METHOD

FIELD OF THE INVENTION

This is a continuation-in-part of co-pending application Serial No. 943,862, filed September 11, 1992, which is a continuation-in-part of co-pending application Serial No. PCT/US 91/09802, filed December 27, 1991, which is a continuation-in-part of co-pending application Serial No. 634,614, filed December 27, 1990, now U.S. Patent No. 5,125,513.

The present invention relates to laundry sorting equipment, and more particularly relates to an apparatus and method for

automatically assembling garments based on associated unique identification data.

BACKGROUND OF THE INVENTION

As used herein the terms "cleaning" and "laundry" and their derivatives and counterparts refer to both dry cleaning (without water) and wet cleaning, and these terms may be used interchangeably to refer to both the act or process of washing and pressing and the things washed and the place where it is done. It is also contemplated that the method and apparatus of the present invention can be used to sort other items, such as uniforms, fabric samples, carpeting pieces, machined parts, tires, or the like. Furthermore, the present invention can be used in any industry where numerous items to be sorted can be identified by unique information and can be moved by the mechanisms of the invention. For the purpose of the present invention the items to be sorted are laundered garments hung on conventional wire hangers.

A commercial cleaner receives items to be cleaned from a number of different accounts. One account may be a large manufacturing facility with hundreds of workers, each having his or her own uniform or garment. A commercial cleaner normally cannot efficiently clean laundry or other items by handling items on a single account basis. The cleaning process is more efficient when the full capacity of machines is used possibly requiring several accounts' items to be grouped together for cleaning. Thus, items from several accounts may be mixed and cleaned as a load to efficiently utilize cleaning equipment. Commercial laundry

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cleaning operations are successful because they process a large number of garments together in large machines at an overall lower cost.

Where the account is a facility that has a large number of garments being used by its workers, the garments must be arranged for delivery in some rational order so that workers are not spending inordinate time and effort locating their shirts or uniforms. Since the soiled garments are being returned to the same cleaners routinely for laundering, a means for identifying the garments can be attached permanently or removably to the garment. If affixed permanently, the cleaning operation does not have to attach new identification tags to the soiled garment every time it is received for cleaning. One means for identifying garments is by using conventional bar code strips affixed to the garments and read by a bar code reader. This identification system also eliminates the need for the individual account to sort soiled garments before being sent for cleaning.

In the uniform rental industry there normally is no invoice nor ticket to match. The identification information is permanently affixed to the garment, and the batches of laundry are kept together.

In the commercial cleaning of residential customers' garments, such as business shirts, a time consuming element of the sorting process is the step of separating the lot of cleaned items and assembling them with the appropriate ticket, remembering that a single ticket may contain several items of cleaning.

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Conventionally, a worker picks the first item in the lot off the rack, looks at the identifying data thereon, places the item with the appropriate ticket, and proceeds to the next item in the lot. This represents several opportunities for worker error. Because the cleaned items cannot be maintained in any particular order in the machines during cleaning, they must be sorted by hand by visually checking and pairing numbers after cleaning. Accordingly, it will be appreciated that it would be highly desirable to unite each item in a lot with their appropriate tickets without manually handling each item at each step of the reassembly process.

A problem associated with the sorting process which occurs after garments are laundered is that a worker must physically handle the tag to read the identification data which may consists of a four, five or even six or more digit number or combination of numbers and letters, creating an opportunity for error in reading the data. Even when being extremely careful, a worker is prone either to misread the identifying data or to transpose digits and thereby place a garment with the wrong ticket. The result of such an error is that an account receives the wrong item or no item at all.

