WO2012118801A2 - Sorting machine - Google Patents

Abstract

Disclosed is a sorting apparatus with several components including a sorting module, a magazine, a diverter gate, a singulator and a image capture module. The disclosed sorting module includes an image capture station that captures address indicia, a processer that interprets the captured address indicia, a printer station that applies sort indicia, a verification station that compares the applied sort indicia to the address indicia, and a transport track extending between the image capture station, the printer station and the verification station with a first bend in the transport track between the image capture station and the print station and a second bend in the transport track between the print station and the verification station, where the first and second bends both subtend an arc greater than π radians. The disclosed magazine includes a base track that defines a ledge above a deck and a recessed wall positioned between a register wall and a guide wall above the base track. Objects diverted into the magazine travel along the base track, are rotated off the base track and drop to the deck in an upright orientation supported between the recessed wall and a movable support member. The disclosed diverter gate includes a flexible pusher coupling a linear actuator to a gate that pivots to selectively intersect a transport track. When the linear actuator pushes, the flexible pusher both buckles and pushes on the gate cause the gate to pivot. The disclosed singulator includes a singulator comb with several resilient projections that extend toward a pick-off conveyor an extend between a first and second grip surface on the pick-off conveyor. The disclosed image capture module includes a first rigid roller and a second compliant roller that define a pinch point. Also included is a camera focused on an imaging line segment positioned proximate to the pinch point along a plane congruent with the first roller.

Description

SORTING MACHINE

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit United States Patent Application Serial No. 61/447,507 filed February 28, 201 1 , which is hereby incorporated by reference.

BACKGROUND

[0002] The present application is directed toward sorting machines. One common sorting machine application is processing mail (e.g., letters, postcards, etc.). A typical mail sorting machine generally includes a feed section that feeds mail pieces on-by-one past a reader that electronically reads the ZIP code or other like destination information on each piece. Based on the read destination information, a controller categorizes and directs the mail sorting machine to deliver the mail piece to a designated sort pocket where the mail piece is grouped with other mail pieces with similar destinations.

[0003] Such sorting machines are used by the US Postal Service as well as by large entities that may either presort outgoing mail to receive discounted postage or for sorting incoming mail for internal distribution. Similar sorting machines can be used for other unrelated applications. For example, a sorting machine could be used to process and sort checks or banknotes. Or a sorting machine could be use to process ballots in an election.

BRIEF DESCRIPTION OF THE DRAWINGS

[0004] Fig. 1 is a top plan view of a sorting machine incorporating a processing module and a plurality of distribution modules.

[0005] Fig. 2 is a perspective view of the Fig. 1 processing module.

[0006] Fig. 3 is a top plan view of the Fig. 2 processing module including a singulator portion, scanner portion and a marker portion.

[0007] Fig. 4 is a perspective view of the singulator portion of the Fig. 2 processing module.

[0008] Fig. 5 is a top plan view of the feed area of the Fig. 4 singulator portion.

[0009] Fig. 6 is a bottom plan view of the Fig. 5 portion of the singulator portion.

[0010] Fig. 7 is a perspective view of the feed portion of the singulator portion with some components removed as compared to the Fig. 4 view.

[0011] Fig. 8 is a perspective view of the Fig. 2 scanner portion in isolation.

[0012] Fig. 9 is a top perspective view of the Fig. 8 scanner portion.

[0013] Fig. 10 is a back perspective view of the Fig. 8 scanner portion.

[0014] Fig. 1 1 is a perspective view of the Fig. 2 marker portion.

[0015] Fig. 12 is a back perspective view of the Fig. 2 marker portion.

[0016] Fig. 13 is a perspective view of a Fig. 1 distribution module.

[0017] Fig. 14 is a perspective view of the diverters and magazine portions of the Fig. 13 diverter module.

[0018] Fig. 15 is a top plan view of the Fig. 14 diverters and magazines.

[0019] Fig. 16 is a cut away view of portions of one Fig. 14 diverter.

[0020] Fig. 17 is a perspective view of two alternative diverter embodiments, with the left one incorporating an optional kicker.

[0021] Fig. 18 is a front elevational view of the Fig. 17 diverters and magazines.

[0022] Fig. 19 is a perspective view of the diverters and magazines of Fig. 13 including previously omitted support members.

[0023] Fig. 20 illustrates a bottom plan view of a diverter guard and actuator mechanism.

[0024] Fig. 21 is a perspective view of alternative embodiments of the Fig. 17 diverters. DETAILED DESCRIPTION

[0025] Reference will now be made to certain embodiments and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of this disclosure and the claims are thereby intended, such alterations, further modifications and further applications of the principles described herein being contemplated as would normally occur to one skilled in the art to which this disclosure relates. In several figures, where there are the same or similar elements, those elements are designated with the same or similar reference numerals.

[0026] Referring to Fig. 1 , sorting machine 100 is illustrated. In the illustrated configuration, sorting machine 100 is configured for sorting letters or ballot cards. It should be understood that sorting machine 100 can be configured to sort other objects and that this description is not intended to limit the type of sortable objects to just letters or voting cards, but also to include any other objects that can also be sorted, including, but not limited to, flats, magazines, post cards, cardstock, envelopes, etc. Each sortable object includes an indicia that can be used to correlate particular objects to particular sort destinations. For example, an address on a letter that includes a zip code that controls which letters are grouped together for distribution to various postal distribution centers or post offices.

