Method for optimally loading objects into storage/transport containers

• US 20070273086A1
• Filed: 05/26/2006
• Published: 11/29/2007
• Est. Priority Date: 05/26/2006
• Status: Active Grant

• Current Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Original Assignee: Pitney Bowes Incorporated (Böwe Systec AG)
• Inventors: Stemmle, Denis J.
• Granted Patent: US 8,556,260 B2
• Time in Patent Office: Days
• US Class Current: 271/176
• CPC Class Codes: B07C 3/02 Apparatus characterised by the means used for distribution
• CPC Class Codes: B65H 2220/01 indicating an entity as a function of which control, adjustment or change is performed, i.e. input
• CPC Class Codes: B65H 2220/03 indicating an entity which is measured, estimated, evaluated, calculated or determined but which does not constitute an entity which is adjusted or changed by the control process per se
• CPC Class Codes: B65H 2301/422548 filling or loading process
• CPC Class Codes: B65H 2511/13 Thickness
• CPC Class Codes: B65H 2511/15 Height, e.g. of stack
• CPC Class Codes: B65H 43/06 detecting, or responding to, completion of pile B65H43/08 takes precedence

Abstract

A method for stacking objects in a container including the step of measuring a thickness value of each object at a plurality of predetermined locations along a face surface of the respective object. A cumulative thickness profile is developed indicative of a plurality of stacked objects, i.e., juxtaposed along each face surface. The cumulative thickness profile is, furthermore, calculated by summing each of the measured thickness dimensions at each of the predetermined locations. Next, a maximum thickness value is determined as each of the objects is measured and compared to a maximum fill value for each container to determine an overfill condition/number. The overfill condition corresponds to the number of objects which additively cause the maximum thickness value to exceed the maximum fill value. The objects may then be stacked based upon the overfill condition such that the total number of objects is less than the number corresponding to the overfill condition. The method facilitates optimum stacking of objects wherein at least one object has an irregular shape or non-uniform thickness profile.

Claims

1. A method for stacking objects in a container, comprising the steps of:

measuring thickness dimensions of each object at a plurality of predetermined locations;

calculating a cumulative thickness profile of a plurality of stacked objects, the cumulative thickness profile being developed by summing the respective thickness dimensions of each object at each of the predetermined locations;

determining a maximum thickness value from the cumulative thickness profile in connection with the thickness dimensions at each of the plurality of predetermined locations;

comparing the maximum thickness value to a maximum fill value for each container to determine an overfill condition; and

stacking objects in the container based on the overfill condition.

2. The method according to claim 1 further comprising the steps of:

conveying each of the objects along a transport;

coordinating the spatial relationship and movement of the objects on the transport with a thickness measurement device;

measuring the thickness dimensions at the predetermined locations as the object passes the thickness measurement device.

3. The method according to claim 1 wherein the step of measuring the thickness dimensions is performed by measuring the thickness value at a plurality of lengthwise locations along the length of the object and a plurality of widthwise locations along the width of the object to develop a thickness profile having a two dimensional array of points on the object.

4. The method according to claim 1 wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the object.

5. The method according to claim 4 wherein the step of measuring the thickness dimensions is performed by an image sensor for optically viewing an image strip disposed in combination with the displacement arm.

6. The method according to claim 5 wherein the image sensor includes a linear array of photosensitive sensors and an illumination device, wherein the image strip includes regions which absorb and reflect light energy, the regions forming an abrupt transition line which is displaced by movement of the pivot arm, and wherein the photosensitive sensors detect the movement of transition line when illuminated by the illumination device to measure the thickness of the object.

7. The method according to claim 4 wherein displacement of the arm is measured by an optical sensing device.

8. The method according to claim 4 wherein displacement of the arm is measured by a rotary transducer.

9. A method for stacking mailpieces having variable thickness characteristics in a mailpiece container/tray, comprising the steps of:

conveying mailpieces along a transport;

coordinating the spatial relationship and movement of the mailpieces on the transport with a thickness measurement device;

measuring thickness dimensions of each mailpiece at predetermined locations as the mailpiece passes the thickness measurement device;

calculating a cumulative thickness profile of a plurality of mailpieces, the cumulative thickness profile being developed by summing the respective thickness dimensions of each mailpiece at the predetermined locations;

determining a maximum thickness value from the cumulative thickness profile in connection with the thickness dimensions at each of the plurality of predetermined locations;

comparing the maximum thickness value to a maximum fill value for each mailpiece container to determine an overfill condition; and

stacking mailpieces in the mailpiece container based on the overfill condition.

10. The method according to claim 9 wherein the step of measuring the thickness dimensions is performed by measuring the thickness value at a plurality of lengthwise locations along the length of the mailpiece and a plurality of widthwise locations along the width of the object to develop a thickness profile having a two dimensional array of points on the object.

11. The method according to claim 9 wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the mailpiece.

12. The method according to claim 11 wherein the step of measuring the thickness dimensions is performed by an image sensor for optically viewing an image strip disposed in combination with the displacement arm.

13. The method according to claim 12 wherein the image sensor includes a linear array of photosensitive sensors and an illumination device, wherein the image strip includes regions which absorb and reflect light energy, the regions forming an abrupt transition line which is displaced by movement of the pivot arm, and wherein the photosensitive sensors detect the movement of transition line when illuminated by the illumination device to measure the thickness of the mailpiece.

14. The method according to claim 11 wherein displacement of the arm is measured by an optical sensing device.

15. The method according to claim 11 wherein displacement of the arm is measured by a rotary transducer.

16. The method according to claim 11 further comprising the step of assigning a unique identifier in connection with each mailpiece.

17. A method for stacking objects in a container, comprising the steps of:

measuring thickness dimensions of each object at a plurality of predetermined locations;

storing the thickness dimensions in a memory storage device;

arranging the objects in a sequence to be stacked;

calculating a cumulative thickness profile of the objects in the sequence to be stacked from the thickness dimensions stored in the memory storage device by summing the respective thickness dimensions at each of the predetermined locations of each object;

determining a maximum thickness value from the cumulative thickness profile;

comparing the maximum thickness value to a maximum fill value for each container to determine an overfill condition; and

stacking objects in the container based on the overfill condition.

18. The method according to claim 17 wherein the step of measuring the thickness dimensions is performed by measuring the thickness value at a plurality of lengthwise locations along the length of the object and a plurality of widthwise locations along the width of the object to develop a thickness profile having a two dimensional array of points on the object.

19. The method according to claim 17 wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the object.

20. The method according to claim 19 wherein the step of measuring the thickness dimensions is performed by an image sensor for optically viewing an image strip disposed in combination with the displacement arm.