Recently, several apparatus have been developed which automate, to a degree, the sortation process. U.S. Patent No. 4,239,435, issued December 16, 1980, to Weiss et al., discloses an apparatus and method for arranging a plurality of randomly arranged identifiable articles into a predetermined order. The apparatus includes a conveyor for releasably supporting the randomly arranged articles and for conveying the articles supported thereon

past at least one receiving station arranged about the conveyor for receiving the articles. Identifying means are associated with the receiving station for identifying each article as it is conveyed past the receiving station. Release means responsive to the identifying means are provided for releasing the article identified by the identifying means from the conveyor means to the receiving station when the article identified is the next succeeding article in the predetermined order with respect to the articles previously received by the receiving station. Articles are only removed from the conveyor means when they are the next succeeding article in a predetermined order. The remaining articles will remain on the conveyor for subsequent passes past the receiving station. The method for arranging randomly arranged articles into a predetermined order comprises releasably supporting the randomly arranged articles on support means and moving the articles past at least one receiving station for receiving the articles. As each of the articles move past the receiving station, each article is released from the support means to the receiving station when the article is the next succeeding article in the predetermined order with respect to the articles previously received by the receiving station. The articles remaining on the support means continue moving past the receiving station until all of the articles on the support means are released to the receiving station.

Weiss et al. teaches that the garments are manually loaded onto a slow moving conveyor; only after all the garments are loaded can the apparatus speed up. Furthermore, the latch release mechanism which holds the wire hanger on the conveyor is very complex and

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mechanically inefficient. The apparatus requires a reference support position so that each of the receiving stations can initialize itself every rotation of the conveyor. Numerous rotations must be employed before all garments are removed by the receiving stations. In other words, because the garments are sorted linearly and in a single sortation conveyor system, a garment must travel around and around until the receiving station assigned to that garment is ready to receive it. This is likened to a card game of solitaire, where the player must deal cards from the deck repeatedly until the next playable card can be used. The deck must be replayed with all remaining cards until the appropriate numerical play can be made. It would be desirable for an automated apparatus to sort garments whereby the garment would be removed from the sorting machine to a receiving assembly within a single rotation. This would efficiently make room for more garments sooner.

U.S. Patent No. 4,907,699, issued March 13, 1990, to Butcher et al., discloses a method and apparatus for sorting and arranging garments in a selected order which have been sequentially placed in an unordered sequence. The garments are identified by a marking affixed to each garment, and each garment arranged in its identified sequence on a sorting conveyor having a multiplicity of movable carriers each for receiving a garment. Identification signals are rearranged in a preselected order, and a plurality of arranged signals are assigned to each one of a corresponding plurality of pick-off mechanisms positioned along the sorting conveyor. A computer calculates bidirectional movement of the

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sorting conveyor to mirήmize conveyor movement for positioning a garment for pick-off in its proper sequence by a respective one of the pick-off mechanisms. The conveyor is driven in a bidirectional mode to properly position the garment, and a pick-off mechanism is activated to remove the garment from the sorting conveyor and position the garment on an unloading conveyor. Each conveyor pick-off apparatus includes a fluid-powered cylinder inclined downward toward the sorting conveyor, and a drive unit for closing the carrier mechanism.

Butcher et al. requires the use of a reference marker to initialize the receiving assemblies for each rotation of the conveyor past the receiving stations. This system also uses a carousel that loads garments onto the conveyor. The carousel acts blindly, transferring every garment to the next position on the conveyor, regardless of order, and is not actively involved in the selective release of garments in a sortation operation. The carousel takes the place of a person in performing a simple transfer function, with little or no computer controlled selection commands.

Butcher et al. also uses a carrier mechanism on the carousel to transfer the garments to a very narrow numbered slot on a conveyor system that may hold hundreds of garments. The bidirectional conveyor motor must jockey back and forth to properly align the slot with the hanger, creating greatly increased wear on the motor. Extreme accuracy is needed by the conveyor stepping motor to index stop precisely at the carrier mechanism release point, otherwise the wire hanger will miss the appropriate

slot. If a hanger should miss the numbered slot, its position will remain empty until all remaining shirts are loaded onto the conveyor and unloaded onto the receiving stations.

Understandably, it will be appreciated that it would be highly desirable to have a laundry sorting apparatus that is compact and does not require an enormous amount of floor space.

SUMMARY OF THE INVENTION

Accordingly, it is a principal object of the present invention to provide an apparatus for the multiple level sortation of garments.

It is another object of the present invention to provide an apparatus which can sort garments based upon unique identification data associated with each garment.

It is another object of the present invention to provide an apparatus having a single sortation assembly capable of performing multiple sortation operations on a set of garments.