Sorting machine 100 includes processing module 102 and a plurality of distribution modules 104. While only portions of 2 distribution modules 104 are shown in Fig. 1 , it should be understood that any desired number of distribution modules 104 may be arranged together.

[0027] One characteristic of sorting machine 100 is that it is comprised of modular components that can be assembled and disassembled and can be reconfigured as needed. One problem encountered by applicants in supplying sorting machines is some clients have available floor space but lack an easy means to bring a prior art sorting machine into that floor space due to lack of access. For example, floor space in a high rise building may be limited by the size of an elevator or the size of a doorway in that building. In some cases it may be necessary to use a crane and to physically remove a wall to bring a prior art sorting machine into such a space. Similarly, available floor space may constrain the size or length of a sorting machine. Applicants have addressed these issues by making sorting machine 100, and in particular processing module 102 and distribution module 104, modular, permitting individual components to fit through smaller openings and in smaller elevator spaces. Modular construction also allows custom system sizing. Both facilitate sorting machine 100 being usable by a wider clientele.

[0028] Sorting machine 100 generally includes several generic features including a singulator portion 106, a scanner portion 108, transport track 1 10, a marker portion 1 12, and a plurality of diverters 1 14 and magazines 1 16. In the illustrated configuration processing module 102 includes singulator portion 106, scanner portion 108 and marker portion 1 12. Transport track 1 10 extends along and between processing module 102 and all the distribution modules 104.

Diverters 1 14 are operable to intersect transport track 1 10 and divert objects into one of the magazines 1 16. In the illustrated embodiments, each distribution module 104 includes four diverters and four magazines 1 16.

[0029] The illustrated embodiments of sorting machine 100 and its associated components are configured for sorting letter type sortable objects, including, but not limited to letters, post cards, ballots, banknotes and checks. Sorting machine 100 and its associated components are configured and arranged to transport and sort such letter type objects on an edge in an upright orientation. For example, a letter could be transported and sorted standing vertically on its bottom edge (longer side) with its front face (including address indicia) facing horizontally.

[0030] Singulator portion 106 generically refers to the portion of a sorting machine that singularly feeds objects from a stack of objects onto the transport track 1 10 for processing and sorting. Scanner portion 108 generally includes a means to read indicia on the objects being sorted to identify where an object should be sorted. This could include a laser barcode reader, an optical character recognition camera, or other such means useful to read the indicia on the objects that is used for sorting. Transport track 1 10 generally includes a means to move the objects through sorting machine 100 to its eventual destination in a magazine 1 16. Marker portion 1 12 is optionally included to add additional indicia to objects being sorted. For example, the US Postal Service provides postage discounts for application of a barcode to each letter as it is processed to expedite future processing. (US Postal Service sorting equipment would include marking capacity.) Marker portion 1 12 may optionally be configured to mark on one or the other side of the object being sorted or if desired both sides. Marker portion 1 12 may also optionally be configured to include an additional scanning capacity to verify the marking applied.

[0031] Referring now to Figs. 2 and 3, a specific embodiment of processing module 102 is illustrated as configured for sorting letter type objects such as letters or voting cards. Processing module 102 is mounted on base 1 18 that includes a plurality of wheels 120 to facilitate positioning of processing module 102. Processing module 102 also includes input device 122 and output device 124 that facilitate an operator to interface with a processor/controller that controls sorting machine 100. In the illustrated embodiment, input device 122 is a keyboard and output device 124 is a monitor.

[0032] As illustrated, singulator portion 106 includes a lateral feed conveyor 126, longitudinal feed conveyor 128 and pick-off conveyor 130. Scanner portion 108 includes camera 132 operable to image the surface of the object being sorted which is coupled to the processor (not illustrated) that uses optical character recognition software to decipher indicia on the surface of the object. In the illustrated configuration, camera 132 is a single line digital scanning camera. In other embodiments, scanner portion 108 could incorporate other means for reading information on the object, including, but not limited to, a bar code reader or an RFID reader.

[0033] Marker portion 1 12 includes marker stations 134, 136, 138, and 140, with marker station 134 being positioned on the back side of the object being sorted and marker stations 136, 138, and 140 being positioned on the front side. While marker portion 1 12 is being illustrated with each of the four marker stations 134, 136, 138, and 140 holding a printer, different numbers and different configurations of printers can be utilized. For example, marker stations 138 and/or 140 could hold a barcode scanner to verify the indicia applied by a printer in marker station 136. Similarly marker station 134 may be optionally empty if back side markings are not desired. Each of the illustrated printers (or other device in one of the marker stations) may optionally include the capacity to adjust the relative height (with respect to the objects being sorted) in which printing is applied. In some embodiments, multiple printers may be configured to apply markings at different relative heights. For example, a printer in marker station 136 could apply a barcode along the bottom of the objects being sorted while a printer in marker station 138 could apply indicia along the top of the object being sorted to cancel any postage. A scanner in marker station 140 could be configured to read the barcode applied by the printer in marker station 136 to verify that the barcode was successfully applied.

