Mail Sorting Conveyor Shingling Dynamics for Throughput
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Solution Overview
Problem
Mail weighing is the rate-limiting step in mail processing systems, as it requires singulated mailpieces, leading to slower throughput compared to address scanning and postage application, which can be conducted at higher speeds.
Innovation Solution
Implementing a conveyor system with adjustable belt speeds and image analysis to shingle or de-shingle mailpieces, allowing for multiple passes through the system where mailpieces can be processed in either a singulated or shingled fashion depending on the processing step, optimizing overall processing speed and footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mailpieces are singulated for weighing on the scale, then weighing accuracy is improved, but processing speed decreases
Solution Approach 1:
The system segments the mail processing into two distinct passes: first pass for accurate weighing with singulated mailpieces, and second pass for high-speed processing with shingled mailpieces. This segmentation allows each pass to be optimized for its specific function, resolving the contradiction between weighing accuracy and processing speed.
Solution Approach 2:
The conveyor system dynamically adjusts between singulated and shingled configurations based on the processing stage. The ability to switch between these two states allows the system to maintain weighing accuracy when needed while achieving high-speed processing when weighing is not required.
2Measurement precision
If mailpieces are processed in singulated fashion through the scale, then weighing precision is improved, but system footprint increases
Solution Approach 1:
The system merges the weighing function with the existing conveyor infrastructure by utilizing the same conveyor path for both singulated weighing and shingled high-speed processing. This eliminates the need for separate dedicated weighing infrastructure, thereby minimizing additional footprint while maintaining weighing precision.
Solution Approach 2:
The conveyor system is designed to perform multiple functions: it can transport singulated mailpieces for accurate weighing and shingled mailpieces for high-speed processing. This multi-functionality allows the system to achieve weighing precision without requiring additional dedicated space, thus minimizing footprint expansion.
3Productivity
If multiple scales are included to achieve high speeds, then processing speed is improved, but system complexity increases
Solution Approach 1:
The system maintains continuous high-speed processing in the second pass by keeping mailpieces shingled throughout the conveyor system, eliminating the need for multiple scales or repeated singulation events. This continuous action approach achieves high productivity while avoiding the complexity of multiple weighing devices.
Solution Approach 2:
The shingled mailpiece configuration acts as an intermediary state that allows high-speed processing without requiring multiple scales. By maintaining the shingled configuration through the conveyor system, the patent achieves high processing speeds using a single scale, thereby reducing system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables higher processing speeds by allowing mailpieces to pass through the scale in a shingled fashion when weighing is not required, significantly increasing throughput without increasing the system's footprint, while ensuring accurate weighing during necessary passes.
Implementation Method 1
A controller may utilize image analysis software to determine dimensional aspects of the mailpieces and may utilize these dimensional aspects to control the first and/or second belt speeds
Data Source
AI summary
A mail processing system utilizes a conveyor to shingle or de-shingle mailpieces as they move through the processing system and utilizes belts to move the mailpieces. A first shingling conveyor moves a first mailpiece to overlap with a second mailpiece to create shingled mailpieces. A second shingling conveyor moves a first mailpiece away from a second mailpiece to de-shingle them to create singulated mailpieces. A camera takes images of the mailpieces in the conveyor and image analysis software is used to determine dimensional aspects of the mailpieces that are used to control the belt speeds to move mailpieces with respect to each other. A mail processing system may include a mail processing station that scans addresses, applies postage and/or weighs the mailpieces. Mail may be de-shingled prior to being weighed and then re-shingled for subsequent processing, or mail may be shingled prior to passing through a scale if weighing is not necessary.