It is another object of the present invention to provide an apparatus having a single sortation assembly utilizing a recycling conveyor to transfer garments that have been sorted once back through the same sortation assembly apparatus for a second, third, etc., sorting.

It is a further object of the present invention to provide an apparatus which can sort a randomly ordered sequence of hanging garments. Information associated with each garment is entered in order into a computer. The garments are conveyed and loaded onto a sortation assembly where each garment is selectively transferred

by means of a wheel assembly to one of a plurality of receiving rails according to an first set of identification data. The thus assembled groups are removed from the individual rails and transferred in group order on a conveyor back through the sortation assembly where the same operation occurs according to the next sortation level criteria. Sorted garments are removed from the individual rails and loaded onto trucks for delivery, stored or further processed.

It is yet another object of the present invention to provide a method and apparatus for the sortation of large numbers of garments requiring few people to operate and supervise the operation.

The present invention overcomes the deficiencies in the prior art and provides for an improved apparatus and method for the multiple level sortation of a number of randomly ordered items. In a preferred embodiment, the invention comprises a computer means for receiving, processing and transmitting data and control signals. A scanning means, such as a bar code reader or RF scanner, is provided for inputting into the computer identification data associated with a randomly ordered stack of garments, each garment having unique identification data associated with it. Each garment can be hung on a conventional wire clothes hanger. A sortation assembly comprises a rotating wheel assembly being capable of receiving at least one garment and subsequently selectively releasing the garment upon receipt of a signal from the computer at one of a plurality of pre-determined points around an arc during the wheel assembly rotation. The wheel assembly uses

carrier mechanisms comprising grippers disposed around the circumference of the wheel to releasably support and transfer the wire hangers. These carriers are responsive to a signal from the computer.

A loading assembly comprising a loading rail, trolley chain and associated pendants, and a stop gate is associated with the wheel assembly for transferring garments to the wheel assembly in a controlled manner after the identification data has been inputted into the computer means. The loading assembly is located generally tangent to and near wheel assembly. A receiving assembly comprises a rail having a curved receiving finger portion at one end and a stop gate and curved off loading finger portion at the opposite end of the rail. Each receiving assembly is in proximity to a release point on the wheel arc for accepting garments from the wheel assembly according to the identification data associated with the garment. Each receiving assembly is associated with the same level of sortation criteria. Each receiving assembly corresponds to a different group within the same sortation level. The resulting assemblage of garments thus defines a set of groups of first sorted garments.

A recycling conveyor accepts the garments from each receiving assembly in a pre-determined order by having the computer signal each rail stop gate to open in a specific order, thus transferring the garments in the sorted order to the recycling conveyor to maintain the overall group order of the given sortation level. The recycling conveyor can return the once sorted garments back to the loading

assembly and back through the sortation assembly for additional sorting according to the next sortation criteria. The twice sorted garments are collected from their rails by the recycling conveyor, as in the first sort. When all sorts are completed a retractable plow off switch on the recycling conveyor directs the garments off the conveyor and onto a rail or other conveyor, thereby exiting the system.

A method is provided for the multiple level sortation of a number of randomly ordered items comprising inputting identification data associated with a randomly ordered stack of garments to a computer. After the information is entered the garment is transferred to the sortation assembly one garment at a time by loading the garments onto the loading rail. The trolley chain pendants are located directly over the loading rail. Each pendant engages one garment and urges it along the rail. As the garment approaches the end of the loading rail it slides down a short decline and is stopped by the stop gate abutting the end of the rail. As one of the carrier mechanisms approaches the stop gate the computer signals the stop gate to open. When the carrier mechanism is directly beneath the stop gate the gate opens and the garment drops onto the carrier mechanism. The wheel assembly transports the garment and selectively releases the garment at a pre-determined position. The garment is accepted by one of several receiving assemblies according to the identification data for that garment maintained in the computer. All garments having the same grouping within the given sortation level will be accepted by one receiving assembly, defining a group of first sorted garments. The

carrier mechanism releases the garment onto the finger of the appropriate receiving assembly. The garment slides down the receiving rail and is stopped by the receiving stop gate. When all garments have been sorted the receiving stop gates are signaled to open selectively so as to permit the garments to slide onto the recycling conveyor, which is disposed in part around the arc formed by the receiving rails, just beneath the end of the rail. The garments are loaded in the sort level order and are transferred with each group maintaining its contiguity. The groups are conveyed back to the loading rail, where they are again conveyed to the loading stop gate for distribution onto the wheel assembly. The computer can change the sort criteria based on the stored data from each garment when it was scanned. A second sort criteria is used and the garments are sorted by the assembly. Additional sorts can be performed. When all sorts are completed a retractable plow off track switch is signaled and the garments are passed off the recycling conveyor in the sorted order and transferred to a holding rail for loading onto trucks for delivery, storage or further processing.