[0034] Referring now to Figs. 4 through 7, singulator portion 106 is illustrated with additional details referenced. Singulator portion 106 includes a plurality of lateral feed belts 142 that define lateral feed conveyor 126 on base 144. Wall 146 defines one edge of lateral feed conveyor 126. Wall 146 optionally includes a plurality of guide tracks 148. The end of lateral feed conveyor 126 is defined by longitudinal feed conveyor 128 and pick-off conveyor 130. Lateral feed conveyor 126 also includes feed support 150 rotatable on slide 152 about rail 154 into contact with one or more lateral feed belts 142. Feed support 150 may optionally be used to support the back end of a stack of objects placed in singulator portion 106 for processing.

[0035] Singulator portion 106 also includes comb 156 positioned over pick-off conveyor 130 to aid in singulation and a pair of feed rollers 158 that feed singulated objects onto transport track 1 10. Comb 156 includes a plurality of resilient projections including resilient projections 160, 162, and 164 shown in Fig. 5. Pick-off conveyor 130 includes a plurality of pick-off belts 166 with gaps 168 positioned between. Resilient projections 162 and 164 include extensions 170 that extend between pick-off belts 166 and into gap 168 of pick-off conveyor 130. Resilient projections 160, 162 and 164 provide a drag force on objects moving toward feed rollers 158 on pick-off conveyor 130. Extensions 170 are positioned to interfere with objects conveyed by pick-off conveyor 130.

[0036] Referring to Fig. 6, the underside of singulator portion 106 is shown including drive motor 176, drive motor 178, rod 180, rod 182, guards 194 with openings 196 and sensor 192. Drive motor 176 drives fixed wheel 184 while drive motor 178 drives fixed wheel 186 with rod 180 coupled to floating wheel 188 and rod 182 coupled to floating wheel 190. Both floating wheels 188 and 190 are resiliently mounted, with a bias toward lateral feed conveyor 126, such that floating wheels 188 and 190 resist advancement of objects carried by movement of lateral feed belt 142. Openings 196 in guards 194 limit the range of motion of rods 180 and 182 (and therefore the range of motion of floating wheels 188 and 190). Sensor 192 is positioned to detect the position of rod 180 when rod 180 (and floating wheel 188) are moved, against the bias, to a position near the movement limited imposed by opening 196. Tripping sensor 192 signals the controller to stop the feed of lateral feed conveyor 126 so that lateral feed conveyor 126 (and lateral feed belts 142) operate only on an as needed basis.

[0037] Figs. 5 and 7 illustrate sensor bar 172 that mounts a plurality of sensors 174 above comb 156 (as illustrated only in Fig. 5). Sensors 174 are configured to detect the leading and trailing edges of objects passing along pick-off conveyor 130 and feed roller 158.

[0038] Singulator portion 106 is configured to operate as follows. A plurality of objects are placed, on edge, on the lateral feed belt 142 up against the pick-off conveyor 130 with one edge guided by the guide tracks 148 on wall 146. Feed support 150 is rotated down and is placed against the back side of the stack of objects on lateral feed belt 142 to support the stack on edge. Lateral feed conveyor 126 pushes the stack of objects toward pick-off conveyor 130. When floating wheel 188 has moved sufficiently far laterally, the drive on lateral feed conveyor 126 (and lateral feed belts 142) stops.

[0039] Longitudinal feed conveyor 128 runs at a constant speed and with longitudinal feed conveyor 128 being configured to provide a minimal amount of grip to nudge objects toward pick-off conveyor 130 while supporting the outside of the stack of objects without providing so much grip or force on objects to buckle or tear them (the relative level of grip may be dependant on the objects being processed). Pick-off conveyor 130 is controlled based on the input to the controller from sensor bar 172. After the trailing edge of the last object fed across pick-off conveyor is detected, then drive motor 176 is activated to rotate pick-off conveyor 130 at a relatively high speed (faster than the operating speed of transport track 1 10) until the leading edge of the next singulated object is distinguished by the sensors 174 on sensor bar 172. Drive motor 176 is then halted until a programmed delay has elapsed since detecting the trailing edge of the last object. Drive motor 176 is then operated at the relatively high speed and the singulated object is pulled through comb 156 and fed into feed rollers 158.

[0040] Feed rollers 158 are compliant rollers configured to allow passage of various sized objects while providing a pinch point and a drive force feeding the singulated objects onto transport track 1 10. Feed rollers 158 are driven at a constant speed consistent with the speed of transport track 1 10. Comb 156 assists the singulation process by providing drag on any additional objects that want to tag along with the object being singulated and residing against pick-off conveyor 130. Resilient projections 162 and 164 also provide a physical block in front of any additional objects as well as a drag force on the edge of any other object being sorted to feed objects singularly through comb 156.

[0041] Referring now to Figs. 8, 9 and 10, scanner portion 108 is illustrated (in isolation). Scanner portion 108 generally includes camera 132, pinch roller 198, guide roller 200, roller stack 202, mirror 204, mirror guard 206, light 209, rails 210, rails 212, belt conveyor 214 and guide 216. Transport track 1 10 in scanner portion 108 is defined primarily by belt conveyor 214, rails 210, 212 and guide 216. In the illustrated embodiment, camera 132 is oriented substantially parallel with belt conveyor 214.

