Method for optimally loading objects into storage/transport containers

• US 8,556,260 B2
• Filed: 05/26/2006
• Issued: 10/15/2013
• Est. Priority Date: 05/26/2006
• Status: Active Grant

• Current Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Original Assignee: Lockheed Martin Corporation (Martin Marietta Corporation)
• Inventors: Stemmle, Denis J.
• Primary Examiner(s): CICCHINO, PATRICK D
• Application Number:
  US11/441,988
• Publication Number:
  US 20070273086A1
• Time in Patent Office: 2,699 Days
• Field of Search: 271/3.15, 271/265.04, 271/176, 271/262, 271/263
• US Class Current: 271/265.04
• 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;

stacking objects in the container based on the overfill condition,

wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the object,

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, and

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.

2. The method according to claim 1 wherein displacement of the arm is measured by an optical sensing device.

3. The method according to claim 1 wherein displacement of the arm is measured by a rotary transducer.

4. 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,

wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the mailpiece,

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, and

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.

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

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

7. The method according to claim 4 further comprising the step of assigning a unique identifier in connection with each mailpiece.

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

measuring thickness dimensions of each object at a plurality of predetermined locations, wherein the measuring the thickness dimensions includes measuring multiple thickness measurements across a plurality of same points along an entire length for the each object to produce an array of thickness dimensions for the each object at the same points;

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;

stacking objects in the container based on the overfill condition; and

storing the array of thickness dimensions for the each of the plurality of objects as measured at the plurality of same points for the each object.

9. The method according to claim 8 wherein the summing the respective thickness dimensions comprises summing each of the thickness dimensions as measured at each same point for the each of the plurality of objects.

10. The method according to claim 9 further comprising the steps of coordinating the spatial relationship and movement of the objects with a thickness measurement device to ensure that the thickness dimensions are measured at the plurality of same points along an entire length for the each object.

11. The method according to claim 9 wherein the comparing the maximum thickness value to a maximum fill value for each container to determine an overfill condition comprising comparing each of the summed dimensions as measured at each same point for the each of the plurality of objects to the maximum fill value for each container.