In a typical laundry processing facility, garments are sorted first by truck route, then by account within the route, and then by individual garment within the account. Additional sorts are possible by adding additional sortation criteria and identification data.

Stated more particularly, a method is provided for performing multiple sortation operations upon a number of garments, each

garment having associated with it a unique identification means, comprising: scanning the identification means to create electronically transmittable data; entering the data into a computer means; loading the garments onto a wheel assembly, the wheel assembly having a plurality of spaced carrier means associated therewith, each carrier means capable of releasably supporting a garment hanger, the wheel assembly being able to rotate such that each of the carrier means passes over a predetermined point; selectively releasing each the garment at a predetermined point during rotation of the wheel assembly in response to a signal from the computer means onto one of a plurality of receiving means, each receiving means corresponding to a distinct group within a first sortation level, the groups of garments defining a first sortation assemblage; and transferring the first sortation assemblage to a recycling conveyor. Optionally, the recycling conveyor can transfer the garments back for additional sorting, thus loading the first sorted garments back onto the wheel assembly for a second sortation operation; collecting together in a sorted group the twice sorted garments; and, moving the sorted garments off the sortation assembly for storage.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 shows side elevational view of an apparatus of the present invention.

Fig. 2 shows a top schematic view of the apparatus.

Fig. 3 shows a side perspective view of the feeder mechanism.

Fig. 4 shows a top detail view of the transfer mechanism.

Fig. 5 shows a top view of the carrier assembly with the carrier positioned over a receiving rail finger.

Fig. 6 shows a detail view of the carrier mechanism and the receiving assembly.

Fig. 7 shows a detailed perspective of the receiving assembly and the recycling conveyor.

Fig. 8 shows a detailed perspective of the recycling conveyor and the plow off switch.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings in which like numbers represent like elements, Fig. 1 shows a side elevational view and Fig. 2 shows a top view of an apparatus 5 comprising a sortation assembly 10.

The items to be sorted are typically garments, such as shirts, slacks, jackets, jumpsuits, uniforms, or the like, but can be any items that can be suspended in a similar manner, such as fabric parts, machine parts, and the like. For die purposes of the present description, garments 15 will be described that are hung individually on conventional wire hangers 16, however any other suitable support will suffice. Referring to the garment will normally include the hanger from which it is hung. Similarly, reference to the hanger will normally include the garment which hangs on it. It will also be assumed that a number of garments 15 can be from different sources, such as different wearers from

different accounts, and are commingled in a random order. Each garment 15 has a unique identification means associated with the garment. Such means can be a UPC bar code numbering tag, or other alpha, numeric, or symbolic identification means. The identification means is attached either removably or fixedly attached to garment 15 or hanger 16. Preferably, the means of identification is a bar code tag affixed to the garment, such as inside the collar. This presents an easily accessible and readable location. Each of garments 15 is scanned automatically or manually by the operator using a signal inputting means, which can be a bar code reader 24, RF scanner or other means for detecting and transforming the identification data into an electronic signal. The bar code reader 24 sends a signal to a computer 26, which stores and processes the information, as will be described in greater detail hereinbelow.

Alternatively, an RF chip can be affixed to the garment. RF chips are small electronic chips which contain stored data, an antenna and a passive energy source. When the chip is bombarded with electromagnetic energy, such as a radio signal from a scanner, the energy source is excited and the data transmitted by the antenna.

The scanner receives the transmitted data and communicates it to the computer. RF chips present the advantage that the scanner does not have to be in visual contact with the identification means, thereby permitting faster and easier identification and processing.