[0042] Mirror guard 206 includes openings 207 and 208 to define a path between camera 132, mirror 204 and an imaging line segment 218 just beyond pinch point 222 between pinch roller 198 and roller stack 202. In the illustrated embodiment, pinch roller 198 is a substantially ridged roller that guides the front side of the object while roller stack 202 includes several compliant rollers stacked on edge. The substantial rigidity of pinch roller 198 defines a plane of travel for objects moving along transport track 1 10 that is congruent with the outer surface of pinch roller 198. This is illustrated in Fig. 9 as plane F. Plane F defines the path of the front surface of objects passing through pinch point 222 while being moved by belt conveyor 214. Guide roller 200 is rotated in unison with pinch roller 198 by belt 220. [0043] Rails 210 guide singulated objects coming off of feed rollers 158 onto belt conveyor 214 where the singulated objects are conveyed, on edge, along a scanner portion 108 substantially at the speed of transport track 1 10. Rails 210 maintains the on edge orientation of the object and guides the object toward roller stack 202 and guide roller 200 where the object is vertically reoriented and directed feed into pinch point 222 between roller stack 202 and pinch roller 198. Pinch point 222 defines a fixed location for every object passing through scanner portion 108.

[0044] Mirror 204 is shrouded inside mirror guard 206. Mirror 204 is configured and arranged so that camera 132 is focused on imaging line segment 218, which is just beyond pinch point 222. Pinch point 222, and pinch roller 198 in particular, defines a fixed front edge plane for every object passing through scanner portion 108. Imaging line segment 218 positioned as close as possible to pinch point 222 to provide a stable imaging location for focusing camera 132. Light 209 is oriented to shine on imaging line segment 218.

[0045] This is best illustrated in Fig. 9, which includes dashed lines

representing the light path of the light entering digital camera 132 and the light path of the light from light 209 incident on imaging line segment 218. The light path of the light entering digital camera 132 from imaging line segment 218 and the light path of light 209 are both incident on imaging line segment 218 from the opposite side of roller 198.

[0046] Angle B is the angle between the light path of the light entering digital camera 132 from imaging line segment 218 and the light path of light 209 incident on imaging line segment 218. In the illustrated embodiment, angle B is equal to approximately 27 degrees. In alternative embodiments (not illustrated), angle B could vary between approximately 20 and approximately 35 degrees. Angle C is the angle that mirror 204 reflects the light path of digital camera 132 to focus digital camera 132 on imaging line segment 218. In the illustrated embodiment, angle C is equal to approximately 55 degrees. In alternative embodiments (not illustrated), angle C could vary between approximately 45 and approximately 60 degrees. [0047] This configuration replaces the platen that is traditionally used to define a front edge plane and camera focus point in this type of application. In some prior art sorting machines, sorted objects are forced against a metallic plate platen to define an imaging point. One problem that has been identified with this configuration is that the surface of the metallic plate platen wears over time due to the rubbing action of the objects being processed. This causes two problems. The first is wear on the platen that results in minor movement of the focus point over time and eventually necessitates replacement of the platen. The second is the edges of the platen hole can wear to form razor sharp edges over time. These edges can damage the objects being processed as well as creating a cutting hazard for individuals operating such equipment.

[0048] Furthermore, another benefit of this configuration identified by applicants is a significant reduction in the required power to move object by the platen. This power reduction has contributed to allowing applicants to use a standard 1 15V- 120V, 15 amp power supply instead of a larger, more specialized power supply such as a 230V, 30 amp or 50 amp power supply. This contributes to making sorting machine 100 usable by a wider clientele, as any standard power outlet is sufficient to operate sorting machine 100.

[0049] Yet another benefit of this configuration identified by applicants has been reduction of glare from light 209 received by camera 132. In some prior art systems, the angle between the light source and the capture camera is such that some objects, such as windowed letters, can reflect a glare from the light source toward the camera that can impede the ability of optical characteristic software to accurately read the indicia on the object being sorted. The configuration shown in scanner portion 108 avoids this problem because the angle of any reflective light on the object being scanned from light 209 is never along the angle that camera 132 captures its image. This is illustrated by the dotted lines in Fig. 9.

[0050] After the object passes through pinch point 222, it is then fed by guide 216, rails 212 and belt conveyor 214 to marker portion 1 12. Referring to Figs. 1 1 and 12, marker portion 1 12 is illustrated. As previously discussed, marker portion 1 12 includes up to four marker stations 134, 136, 138, and 140. In the

embodiment illustrated in Figs. 1 1 and 12, marker station 134 is left empty with marker stations 136, 138 and 140 each illustrated with a "front side" printer. Each of marker stations 134, 136, 138, and 140 include a compliant roller 243 on the opposite side of the marker stations 134, 136, 138, and 140.

