Coupon sorting system and method of sorting coupons

• US 5,819,954 A
• Filed: 09/29/1993
• Issued: 10/13/1998
• Est. Priority Date: 09/29/1993
• Status: Expired due to Fees

• Current Assignee: Ralphs Grocery Company (Kroger Company)
• Original Assignee: Ralphs Grocery Company (Kroger Company)
• Inventors: Lacriola, John Michael
• Primary Examiner(s): Nguyen, Tuan N.
• Application Number:
  US08/128,976
• Time in Patent Office: 1,840 Days
• Field of Search: 209/559, 209/563, 209/576, 209/577, 209/583, 209/643, 209/644, 209/900, 209/917, 198/349, 198/349.95, 198/367, 198/502.3, 198/813, 198/814, 414/744.2, 414/797
• US Class Current: 209/563
• CPC Class Codes: B07C 5/3412 according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication sorting according to size measured by light-responsive means B07C5/10; sorting according to optical properties B07C5/342; for packages B65D79/02; for information carriers G06K7/00
• CPC Class Codes: B07C 5/365 using a single separation means
• CPC Class Codes: B65H 29/18 and introducing into a pile
• CPC Class Codes: B65H 29/58 Article switches or diverters
• CPC Class Codes: B65H 3/0808 Suction grippers
• CPC Class Codes: Y10S 209/90 Sorting flat-type mail

Abstract

A system for sorting coupons according to information contained within bar codes or similar markings printed thereon. The system includes a storage bin in which the coupons are received and from which they are removed one at a time. A coupon picker removes the coupon from the storage bin and deposits it upon a conveyor belt at a loading station. The information contained on the coupon is read by an appropriate scanner which ascertains through the use of an appropriate data processing system the address of a receiving bin in which the coupon is to be deposited. The position of the coupon on the conveyor belt is tracked and when the coupon arrives at the address of the receiving bin an air jet is activated to propel the coupon from the conveyor belt into the receiving bin.

Claims

1. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on the top of said stack exposed;

Retaining means engaging said top sheet and applying a force on said stacked sheets to retain said sheets in said hopper but allowing removal of the top sheet therefrom;

A plurality of destination bins,

A conveyor belt means divided into a plurality of pocket-like areas for transporting each of said sheets from a loading station to a predetermined one of said plurality of destination bins;

A picker means for removing said top sheet from said hopper and depositing it in a pocket-like area on said conveyor belt means at said loading station;

Reader means for scanning said top sheet to read the indicia thereon and developing a first signal identifying said predetermined one of said destination bins as determined by said indicia in which said sheet is to be deposited;

Means for determining the distance between said loading station and said predetermined one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said predetermined one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said pocket in said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

2. An automatic retail store coupon sorter system as defined in claim 1 wherein said picker means includes a plurality of arms, each attached at one end to a central member and having a pick-up means affixed to the other end thereof.

3. An automatic retail store coupon sorter system as defined in claim 2 which further includes first drive means coupled to said central member for rotating said pick-up means past said exposed top coupon.

4. An automatic retail store coupon sorter system as defined in claim 3 wherein said pick-up means includes a suction cup and said system further includes means for applying a vacuum to each said suction cup only during the time each said suction cup moves from a point preceding said top coupon to said loading station and for releasing said vacuum at said loading station.

5. An automatic retail store coupon sorter system as defined in claim 4 wherein said system further includes means for momentarily applying gas under pressure to each said suction cup at said loading station after said vacuum is released therefrom.

6. An automatic sorter system for sorting sheets of material having identifying indicia thereon as defined in claim 1 wherein said continuous conveyor belt includes an outer surface, a plurality of spaced apart outwardly directed members extending from said outer surface of said conveyor belt thereby dividing said conveyor belt means into said plurality of pocket-like areas.

7. An automatic sorter system for sorting sheets of material having identifying indicia thereon as defined in claim 6 wherein said tracking means includes a photoelectric cell disposed adjacent said outer surface of said conveyor belt and adapted to provide a signal as each said outwardly extending member passes said photocell.

8. An automatic sorter system for sorting sheets of material having identifying indicia thereon as defined in claim 7 wherein said reader means is disposed over said conveyor belt means downstream from said loading station.

9. An automatic sorter system for sorting sheets of material having identifying indicia thereon as defined in claim 8 wherein said reader means includes first and second optical scanners.

10. An automatic sorter system for sorting sheets of material having identifying indicia thereon as defined in claim 1 wherein said blower means includes a plurality of nozzle means each disposed to direct an air jet across said conveyor belt means toward one of said plurality of predetermined destination bins, said nozzle means being intermittently operative only in response to said second signal.

11. The method of automatically sorting sheets of material having indicia thereon comprising the steps of:

Storing sheets of said material in a storage area;

Removing sheets one at a time from said storage area;

Depositing each said sheet after its removal on a conveyor belt having a surface divided into a plurality of pocket-like areas by members extending outwardly from said surface at a loading station disposed remote from said storage area;

Reading each said sheet to ascertain information therefrom;

Identifying from such information a predetermined address of a receiving bin into which such sheet is to be placed;

Tracking the position of said sheet on said belt by counting each said outwardly extending member to determine when said sheet arrives at said address of said receiving bin; and

Activating an air jet to propel the sheet from said belt into said receiving bin.

12. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

A central member;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station, said picker means including a plurality of arms, each attached at one end to a said central member and having a pick-up means including a suction cup affixed to the other end thereof;

First drive means coupled to said central member for rotating said pick-up means past said exposed top sheet;

Means for applying a vacuum to each said suction cup only during the time each said suction cup moves from a point preceding said top sheet to said loading station and for releasing said vacuum at said loading station, said means for applying a vacuum including a first stationary plate defining a channel therein, a source of vacuum, means coupling said source of vacuum to said channel, and a rotating plate having a plurality of openings therethrough disposed such that a portion of said openings register with said channel as said rotating plate is rotated,

Reader means for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

13. An automatic retail store coupon sorter system as defined in claim 12 wherein each of said plurality of arms is attached to said rotating plate.

14. An automatic retail store coupon sorter system as defined in claim 13 wherein said suction cup on each of said arms is connected to said opening in said rotating plate which registers with said channel to thereby apply vacuum to said suction cup.

15. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet coupon on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station, said picker means including a plurality of arms each attached at one end to a central member and having a pick-up means affixed to the other end thereof;

Means defining a camming surface disposed so that said arms ride upon said camming surface;

Reader means for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

16. An automatic retail store coupon sorter system as defined in claim 15 wherein said camming surface includes first and second depressed surfaces, one of said depressed surfaces being disposed adjacent said hopper and the other of said depressed surfaces being disposed adjacent said loading station.

17. An automatic retail store coupon sorter system as defined in claim 16 wherein each said arm as it traverses said first depressed camming surface causes the suction cup thereon to engage a coupon in said hopper and to remove the top most coupon therefrom.

18. An automatic retail store coupon sorter system as defined in claim 17 wherein as each said arm traverses said second depressed cam surface the suction cup affixed thereto moves so as to position the coupon held by the suction cup immediately over said loading station.

19. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins, A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station, said picker means including a plurality of arms, each attached at one end to a central member and having a pick-up means affixed to the other end thereof;

A variable speed direct current motor, means coupling said motor to said picker means and means for controlling the speed of said variable speed DC motor;

Said coupling means including a gear box connected to said direct current motor, a shaft which is rotated by said gear box, and a rod connected to said picker means for rotating said arms, said rod being coupled to said shaft by a key and a keyway;

Reader means for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

20. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station;

Said picker means including a plurality of arms, each attached at one end to a central member and having a pick-up means affixed to the other end thereof;

A variable speed direct current motor, means coupling said motor to said picker means and means for controlling the speed of said variable speed DC motor;

First and second proximity switches disposed such that adjacent arms of said plurality of arms can simultaneously activate said proximity switches, means for determining the speed of travel of said conveyor belt means, lack of coincidence between activation of said proximity switches and the speed indication of said conveyor belt means generating a signal for changing the speed of said variable speed direct current motor;

Reader means for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to to said second signal.

21. An automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

Said conveyor belt means including an elongated support means having a roller at each end thereof, a stationary support means having a flat surface disposed adjacent each said roller and extending therebetween, and a continuous conveyor belt engaging each of said rollers and said flat surface of said support means;

Said support means defining a V-shaped groove therein and said belt including a V-shaped protrusion extending therefrom, said protrusion riding within said groove;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station;

Reader means for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

22. An automatic retail sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

Said conveyor belt means including an elongated support means having a roller at each end thereof, a stationary support means having a flat surface disposed adjacent each said roller and extending therebetween, and a continuous conveyor belt engaging each of said rollers and said flat surface of said support means, said continuous conveyor belt including an outer surface, a plurality of spaced apart outwardly directed members extending from said outer surface of said conveyor belt thereby dividing said conveyor belt into a number of pocket-like areas;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station;

Reader means including first and second optical scanners for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

Third optical scanner disposed between said hopper means and said loading station and adapted to read a lower surface of said sheet;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal.

23. A automatic sorter system for sorting sheets of material having identifying indicia thereon comprising:

A hopper for storing a plurality of said sheets stacked one upon the other in random order with a top sheet on top of said stack exposed;

A plurality of destination bins,

A conveyor belt means for transporting each of said sheets from a loading station to one of said plurality of destination bins;

Said conveyor belt means including an elongated support means having a roller at each end thereof, a stationary support means having a flat surface disposed adjacent each said roller and extending therebetween, and a continuous conveyor belt engaging each of said rollers and said flat surface of said support means, said continuous conveyor belt including an outer surface, a plurality of spaced apart outwardly directed members extending from said outer surface of said conveyor belt thereby dividing said conveyor belt into a number of pocket-like areas;

A picker means for removing said top sheet from said hopper and depositing it on said conveyor belt means at said loading station;

Reader means including first and second optical scanners for scanning said top sheet and developing a first signal identifying one of said destination bins in which said top sheet is to be deposited;

A third optical scanner disposed between said hopper means and said loading station and adapted to read a lower surface of said sheet;

Means for determining the distance between said loading station and said one of said destination bins;

Tracking means associated with said conveyor belt means for determining when said top sheet has been moved by said conveyor belt means from said loading station to said one of said destination bins and for developing a second signal indicative thereof;

Blower means including a nozzle for removing said top sheet from said conveyor belt and depositing it in said one of said destination bins; and

Means for activating said blower means responsive to said second signal, said means for activating said blower means including an electrically operated solenoid connected to said nozzle, said solenoid being electrically activated only when said second signal is generated.