At a data entry area 20 hangers 16 are positioned in an unordered sequence on a loading rail 22 for entry into a loading assembly 30.

Loading rail 22, as well as the other rails used in the present invention are conventional slick rails, with polished surfaces for lowering friction with hangers 16. Alternatively the rails can be conventional helix screw conveyors or any other usable conveyor. Preferably, loading rail 22 has a groove 33 disposed longitudinally along its upper surface.

Turning to Fig. 3, loading assembly 30 has a trolley chain conveyor 34 containing a plurality of pendants (also known in the industry as "pusher dogs") 36 depending downward therefrom and is disposed above loading rail 22. The trolley chain 34 is actuated by a gear 38 and a motor 39 (not shown), which is responsive to a signal from computer 26. In this manner, the trolley chain speed can be, synchronized with other elements of the apparatus 5. The lower portion of the individual pendants 36 travels within groove 33. The hangers 16 are loaded onto loading rail 22 such that one hanger 16 is between two pendants 36. When trolley chain 34 is activated, pendants 36 will push or urge hanger 16 in front of the pendant 36 and along loading rail 22.

A loading stop gate mechanism 40 is positioned abutting die end of loading rail 22 to individually advance and present hangers 16. As shown in Fig. 3, loading rail 22 terminates in a short declining angle portion 42, which causes hangers 16 to drop by gravity after being pushed by pendant 36. A stop gate 44 comprises a block 46 connected to an air cylinder 48 or other powered source of movement. The block 46 moves back and forth in response to a signal from computer 26. In the forward position block 46 contacts

or nearly contacts the end of loading rail 22, preventing the fall of hanger 16. In response to a computer signal, block 46 moves to a back position permitting hanger 16 to drop.

A wheel assembly 50, shown in top view by Fig. 2 and in a top detail view by Fig. 4, generally comprises a frame 52, a wheel 58, a motor 60, and a plurality of fingers 62, each having a carrier mechanism 64 attached thereto. Fig. 1 shows frame 52, which comprises a set of downwardly extending legs 54 attached to a support 56, which maintains the sortation assembly 10 in an elevated position. Alternatively, support 56 may be suspended from a ceiling support lattice, ehminating the need for legs. The wheel assembly 50 comprises a generally circular wheel 58 mounted with the axis in a vertical orientation, and is powered by a motor 60 (not shown) attached to the hub of wheel 58. The motor 60 is preferably a servo motor which permits wheel 58 to rotate about its axis in response to a control signal from computer 26. The wheel 58 rotates in a counterclockwise direction as viewed from above. It is to be understood that the apparatus can be constructed in a mirror image fashion, in which case wheel 58 would rotate clockwise.

A number of attached mounting brackets 62 are spaced evenly around the outside circumference of wheel 58, to each of which is mounted a carrier mechanism 64 radially projecting in an outward direction. A detailed view of carrier 64 is shown in Figs. 4 and 6. The carrier 64 comprises a conventional pneumatic cylinder mechanism 66 which, in response to a signal, opens or closes a pair

of mated pincers 68. The distal portions of pincers 68 form a V- shaped notch 69 when closed together. The pincers 68 support the hook of hanger 16 within notch 69. When carrier 64 is in the open position, hanger 16 is released and drops through the opening created between pincers 68. In this manner carrier 64 can accept, support, transfer, and release hanger 16 more rapidly and accurately than by gripping hanger 16.

Standardization of readily available parts, such as carrier and pneumatic cylinders, and the like, and easy replacement or repair is advantageous in the present invention where several dozen carrier mechanisms may be used. Defective or failed parts can be replaced quickly without significant down time. Commercially available carrier mechanisms also reduce construction costs.

The motor 60 rotates so that each carrier 64 passes at a point directly under stop gate 44. When a carrier 64 approaches a position directly below stop gate 44, computer 26 signals stop gate 44 to open, releasing hanger 16 directly onto carrier 64, which is immediately below. The drop is minimal and no significant bouncing occurs.