[0051] Transport track 1 10 in marker portion 1 12 is defined by belts 224, 226, 228 and 230. Belts 224, 226, 228 and 230 are driven by drive motors 232 and 234. Drive motor 232 directly engages belt 226 while drive motor 234 directly engages belt 230. Belt 224 and belt 226 are engaged together around a plurality of rollers 236 defining arc 238 between scanner portion 108 and marker stations 134 and 136. Belts 228 and 230 are engaged together around a plurality of rollers 240 to define arc 242 between marker stations 136 and 138. In the illustrated embodiment, arcs 238 and 242 each subtend approximately 1 .2 π radians to define a "S" shaped portion of transport track 1 10.

[0052] Because belts 224 and 226 are in direct contact around arc 238 they are forced to run the same speed, assuming no slippage. Similarly, belts 228 and 230 are engaged together around rollers 240 to define arc 242 and therefore are driven at the same speed, again assuming no slippage. Finally, belts 224 and 228 are engaged together along the same track after marker stations 140 and are similarly forced to run at the same speed, once again assuming no slippage. Therefore, assuming no slippage, all belts 224, 226, 228 and 230 run at a substantially uniform speed. To accommodate this in the illustrated embodiment, drive motors 232 and 234 are asynchronous motors configured to uniformly adjust speed in response to varying loads. Also note that belt 226 runs through the pinch point 222 defined by roller stack 202 and pinch roller 198 which both helps maintain a consistent speed amongst transport track 1 10 and assists in guiding the article out of the pinch point 222 onto transport track 1 10.

[0053] Marker portion 1 12 optionally includes thickness sensor 244 that is configured to detect the distance between thickness sensor 244 and belt 224 as an object passes through belts 224 and 226 in front of thickness sensor 244. Thickness sensor 244 detects the change in position of belt 224 which

corresponds to the thickness of the object between belts 224 and 226.

[0054] Marker portion 1 12 also optionally includes encoder 246 which detects the relative position of belt 226. As previously discussed, assuming no slippage, belts 224, 226, 228 and 230 all run at a substantially uniform speed. Therefore encoder 246 provides relative position information for all of belts 224, 226, 228 and 230. In the illustrated embodiment, encoder 246 is a belt encoder that sends an impulse to the controller for every unit of belt travel.

[0055] Marker portion 1 12 also includes position sensors 248, 250, 252 and 254 each of which are configured to detect the presence of an object in transport track 1 10. This position information combined with the relative belt position information produced by encoder 246 allows that controller to track the location of objects in transport track 1 10. For example, encoder 246 in combination with position sensor 250 provides timing information for the activation of a printer in marker station 134 and/or 136. Similarly, position sensor 252 provides baseline timing information for the operation of a scanner and/or printer in marker stations 138 and 140. Finally, position sensor 254 provides information regarding objects leaving marker portion 1 12 for the sorting process explained in the following sections.

[0056] Referring to Fig. 13, distribution module 104 is illustrated. As discussed above, distribution module 104 includes transport track 1 10, diverters 1 14 and plurality of magazines 1 16 with diverters 1 14 being configured to intercept objects being transported along transport track 1 10 and divert them into individual magazines 1 16. As shown in Fig. 13, distribution module 104 also includes base 256 optionally having a plurality of wheels 258. Each distribution module 104 also optionally includes a plurality of tray storage shelves 260 located under each magazine 1 16. In the illustrated embodiment, tray storage shelves 260 are arranged to hold letter trays permitting an operator to readily transfer sorted letters in magazines 1 16 onto standard U.S. postal service letter trays. Other embodiments may have magazines 1 16 and tray storage shelves 260 configured and arranged for receiving other types of objects.

[0057] Referring now to Figs. 14-19, the arrangement of diverter 1 14 and magazine 1 16 from Fig. 13 are shown in greater detail. Transport track 1 10 across each distribution module 104 is defined by belt 262 that is strung around a series of rollers 264 and 266 and by belts 267 strung around rollers 268 opposite belt 262. In this illustrated embodiment, rollers 264 are fixed and define non- contact regions of the run of belt 262 while rollers 266 are compliant rollers and define portions of the run of belt 262 that is in contact with objects being transported along transport track 1 10. The other side of transport track 1 10 is defined by belt 267 riding around a plurality of rollers 268 that ride against the opposite side of belt 262 and also against objects being transported along belt 262. Assuming no slippage, belts 262 and 267 run together at substantially uniform speed. Encoder 270 tracks the position of belt 262. In the illustrated embodiment, encoder 270 is a belt encoder that sends an impulse to the controller for every unit of belt travel.

[0058] Each diverter 1 14 includes a transport pathway between transport track 1 10 and magazine 1 16 that includes guide wall 278, base track 280, roller 282, recess wall 284 and may optionally include kicker 286. Each diverter 1 14 also includes a deflector 272, pivotal about pivot point 274 such that the tip portion 276 of deflector 272 intersects transport track 1 10, with deflector 272 being configured to redirect objects off transport track 1 10 and onto base track 280. Controlled pivoting of deflector 272 about pivot point 274 causes deflector 272 to be positioned to interface with sortable objects traveling along transport track 1 10 to divert objects toward magazine 1 16.

