The tray system of claim 5, further comprising:

a blockout panel adjacent to the first position.

7. A tray system to store sorted documents, comprising:

a mail sorting machine;

a first shelf associated with a first scheme;

a second shelf associated with a second scheme;

a lift subsystem configured for raising and lowering the first shelf and the second shelf;

a drive subsystem configured for driving the lift subsystem; and

a control subsystem.

8. The tray system of claim 7, the lift subsystem comprising:

a first gear;

a second gear; and

a chain rotatably coupled to the first gear and the second gear.

9. The tray system of claim 7, the control subsystem comprising:

a switch operably associated with the lift subsystem.

10. The tray system of claim 9, wherein the switch is controlled by the mail sorting machine based upon which scheme the mail sorting machine is processing.

11. The tray system of claim 7, further comprising:

a blocked position; and

an accessible position;

wherein the first shelf and second shelf are moved between the blocked position and the accessible position to limit access.

12. The tray system of claim 11, further comprising:

a panel adjacent to the blocked position.

13. A automated shelving system, comprising:

a first shelf;

a second shelf;

a lifting system operably associated with the first shelf and with the second shelf, the lifting system configured to move the first shelf between an exposed position and a hidden position;

a drive subsystem operably associated with the lifting system; and

a control subsystem configured for controlling the lifting system.

14. The automated shelving system of claim 13, further comprising:

a blockout panel, wherein the blockout panel is configured for blocking access to shelves located in the hidden position.

15. The automated shelving system of claim 13, the lifting system comprising:

a first gear;

a second gear; and

a chain rotatably coupled to the first gear and the second gear.

16. The automated shelving system of claim 13, the control subsystem comprising:

a switch operably associated with the lifting system;

wherein the switch is configured to be remotely controlled by a computer.

17. The automated shelving system of claim 13, the control subsystem comprising:

a switch operably associated with the lifting system;

wherein the switch is configured to be controlled a user.

18. The automated shelving system of claim 16, wherein the computer is in control of a mail sorting machine.