The hangers 16 are selectively transferred in accordance with the algorithm (discussed in detail hereinbelow) to a receiving assembly 70, shown in Figs. 5 and 6. A number of receiving rails 71, which preferably are gravity shck rails, are preferably mounted at a declining angle away from wheel assembly 50. Each receiving rail 71 has a curved receiving finger portion 72 positioned around the circumference of wheel assembly 50 at even spaced apart

distances, a slide rail portion 74, and an off loading finger portion 75. Each receiving rail 71 is held in a fixed position relative to wheel assembly 50 by a support 73. Support 73 is mounted so as to not interfere with the passage of hangers 16 on finger portion 71.. Receiving fingers 72 are disposed below the arc of carrier 64 such that when a carrier 64 releases its hanger 16, it drops onto one of receiving fingers 72.

The hanger 16 slides down by gravity to the bottom portion of slide rail 71, as shown in Figs. 6 and 7. The rails 71 fan outward from each other to permit unobstructed passage of hangers 16. The hanger 16 stops at a receiving stop gate 76. Similar to ^" loading stop gate 44, receiving stop gate 76 comprises a pneumatic or otherwise powered cylinder 78 which is connected to a stop block 79. In the closed position stop block 79 is in contact with receiving rail 71, preventing passage of hangers 16. In the open position hangers 16 may pass.

Fig. 8 shows part of a recycling conveyor 90 comprises a closed loop conveyor well known in the art and powered by a motor 92 (not shown). The motor 92 is actuable by a signal from computer 26. In a preferred embodiment, recycling conveyor 90 is a trolley chain having pendants 91 projecting upward, whereby the hangers 16 travel between the pendants. A portion of recycling conveyor 90 forms an arc which approximates the arc of receiving rails 71. Off loading finger portion 75 curves in an arc, die terminus of which is generally parallel with and just above the arc of recycling conveyor

90.

A plow off switch 94 is positioned next to recycling conveyor 90 and is responsive to computer 26. The switch 94 is mounted on a pivotable pin 95 which allows one portion of the switch to move toward and away from receiving rail 71. When actuated switch 94 catches hangers 16 and removes them from recycling conveyor 90 onto an exit conveyor 96. The switch directs garments on recycling conveyor 90 to be transferred either back to loading assembly 30 for additional sortations or, at the end of the sortation process, out of die sortation assembly and to storage rails or conveyors. Fig. 8 shows switch 94 in the inward position in solid and in the outward position in phantom.

In operation, computer 26 controls the various functions of apparatus 5 in accordance with a predetermined algorithm. The sortation assembly 10 is driven by d e algorithm and the order in which garment identification means is read and inputted into computer 26. When a garment's unique identification data is registered into computer 26, die position relative to other garments 15 is determined. From the time of data entry the location of every garment 15 is tracked by computer 26. During the sortation processes the particular garment 15 and its location are maintained in computer 26. Once scanned, garments 15 will remain in a determinable relative order.

After the identification number is entered by scanning the identification means by bar code reader 24, RF scanner, or other means, hanger 16 is placed onto loading rail 22. Optionally, a hanger separator apparatus, such as that described in co-pending

application Serial No. 943,862, can be used to separate any crossed hangers and more effectively present hangers 16 to loading rail 22. The trolley chain 34 and pendants 36 push garments toward stop gate 44. The pneumatically driven gate 44 controllably permits passage of one hanger 16 at a time.

A critical feature of the present invention is the ability of wheel assembly 50 to selectively release hangers 16 on carriers 64 at the correct receiving finger 72. Each receiving finger 72, connected to receiving rail 71, represents the first sortation criteria, such as by route, and hangers 16 are sorted by route number that is part of the identification number. The hangers 16 are loaded onto wheel assembly 50, one per carrier 64, by stop gate 44 releasing a hanger 16 when a carrier 64 is directly below. It is preferable that the rotational speed of wheel 58 matches the rate of hangers 16 being off loaded by pendants 36 to stop gate 44. In this way tiiere will be proper synchronization of release by stop gate 44 and reception by carrier 64.

A hanger 16 is loaded onto wheel 58 and rotates around counterclockwise (as viewed from above) until receiving finger 72 corresponding to the correct route is located. Each receiving finger

72 represents a point in the wheel 58 rotation. As wheel 58 turns, carrier 64 opens and releases hanger 16 onto the correct receiving finger 71, in accordance with a signal transmitted by computer 26. This accomplishes the sortation of unordered hangers 16 into a desired order.