[0059] Each magazine 1 16 includes deck 288 and register wall 290. In the illustrated embodiment, deck 288 is gradually inclined downwardly away from diverter 1 14. As shown in Fig. 19, each magazine 1 16 also includes support member 292 that is movable longitudinally along magazine 1 16 on slide 294 on rail 296. The position of support member 292 and magazine 1 16 may be controlled by automatic biasing means reactive to the number of objects located in magazine 1 16 or through a sensed motion control position to support the stack of objects sorted into individual magazines 1 16 and to index the position of support member 292 as additional sortable items are added to magazine 1 16. Support member 292 secures sortable objects in magazine 1 16 in an upright orientation between recess wall 284 and support member 292. (Support member 292 is not illustrated in other figures to more clearly illustrate other features of interest. It should be understood that, while not illustrated, support member 292 is present, where appropriate, in all the illustrated embodiment(s).) [0060] As best shown in Figs. 14, 17 and 18, base track 280 is positioned above deck 288 creating ledge 298. Ledge 298, shaped by base track 280, protrudes along guide wall 278 to approximately the position of roller 282 but does not extend along recessed wall 284. In operation, an object being sorted such as a letter is diverted by deflector 272 onto the base track 280 against guide wall 278. Objects directed toward magazine 1 16 by deflector 272 slide, on edge, long base track 280 with guide wall 278 supporting the object in the upright orientation. As the object transitions toward magazine 1 16 it encounters roller 282 which is vertically oriented and powered to provide an energy impulse assisting conveying the object and directing it toward register wall 290. The object is forced between support member 292 (or the last object sorted in magazine 1 16) and recessed wall 284 which causes the object to rotate and drop off ledge 298 onto deck 288 on edge, supported between recessed wall 284 and support member 292.

[0061] In the illustrated embodiment, ledge 298 defines curved edge 299.

Curved edge 299 of ledge 298 may also serve to support objects already sorted into magazine 1 16. This support can help keep base track 280 clear so that further object sorting is not blocked by objects already sorted into magazine 1 16. Sorted object are then retained, on edge, in magazine 1 16 between recessed wall 284 and ledge 298 and support member 292 and against register wall 290.

[0062] Kicker 286 may optionally be included to help prevent already sorted objects from interfering or jamming the inlet path of future objects to be sorted. Kicker 286 operates to push objects already sorted away from base track 280. As best shown in Fig. 17, kicker 286 has an initial position that is extended away from guide wall 278 and a recessed position 300 where kicker 286 is substantially flush against guide wall 278. Kicker 286 is operated by moving it into recess position 300 right before an object diverted by deflector 272 is passing onto base track 280 with kicker 286 in recess position 300. The object being sorted is permitted to pass unhindered along base track 280 on edge and is subsequently inserted into magazine 1 16 as described above. Shortly after the object rotates off base track 280 and falls to deck 288, kicker 286 returns to the initial position illustrated in Figs. 15 and 17 to prevent the stack of objects already sorted from bending back and impeding additional sorted objects from traveling along base track 280. [0063] Kicker 286 is moved at a relatively rapid speed so that any object(s) being held up while in the initial position do not have time to fall into the area above base track 280 before the object being diverted into the particular magazine 1 16 has already passed. This is controlled using a series of sensors along transport track 100 similar to those described above with regard to marking portion 212 in combination with relative position information from encoder 270. Please note that the sensors in the distribution module are not specifically illustrated herein.

[0064] The mechanism for controlling kicker 286 is not illustrated. In the illustrated embodiments, kicker 286 is actuated with a pneumatic actuator that keeps maximum force against objects in magazine 1 16 without substantial continual power consumption. The only significant power consumption occurs when the position of kicker 286 is moved from the extended position to recessed position 300 (and back).

[0065] Referring to Fig. 16 a means for pivoting deflector 272 is illustrated. Movement of deflector 272 is controlled by actuator 302 which is linked to deflector 272 by pusher 304. Pusher 304 is flexible and configured to buckle upon application of a compressive load. In the illustrated embodiment, pusher 304 is rigidly attached to both deflector 272 and actuator 302. The buckling nature of pusher 304 defines the pivoting movement of deflector 272. In particular, pusher 304 is connected to deflector 272 at a union point 306 that is radially offset from pivot point 274. Pusher 304 does not substantially flex at or near union point 306 when deflector 272 is pivoted about pivot point 274. Instead, as deflector 272 pivots and pusher 304 buckles, the relative angle between deflector 272 and pusher 304 remains substantially unchanged. Buckling pusher 304 maintains the relative position of pusher 304 with respect to deflector 272 through the illustrated pivot range. As shown by comparing Figs. 16 and 18, pusher 304 is

comparatively thick along its vertical orientation while being comparatively thin long its horizontal orientation. This may limit buckling to a single plane along its vertical axis, as shown in Fig. 16.

[0066] As shown in Figs. 16 and 20, the buckling of pusher 304 along its vertical axis is limited by guides 308, 310, 312, 314 and 316. As shown in Fig. 16, movement of linear actuator 302 buckles pusher 304 and reshapes it as 304' and deflects deflector 272 to position 272'.

