Mail Sorter Dynamic Presort Break Sorting
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Solution Overview
Problem
Current mail processing systems face inefficiencies and errors in sorting mailpieces from inserters or printers, leading to potential loss of postal discounts due to incorrect tray grouping and lack of verification, requiring a system that can dynamically sort mailpieces without a predefined scheme and ensure all pieces are accounted for.
Innovation Solution
A mail sorter system that acquires documentation data for mailpieces, dynamically generates sorting schemes, and allocates mailpieces to bins based on presort break sequences, allowing for real-time correction of errors and verification of tray contents, enabling efficient processing of up to 40,000 mailpieces per hour without pre-defined sort schemes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sweeping and tray filling is used, then operators can group mailpieces by tray, but the process is slow and introduces errors due to visual identification and sweeping mistakes
Solution Approach 1:
The patent replaces the manual mechanical sweeping and visual identification process with an automated optical scanning system. The mail sorter uses optical sensors and control systems to automatically identify mailpieces, determine their tray assignments, and direct them to the correct bins, eliminating manual sweeping errors while maintaining high processing speeds of 40-50 thousand mailpieces per hour
Solution Approach 2:
The system enables mailpieces to be automatically sorted based on their own identification information (ZIP codes, delivery points) without requiring manual intervention. The control system reads mailpiece data, compares it against the presort break sequence, and autonomously directs each mailpiece to the appropriate tray bin, making the sorting process self-correcting and highly reliable
2Adaptability or versatility
If a predefined sort scheme is used, then sorting can be controlled, but setup time increases and flexibility to correct errors is reduced
Solution Approach 1:
The patent implements a dynamic sort scheme where the sorting configuration is not fixed in advance but is generated and adjusted in real-time based on the actual mailpiece flow and presort break sequence. The control system continuously adapts the sorting parameters during operation, allowing immediate correction of grouping errors without requiring predefined schemes or extensive setup time
Solution Approach 2:
The system performs preliminary analysis of the presort break sequence and tray assignments before sorting begins. The control system pre-configures the optimal sort scheme based on the documented tray groupings, minimizing setup time while maintaining the flexibility to correct errors during the actual sorting process through real-time monitoring and adjustment
3Reliability
If multiple trays are processed manually, then all mailpieces can be grouped, but operator workload increases and throughput decreases
Solution Approach 1:
The patent replaces manual tray processing with an automated multi-bin sorting system. The mail sorter simultaneously manages multiple bins corresponding to different tray groups, using optical scanning and control systems to distribute mailpieces across all bins in parallel. This maintains presort compliance by accurately following the presort break sequence while achieving throughput of 40-50 thousand mailpieces per hour, far exceeding manual capabilities
Solution Approach 2:
The system is designed to handle multiple tray groups and presort breaks simultaneously through a single automated sorter. The control system can process different mail streams, apply different sort schemes, and manage multiple bins all at once, making the system universally applicable to various presort requirements without requiring separate manual operations for each tray group
4Ease of operation
If visual identification and manual sweeping are used, then trays can be filled, but errors occur when edge marks are missed or mail is disturbed
Solution Approach 1:
The patent replaces visual identification of edge marks with automated optical sensing. The mail sorter uses optical scanners to detect and read mailpiece information, automatically identifying the start and end of tray groups without relying on visual edge marks. This eliminates errors caused by missed edge marks or disturbed mail, while maintaining ease of operation through automated bin indication and sweeping signals
Solution Approach 2:
The system incorporates feedback mechanisms where the control system continuously monitors the sorting process, verifies mailpiece assignments against the presort break sequence, and provides real-time confirmation of correct tray groupings. This feedback loop ensures that offset mailpiece indications are accurately maintained and verified, preventing errors even when mail is temporarily disturbed during processing
Data Source
AI summary
The present subject matter relates to techniques and equipment for processing mailpieces. The mailpieces have been manufacture on a mailpiece inserter or directly from a printer The manufactured mailpieces are processed on a mail sorter to produce trays of mail that are grouped by zone improvement program. The mailpieces are sorted without a predefined sort scheme loaded on the mail sorter.