Visual Guidance for Manual Mail Merging
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Solution Overview
Problem
Current methods for manually merging non-mechanizable postal items with machine-sorted mail in the preparation of a postman's round are inefficient in terms of cost, time, and workspace usage, as they require complex equipment and operator intervention without adequate ergonomic assistance.
Innovation Solution
A device comprising a merging table, two cameras, and a control/command unit with a display screen that provides visual guidance for the operator to insert non-mechanizable postal items into a sorted stack, using one camera to image the item and another to view the stack from the operator's perspective, with augmented reality integration as an option, to simplify and streamline the merging process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual merging is performed without visual assistance, then equipment complexity is reduced, but operator efficiency and accuracy deteriorate
Solution Approach 1:
The system creates a digital copy (image) of the physical mail stack and displays it on a screen, allowing the operator to see the insertion position without physically searching through the stack. This optical copy resolves the contradiction by providing visual assistance while keeping the physical merging process simple.
Solution Approach 2:
The display screen acts as an intermediary between the mail sorting system and the operator, translating the complex task of finding insertion positions into simple visual cues. This mediator resolves the contradiction by enhancing operator efficiency without requiring complex mechanical assistance.
2Ease of operation
If the display screen is positioned away from the mail stack, then operator comfort is improved, but visual alignment and accuracy deteriorate
Solution Approach 1:
Instead of requiring the operator to view the physical stack directly, the system displays a digital copy of the stack on a screen positioned for comfortable viewing. The digital copy maintains spatial relationships and visual cues, resolving the contradiction between comfort and accuracy.
Solution Approach 2:
The system transitions from two-dimensional physical stack viewing to a different dimensional viewing experience through the display screen, allowing the operator to view the stack from an optimized perspective that balances comfort and accuracy.
3Manufacturing precision
If multiple cameras and display screens are added to assist merging, then merging accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The camera system serves multiple functions: capturing the mail stack image, determining insertion positions, and providing visual feedback. This multi-functionality resolves the contradiction by achieving high accuracy while limiting the increase in device complexity through versatile component usage.
Solution Approach 2:
The system implements a feedback loop where the camera captures the stack, the control unit processes the image to determine insertion positions, and the display provides visual feedback to the operator. This feedback mechanism resolves the contradiction by achieving high accuracy through information processing rather than mechanical complexity.
4Loss of time
If the operator must scan through the mail stack to find insertion positions, then time consumption increases, but equipment simplicity is maintained
Solution Approach 1:
The digital image of the mail stack displayed on the screen allows the operator to quickly identify insertion positions without physically scanning through the stack. This optical copy resolves the time loss by providing immediate visual information while maintaining operational simplicity.
Solution Approach 2:
The system performs preliminary action by capturing the mail stack image and processing it to identify insertion positions before the operator begins merging. This advance preparation resolves the time loss by providing ready-to-use visual information.
Data Source
Figure 1
AI summary
The invention relates to a device (1) for assisting with the merging of postal objects (2) into a stack of mail items (3) that have already been sorted according to a certain sequence, including a merging table (5) capable of storing the stack of mail items on edge, a first camera (8) capable of forming a digital image of a current postal object to be merged into the stack of mail items, a second camera (11) which observes the stack of mail items as an operator placed at one end (5A) of the merging table, and a control and command unit (13) having a display screen (10) which is placed at the end (5A) of the merging table.