[0067] In the illustrated embodiment, this actuation system, including actuator 302, pusher 304 and guides 308, 310, 312, 314 and 316 are housed in guard 320 that is positioned above rollers 282, guide wall 278 and deflector 272. In the illustrated embodiment, deflector 272 includes projection 322 which extends into a bushing hole 324 in guard 320 and another bushing hole in the base track 280 (not illustrated) to define pivot point 274.

[0068] In the illustrated embodiment, actuator 302 is a pneumatic actuator that can be maintained in neutral or actuation position without substantial additional power consumption. The only significant power consumption comes when a position is changed and air pressure is applied to switch the position of actuator 302. In some applications, Applicants have found this to be beneficial in comparison to electrical solenoid actuators that have been used in similar prior art applications past that require a continuous power draw in one position associated energy, heat generation and potential component failure.

[0069] Referring to Fig. 21 , an alternative embodiment of diverters 1 14 is illustrated with base track 281 being defined by profiled edge 326 defining ledge 328. Profiled edge 326 substantially follows the contour of guidewall 278. Base track 281 in this embodiment is substantially narrower than base track 280 illustrated in Figs. 13-19. As compared to curved edge 299, profiled edge 326 provides less support for objects already sorted into magazine 1 16. On the other hand, Applicants have found that it is easier to rotate items around 282 towards 284 which are being sorted off base track 281 as compared to base track 280, particularly when sorting pliant objects.

[0070] This disclosure serves to illustrate and describe the claimed invention to aid in the interpretation of the claims. However, this disclosure is not restrictive in character because not every embodiment covered by the claims is necessarily illustrated and described. All changes and modifications that come within the scope of the claims are desired to be protected, not just those embodiments explicitly described.

Claims

CLAIMS We claim:

1. An apparatus for sorting sortable objects, the apparatus comprising:

a transport track extending along the apparatus constructed and arranged to move sortable objects along said transport track on an edge in an upright orientation;

a magazine defining a register wall and a deck;

a support member in said magazine constructed and arranged to secure sortable objects in an upright orientation in said magazine and wherein said magazine and said support member are constructed and arranged to allow said support member to move as sortable objects are added to said magazine;

a diverter section positioned between said transport track and said magazine, said diverter including a deflector constructed and arranged to selectively interface with sortable objects traveling along said transport track to selectively divert a particular sortable object into said magazine in an upright orientation, said diverter section also including a base track and a guide wall constructed and arranged to guide sortable objects at least partially along said diverter section in an upright orientation with the edge of the sortable object supported by said base track; and

a recessed wall positioned between said register wall and said guide wall, wherein said base track defines a ledge positioned above said deck extending along said guide wall, wherein said base track and said ledge do not extend along said recessed wall and wherein said ledge, said guide wall, said recessed wall and said support member are constructed and arranged to rotate sortable objects moving on the base track off the base track such that the sortable objects drop to said deck in an upright orientation supported between said recessed wall and said support member.

2. The apparatus of claim 1 , further comprising a conveyor in said diverter section that exerts force directed toward said register wall on sortable objects traveling along said diverter section.

3. The apparatus of claim 2, wherein said conveyor incorporates a vertically oriented powered roller positioned between said guide wall and said recessed wall, wherein said vertically oriented powered roller is constructed and arranged to exert force directed toward said register wall on sortable objects traveling along said ledge while not exerting substantial force on sortable objects that are against said recessed wall but not on said ledge.

4. The apparatus of any one of the preceding claims, wherein said deck is inclined downwardly away from said base track.

5. The apparatus of any one of the preceding claims, wherein said deflector comprises a gate selectively pivotable to intersect said transport track.

6. The apparatus of claim 5, further comprising a linear actuator and a flexible pusher coupling said linear actuator to said gate, wherein actuation of said linear actuator moves said flexible pusher toward said gate, causing said flexible pusher to both buckle and to push on said gate, thereby pivoting said gate to intersect said transport track.

7. The apparatus of claim 6, further comprising a guard positioned around said flexible pusher constructed and arranged to restrain the degree of buckling of said flexible pusher during actuation of said linear actuator while permitting substantially unrestrained longitudinal movement of said flexible pusher.

8. The apparatus of claim 7, wherein said linear actuator is affixed to said guard and wherein said guard is positioned over said gate and includes a pivot point that said gate pivots about.

9. The apparatus of one of claims 7-8, wherein said flexible pusher is directly coupled to said gate in a substantially rigid connection.

10. The apparatus of one of claims 7-9, wherein said linear actuator is a pneumatic actuator.

1 1 . An apparatus for use in a conveyor system for switching from a transport track to a diverter track, the apparatus comprising:

a gate constructed and arranged to pivot to selectively intersect the transport track;

a linear actuator;

a flexible pusher coupling said linear actuator to said gate, wherein actuation of said linear actuator moves said flexible pusher toward said gate, causing said flexible pusher to both buckle and to push on said gate, thereby pivoting said gate to intersect the transport track.

12. The apparatus of claim 1 1 , further comprising a guard positioned around said flexible pusher that is constructed and arranged to restrain the degree of buckling of said flexible pusher during actuation of said linear actuator while permitting substantially unrestrained longitudinal movement of said flexible pusher.

