Mail Carrier Sequencer Single-Pass DPS Sorting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current mail processing systems, such as the FSS, require multiple passes and are plagued by inefficiencies, machine downtime, and labor-intensive manual sorting, failing to effectively sequence flat mail into delivery point sequence (DPS) order efficiently.
Innovation Solution
A single-pass delivery point sequencing system, the Flats Carrier Sequencer (FCSR), which can be retrofitted onto existing sorters like the AFSM-100, uses a Random-In-Sequenced-Out (RISO) assembly, BinBot module, and programmable controller to process mail from random order to DPS order, eliminating the need for staging and conveyor handling, thereby reducing size and cost while increasing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dual pass sort technique is used to sequence flat mail, then the mail can be sorted by ZIP code first and then resequenced according to DPS, but the system experiences machine downtime, late deliveries, and requires complex staging equipment
Solution Approach 1:
The system divides the mail processing into discrete segments handled by individual robotic arms, each responsible for specific receptacles. The mail path is segmented into multiple independent stations rather than a single complex conveyor system, allowing parallel processing and reducing overall system complexity.
Solution Approach 2:
The patent introduces robotic arms as intermediary devices between the mail input and final sequencing output. These robotic arms act as flexible mediators that can adapt to different mail volumes and sequencing requirements without requiring complex mechanical reconfiguration of the entire system.
2Manufacturing precision
If manual DPS casing is used to organize mail into delivery point sequence, then the mail can be sorted accurately, but the process is time and labor intensive
Solution Approach 1:
The system enables self-service automation where robotic arms automatically perform the sequencing task that previously required human carriers. The programmable controller manages the entire process autonomously, reading mail information and directing robotic arms to place mail in correct receptacles without human intervention.
Solution Approach 2:
The patent replaces the mechanical manual sorting process with an automated robotic system controlled by programmable logic. Instead of human carriers physically handling and sorting mail, electronic control systems direct robotic arms to perform the same function with greater speed and consistency.
3Productivity
If automated flat sorting machines like AFSM-100 are deployed to process mail, then throughput increases to over 16,000 flats per hour, but the machines can only perform primary sort by ZIP code and require additional equipment for DPS processing
Solution Approach 1:
The robotic arm system is designed to perform multiple functions: it can sort mail by ZIP code, resequence by DPS, and adapt to different mail volumes and routes. This multi-functional approach eliminates the need for separate dedicated equipment for each sorting task, reducing overall system complexity while maintaining high throughput.
Solution Approach 2:
The system incorporates dynamic adaptability where the programmable controller can adjust sorting parameters, receptacle assignments, and robotic arm trajectories based on real-time mail volume and destination requirements. This dynamic flexibility allows the same equipment to handle various sorting scenarios without mechanical reconfiguration.
4Extent of automation
If FSS is introduced to automate sequencing with $1.4 billion investment, then labor costs are reduced, but the system is plagued by machine downtime and requires extensive staging equipment
Solution Approach 1:
The patent implements a nested structure where robotic arms operate within a compact framework of receptacles and mail handling stations. The system nests multiple functional elements (sorting, sequencing, transport) within a unified space, eliminating the need for extensive external staging equipment and reducing machine footprint while improving reliability.
Data Source
AI summary
A mail sortation system that can process mail, either letter or flat, from random order to delivery point sequence (DPS) order, in a single sortation pass. The system has a first sortation assembly comprising a plurality of individual open-topped receptacles into which mail is received, each receptacle having a trap door for selectively dumping its contents. A second sortation assembly comprises a linearly-translating conveyor positioned beneath the first sortation assembly, and an open topped bin travels along the conveyor to gather mail from the first assembly in a DPS sequence. A third sortation assembly comprises a linearly-translating conveyor arranged parallel to and directly beneath the second sortation assembly, and a plurality of mail bins mounted atop for receiving DPS-sorted batches from the second assembly.