As a simplified example, consider the identification data for a hypothetical garment #1 as "ABH", garment #2 "BCF" and garment #3 "AFG", the first letter of each garment data representing the route, the second letter representing the account and the third letter representing the individual. In this example then, garments #1 and #3 are from the same route, but different accounts. Consider also, that mere are eight receiving rails 71 marked A, B, C, D, E, F, G and H (more would typically be preferable, but it can be any suitable number). The three garments are scanned in the random presented order and their unique identification data stored in computer 26. From this point, each garment is tracked for the remainder of all sorting operations. During the first sort, garment #1 is loaded onto loading assembly 30, and comes to stop gate 44. As the next carrier 64 approaches, stop gate 44 opens, releasing garment #1 onto the closed pincers 68 of carrier 64. As wheel 58 rotates it passes over receiving rail A, at which time computer 26, recognizing tiiat garment #l's route code is "A", signals carrier 64 supporting garment #1 to open, releasing die garment onto receiving rail A. During this rotation and release, garment #2 is moved to stop gate 44 and awaits the next carrier 64 to pass beneath it. At such time, stop gate 44 opens releasing garment #2 onto carrier 64. Garment #2 travels around on wheel 58, bypassing receiving rail A, until it passes over receiving rail B, whereupon carrier 64 releases garment #2 onto receiving rail B. Similarly, garment #3 is loaded onto the next carrier 64, and rotates around until it passes over receiving rail A, when it is released and slides down the rail by gravity until it comes to rest behind stop

gate 76 and behind garment #1. Assuming this completes the first sortation level, computer 26 signals stop gate 76 on receiving rail A to open and release any garments on its rail to the recycling conveyor 90. Then receiving rail stop gate B does the same, thus preserving the A, B, C, etc., route order of garments. Switch 94 is signaled to have recycling conveyor 90 return garments #1 , #2, and #3 to loading assembly 30, where loading rail 22 receives the garments. The computer 26 then sets for the second sort (the second letter of the identification data). Garment #1 is placed on wheel 58 via stop gate 44, and rotates around until it is released onto receiving rail B. Garment #2 is similarly placed and released onto receiving rail C. Garment #3 is released onto receiving rail F. The sorted garments and collected onto recycling conveyor 90 and recycled through the sortation assembly again, this time according to the third letter of the identification data. After sortation, the three garments are collected onto recycling conveyor 90. This time however, switch 94 is signaled to direct the garments to exit the system onto an exit conveyor 96 where they are loaded onto the route delivery trucks, stored or further processed.

An advantage of the present invention, then, is the ability of the sortation assembly to selectively transfer unordered garments from wheel 58 to receiving assembly 70 in accordance with the selection criteria and computer algorithm, ehminating inefficient traveUng of garments around and around a conveyor until the correct previous garment has been transferred to the collecting rails, as in Weiss et al. With the present invention garments are delivered to their appropriate receiving rail within a single rotation. A garment pass

over the wrong rails until it passes over the rail it is assigned to for the particular sort by the algorithm, at which time it is released onto me correct rail. Furthermore, no reference marker or initial starting point for the wheel is needed, as computer recognizes each garment in order as it is loaded onto loading rail 22. Additionally, mere is no need for a bidirectionally moving conveyor to properly position the garments, as in Butcher et al., since predetermined release points are programmed into me system. This provides a more accurate transfer from carrier to receiving rail.

In one aspect the efficiency of die present invention, and a point of distinction over the prior art, lies in the ability of the sortation assemblies to selectively and "intelligently" transfer garments to receiving assemblies. In the event a garment falls off or is removed from apparatus 5, an operator need merely go to computer 26 and enter die garment identification number. The computer 26 will delete the information from the system without destroying the sequence or operation. Other garments are simply advanced in die computer algorithm with no gap appearing. The garment can be rescanned at data entry area and reprocessed.

While die invention has been described in connection with certain preferred embodiments, it is not intended to hmit the scope of the invention to die particular forms set forth, but, on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included witiiin the spirit and scope of the invention as defined by the appended claims.