13. The apparatus of claim 12, wherein said linear actuator is affixed to said guard.

14. The apparatus of claim 12, wherein said guard is positioned over said gate and includes a pivot point that said gate pivots about.

15. The apparatus of any one of the preceding claims, wherein said linear actuator is a pneumatic actuator.

16. The apparatus of any one of the preceding claims, wherein the transport track moves sortable objects along the transport track on an edge in an upright orientation.

17. The apparatus of any one of the preceding claims, wherein said flexible pusher is rigidly coupled to said gate and wherein said flexible pusher is constructed and arranged such that a portion of said flexible pusher proximate to said gate does not substantially bend relative to either the flexible pusher or the gate when said flexible pusher pushes on said gate.

18. A singulator comprising:

a pick-off conveyor including first and second grip surfaces separated by an opening therebetween;

a singulator comb including a plurality of resilient projections that extend toward said pick-off conveyor and reside near both the first and second grip surfaces and extend into the opening between the first and second grip surfaces.

19. The singulator of claim 18, wherein said plurality of resilient projections are oriented substantially normally with respect to the portion of said pick-off conveyor most proximate to said resilient projections.

20. The singulator of any one of the preceding claims, wherein said plurality of resilient projections are constructed and arranged to collectively bar passage of more than one object at a time along the length of said pick-off conveyor.

21 . An image capture module for use with a conveyor system, the image capture module comprising:

a conveyor constructed and arranged to convey objects across the image capture module;

a first roller, wherein the first roller is substantially rigid;

a second roller, wherein the second roller is substantially compliant and wherein the first and second rollers define a pinch point that objects conveyed by the conveyor pass through; and

a digital camera focused on an imaging line segment positioned proximate to the pinch point and along a plane congruent with the first roller.

22. The image capture module of claim 21 , further comprising a light source focused on the imaging line segment and incident from a side opposite the first roller.

23. The image capture module of claim 22, wherein the light path entering the digital camera is incident on the imaging line segment from the side opposite the first roller.

24. The image capture module of claim 23, wherein an angle between the light path entering the digital camera from the imaging line segment and the light path from the light source incident on the imaging line segment is no greater than 40 degrees.

25. The image capture module of claim 23, wherein an angle between the light path entering the digital camera from the imaging line segment and the light path from the light source incident on the imaging line segment is no greater than 30 degrees.

26. The image capture module of claim 22, wherein the digital camera and the light source are arranged such that the light path of reflections off the object from the light source are substantially never incident on the light path entering the digital camera.

27. The image capture module of any one of the preceding claims, further comprising a mirror, wherein the light path entering the digital camera is oriented substantially parallel to the conveyor and wherein the mirror is constructed and arranged to direct a reflection of the imaging line segment toward the digital camera.

28. The image capture module of claim 27, wherein the mirror is angled to reflect the image of the line segment approximately 60 degrees toward the digital camera.

29. The image capture module of any one of the preceding claims, wherein the conveyor comprises a base conveyor and a plurality of guides constructed and arranged to move objects on edge in an upright orientation.

30. An apparatus for sorting sortable objects, the apparatus comprising:

an image capture station constructed and arranged to capture address indicia on the sortable objects;

an electronic processor constructed and arranged to interpret the detected indicia and to determine a sort destination;

a first printer station constructed and arranged to apply a sort indicia on the sortable objects, wherein the sort indicia is based on the sort destination;

a verification station constructed and arranged to capture the sort indicia, wherein the electronic processor is constructed and arranged to compare the captured sort indicia with the applied sort indicia to verify the applied sort indicia; a transport track extending along the apparatus constructed and arranged to move sortable objects from the image capture station to the first printer station and then to the verification station;

a first bend in the transport track that subtends a first arc greater than π radians, wherein the first bend is positioned between the image capture station and the first printer station; and

a second bend in the transport track that subtends a second arc greater than π radians, wherein the second bend is positioned between the first printer station and the verification station.

31 . The apparatus of claim 30, wherein the first arc and the second arc are substantially equal.

32. The apparatus of claim 31 , wherein the first arc and the second arc are equal to approximately 1 .2 π radians.

33. The apparatus of any one of the preceding claims, wherein the transport track is constructed and arranged to transport objects on an edge in an upright orientation.

34. A magazine for receiving sortable objects, the magazine comprising:

a register wall;

a deck;

a base track positioned above said deck;

a guide wall constructed and arranged to guide sortable objects at least partially along said base track section in an upright orientation with an edge of the sortable object supported by said base track;

a support member in said magazine constructed and arranged to secure sortable objects in an upright orientation in said magazine and wherein said magazine and said support member are constructed and arranged to allow said support member to move as objects are added to said magazine; and

a recessed wall positioned between said register wall and said guide wall, wherein said base track defines a ledge positioned above said deck extending along said guide wall, wherein said base track and said ledge do not extend along said recessed wall and wherein said ledge, said guide wall, said recessed wall and said support member are constructed and arranged to rotate sortable objects moving on the base track off the base track such that the sortable objects drop to said deck in an upright orientation supported between said recessed wall and said support member.

35. The apparatus of claim 34, wherein said deck is inclined downwardly away from said base track.