On-Press Mail Sorting Controller and Stacking Device
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Solution Overview
Problem
Current mail sorting systems on printing presses require multiple workers to manage high output volumes and struggle with efficient batch separation, as they rely on manual identification and separation of bundle and tray breaks, which is labor-intensive and prone to errors.
Innovation Solution
Implementing an on-press sorting system that uses a controller to direct a stacking device to create batch separation points among mail pieces, converting shingled streams into batches of stacked mail pieces belonging to common groups, and incorporating automated diverters to remove defective or sample pieces from the stream, thereby reducing labor and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual identification and separation of bundle and tray breaks is used, then workers can handle mail pieces, but labor requirements increase and errors occur
Solution Approach 1:
The patent replaces manual mechanical sorting operations with an automated control system that uses sensors to detect batch separation points and controls diverters to automatically separate mail piece batches. The controller system substitutes human workers' manual identification and separation tasks, achieving higher throughput and eliminating labor-related errors while maintaining proper batch grouping.
2Productivity
If automated sorting system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The controller system serves multiple functions: it controls variable information printing, manages batch separation point identification through sensors, operates diverters for batch separation, and coordinates with the stacking device. By consolidating these diverse functions into a single multi-functional controller, the system achieves high productivity without proportionally increasing overall system complexity.
3Productivity
If batch separation points are not clearly identified, then mail pieces can be continuously processed, but sorting accuracy decreases
Solution Approach 1:
The system employs sensors that detect batch separation points and provide feedback to the controller. The controller uses this feedback information to precisely control the diverters, ensuring accurate batch separation while maintaining continuous processing. The feedback loop enables the system to identify and respond to batch boundaries in real-time, achieving both high productivity and high sorting accuracy.
Data Source
AI summary
A method includes creating a stream of uniquely-addressed mail pieces on a web offset press by printing on sections of a web, separating the sections of the web, and printing unique address information on each section of the press-printed material. The unique address is printed by a variable printer according to a mail file of intended recipients. The stream of uniquely-addressed mail pieces is conveyed in a shingled formation. An on-press conversion of the stream of uniquely-addressed mail pieces into a plurality of batches of stacked mail pieces is performed, each batch containing only mail pieces belonging to a common mail delivery group. The on-press conversion includes controlling via the controller the creation of batch separation points among the mail pieces according to the mail file, conveying the stream of mail pieces in the shingled formation into a stacking device, and stacking the mail pieces with the stacking device.