Flats bundle processing system
First Claim
1. A system for processing mail, comprising:
- a packing mechanism for packaging flats into one or more bundles;
a stacking mechanism for stacking the one or more bundles onto one or more pallets in a first sequence based on bundle information;
a de-stacking mechanism for breaking down the one or more pallets in a second sequence based on the bundle information;
a transport system for transporting the one or more pallets from the stacking mechanism to the de-stacking mechanism; and
a controller for controlling at least one of (i) the stacking mechanism to load each of the one or more bundles in the first sequence based on at least bundle information and (ii) the de-stacking mechanism to unload each of the one or more bundles in the second sequence based on at least the bundle information.
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Accused Products
Abstract
A processing system for automating the packaging, packing, unpacking, transfer/short term storage and loading of flats mail into flats sorters for sortation is disclosed. This involves bundling flats mail into bundles or logs and creating pallets for transporting in a standardized manner at mailer facilities such as publishers so that the sort depth and final destination of the bundle contents are preserved and used throughout its journey through postal facilities. Sort depth and destination bar coding is placed on each bundle. An automated method for palletizing involves creating a stack of bundles on a pallet in a predetermined sequence so that sorting processes in the postal facility become more efficient. Once the pallets are received at the postal facilities, the pallets are broken down in a pre-determined sequence in accordance with the sequence of original creation. The bundles are scanned into the sorter processes of the postal facility where the scanned information concerning destination codes and sort depth facilitates or eliminates routing and sorting within the postal facility, thereby reducing overhead and costs. A system to create pallets using both robotic and conveyor mechanisms is disclosed.
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Citations
27 Claims
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1. A system for processing mail, comprising:
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a packing mechanism for packaging flats into one or more bundles;
a stacking mechanism for stacking the one or more bundles onto one or more pallets in a first sequence based on bundle information;
a de-stacking mechanism for breaking down the one or more pallets in a second sequence based on the bundle information;
a transport system for transporting the one or more pallets from the stacking mechanism to the de-stacking mechanism; and
a controller for controlling at least one of (i) the stacking mechanism to load each of the one or more bundles in the first sequence based on at least bundle information and (ii) the de-stacking mechanism to unload each of the one or more bundles in the second sequence based on at least the bundle information. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A control system for controlling a mechanism for stacking one or more bundles onto one or more pallets, comprising:
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a first controller for storing bundle information associated with the one or more bundles;
a second controller for controlling a scanner which scans the bundle information;
a third controller for determining the availability and errant bundle information associated with the one or more bundles;
a fourth controller for controlling a moving mechanism to load each of the one or more bundles to a predetermined pallet or location based on the bundle information, availability and errant bundle information; and
a fifth controller for determining whether the pallet is full and if not determining a position of a non-filled pallet for moving a bundle of the one or more bundles. - View Dependent Claims (15, 16, 17, 18)
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19. A control system for controlling the breakdown of pallets into bundles, comprising:
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a first controller for storing bundle information associated with one or more bundles;
a second controller for controlling a scanner which scans the bundle information;
a third controller for controlling an unloading mechanism to move each of the one or more bundles to a predetermined conveyance system; and
a fourth controller for determining whether the pallet is empty and moving the pallet to an empty pallet stack. - View Dependent Claims (20)
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21. A method of processing mail, comprising the steps of:
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building bundles, wherein the bundles contain flats;
stacking the bundles onto one or more pallets according to a sequence;
transporting the one or more pallets;
breaking down the one or more pallets into bundles according to a second sequence; and
scanning the bundles to read information. - View Dependent Claims (22, 23, 24, 25, 26, 27)
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Specification