Material or article handling – Device for emptying portable receptacle
Reexamination Certificate
1999-09-28
2001-02-20
Bratlie, Steven A. (Department: 3652)
Material or article handling
Device for emptying portable receptacle
C414S403000, C414S419000, C414S421000, C414S810000, C250S221000
Reexamination Certificate
active
06190110
ABSTRACT:
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates to mail processing, and more particularly, to an image processing system which first verifies the alignment of a bulk mail container to a conveyance moving the mail to an unloading site at which the container is emptied and then, second, determines that the container is either empty and so can be removed from the unloading site, or detects leftover (residual) mail remaining in a container for the container to again be emptied in an attempt to remove the residual mail pieces.
A substantial amount of mail is bulk shipped. That is, a large volume of mail, advertising pieces, for example, is identical except for the name of the addressee to whom it is being sent. Such mailings are placed in large containers for delivery to bulk mail centers operated by the Postal Service and at which the mail is processed. Currently, a manual process is employed at these centers to unload the containers so the pieces can be processed for delivery. Automating this process would both reduce the time and costs of processing bulk mailings. However, automation creates other problems which must be resolved for successful implementation.
An automated system would involve placing bulk mail containers on a conveyor with the containers being conveyed from a loading station to an emptying (dumping) site at which the bulk mail containers are tipped over or inverted. After unloading, the bulk mail containers are moved back onto the conveyor system for transport to another station where they are removed for their next usage. Two problems arise in implementing this system.
First, a container must be properly realigned with the conveyor on which it travels so as to readily move through the system, and particularly that it be oriented with respect to a dumping mechanism used to empty the container of its contents. It will be understood that there are a number of different size containers (approximately seven) which the system must accommodate. The system must therefor insure that regardless of the bulk shipping container employed, it is aligned with the conveyor system prior to moving the container along the conveyor. Otherwise, the containers will move properly along the conveyor, jams will occur, containers may be improperly dumped, etc.
Second is insuring that when the container is emptied, all of the mail pieces have fallen from the container and there are no “residual” mail pieces left in the container. Recognizing the presence of residual mail pieces allows enables the container to be kept in place so the residual pieces of mail can be removed, rather than the container being automatically moved away from the unloading site. All pieces of mail will therefore be kept in the system and delivered, and no pieces will be lost. Even if a container must be emptied by hand, the system will require much less manual labor since each container is remotely inspected and those containers having residuals readily identified. As described hereinafter, however, the system attempts to dump these pieces from these containers automatically so substantially no manual labor is required.
BRIEF SUMMARY OF THE INVENTION
Among the several objects of the present invention may be noted the provision of a bulk mail processing system and an imaging system for use therewith to check alignment of containers with a conveyor and to determine if bulk mail containers are completely unloaded after dumping or if residual pieces of mail remain therein;
the provision of such a bulk mail processing system to facilitate processing of bulk mail and thereby reduce the cost of its processing and delivery and of the imaging system to enhance the system's operational efficiency;
the provision of such a system to first view bulk mail containers placed on a conveyor to verify their alignment with the conveyor;
the provision of such an image processing system to later view an emptied container to determine that no mail is left in it; or, if there is residual mail left in the container, that the container is re-emptied to remove the residual mail pieces;
the provision of the image processing system to use a pair of cameras to obtain an image of a “loaded” container when it is first placed on the conveyor, and of the “unloaded” container after it has been emptied;
the provision of such an image processing system to simultaneously monitor a plurality of conveyor lines over which bulk mail containers are conveyed;
the provision of such an image processing to provide “real time” residual mail and container alignment information to a controller for the conveyor system so that bulk mail containers are properly routed through the system; and,
the provision of such an image processing system to use “off the shelf” components whereby the system is not only low in cost, but is readily expandable as more bulk processing conveyor lines are implement at a processing center.
In accordance with the invention, generally stated, a bulk mail processing system conveys bulk mail containers from a receiving station at which the container is placed on the conveyor to a station at which the contents of the container are emptied. Apparatus for monitoring the container comprises a video camera or other means for viewing the container and the its contents. A first camera obtains an image of the container when placed on the conveyor at the receiving station. The resulting image is processed to determine proper alignment of the container with the conveyor. A second camera obtains an image of the container after it has been emptied to determine if the container is completely empty, or if it contains residual pieces of mail. The respective images obtained by the cameras are transmitted to a processor which processes the images to determine alignment and verify if the container is empty or not. An unloading mechanism at the emptying station first removes the container from the conveyor, inverts the container for its contents to spill out, returns the container back to its upright position, and replaces the conveyor back onto the conveyor. A controller for the mechanism is responsive to an input from the processor that all the contents of a container have been emptied to have the mechanism replace the empty container on the conveyor. However, the controller is further responsive to an input from the processor that there is residual mail left in the container to re-invert the container to empty the remaining contents of the container so the container is completely empty before being returned to the conveyor. Other objects and features will be in part apparent and in part pointed out hereinafter.
REFERENCES:
patent: 5610584 (1997-03-01), Schrade
patent: 5801764 (1998-09-01), Koizumi et al.
patent: 19509631 (1996-09-01), None
patent: 562688 (1993-09-01), None
Hobson Gregory
Stanley R. Joe
Waldman Gary
Wootton John R.
Bratlie Steven A.
Polster Lieder Woodruff & Lucchesi L.C.
Systems & Electronics, Inc.
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