Technical Field The present invention relates to the field of package sortation systems, and more particularly to a coded package or the like sortation system, and to a related method for sorting coded packages for distribution.

Background of the Invention Over the past several years the demand from businesses and individuals alike for second day and overnight deliveries of small to midsized parcels, packages and letters has steadily increased.

Consequently, the need for methods and systems capable of transporting, sorting and distributing this ever increasing volume of packages in a relatively short amount of time has likewise increased.

In fact, it is now general practice for common carriers to transport these small to midsized

packages or the like to a central sorting terminal or hub, to sort the packages according to selected parameters, such as regional destinations. Once these destinations are reached it is necessary to sort again to distribute the packages to the final destinations.

In order to accomplish these tasks in the amount of time required to insure overnight delivery, the central as well as the regional sorting terminals or hubs must be capable of receiving, sorting and distributing hundreds of thousands of coded packages each day. Necessarily, the sortation systems used must be capable of processing the packages within these defined time parameters. Indeed, in response to the continuously increasing number of packages requiring next day or overnight delivery, the sortation systems must operate much faster and more efficiently than just a few years ago. It is also desirable for the systems to be more adaptable to accommodate fluctuations in need/demand, as well as be simpler and less expensive.

Since as early as the 1960's various package sortation systems utilized at central receiving hubs have relied upon wheeled tilt tray assembly units to receive, transport and deposit packages at selected distribution stations. Specifically, U. S. Patents 3,167,192 to Harrison et al. and 3,327,836 to Burt each disclose package sortation systems which utilize a number of tilt tray assembly units propelled by an endless conveyor chain. Timers and magnetic readers

are used to actuate tip solenoids to tilt the trays to one side, thus allowing gravity to passively pull the packages from atop the trays upon reaching their destination.

A more recent sortation system described in U. S. Patent 4,832,204 to Handy et al. integrates these prior art tilt tray sortation systems with more complicated scanning equipment and computer control in an attempt to improve overall system speed and efficiency. Despite the successful integration of these components into a supposedly more modern and state of the art system, and at a cost of much greater complexity and cost, the system of the'204 patent still fails to improve the basic sortation apparatus and methods. In essence, package delivery customers are calling for a move away from the continued reliance on the complex and expensive tilt tray systems, such as in the'204 patent, and at the same time demanding significant increases in the overall speed, efficiency and adaptability of the package sortation system.

Thus, an important aspect of the effort to improve this technology, is to provide a package or the like sortation system and related method capable of transporting, sorting and distributing the increasing volume of such articles within a defined shorter period of time. The desired approach should be to eliminate the complexity, especially with regard

to having to provide a series of tilt trays, and instead go to a simple conveyor belt capable of side and elevational flexing action and supported at an angle to the horizontal plane to form a simple carousel for the articles. Additionally, a simple controlled ejector to positively discharge the articles from the conveyor belt without tilting at the distribution stations is desirable. As a result, increased system speed, efficiency and adaptability, as well as lower cost and maintenance are attained.

Summarv of the Invention Accordingly, it is a primary object of the present invention to provide a novel and improved sortation system and related method that are particularly adapted to provide improved operating speed and efficiency, in order to overcome the limitations of the prior art.

Another object of the present invention is to provide a simplified sortation system that is particularly adapted to utilize an endless conveyor belt capable of side and elevational flexing action.

It is yet another object of the present invention to provide a sortation system that is further characterized by use of a conveyor belt such that the plane of the conveyor belt forms an angle to the horizontal plane to define a carousel.

Still another object of the present

invention is to provide a novel and improved method of sorting coded packages according to a selected parameter.

Yet another object of the present invention is to provide a sortation system which utilizes coded information on the packages, or other articles, and a controller to determine a proper distribution station for ejection of the packages according to a selected parameter of the coded information.

Another object of the present invention is to provide a method of sorting coded packages including positioning the packages in a plane at an angle to the horizontal plane on a conveyor belt capable of side and elevational flexing action, scanning the packages to read the selected parameter and ejecting the packages at the proper distribution station according to the selected parameter.

It is yet another object of the present invention to provide a method of sorting coded packages including the step of extending a pivotal blade outwardly to cut across the angled plane of the positioned packages for ejecting the packages at the proper distribution station.

Additional objects, advantages, and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with

the practice of the invention. The objects and advantages of the invention any be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.

To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described herein, an improved sortation system is provided for sorting coded packages according to a selected parameter. The coded package sortation system includes a continuous, side and elevational flexing conveyor belt for supporting and moving the packages on a bottom edge in an endless path. The conveyor belt defines a carousel and a scanner is used to read selected coded parameters on each package, and in response a plurality of controllable ejectors positively discharges the packages from the carousel at the proper distribution station located around the carousel. While the preferred embodiment of the present invention is described as being most efficiently used in an environment of sorting packages, it is clear that other like articles can be sorted utilizing the same principles in accordance with the broadest aspects of the invention.

Preferably, the continuous conveyor belt is formed by a plurality of interconnecting modular links and a plurality of transverse connectors or cross rods

to retain the modular links together. Advantageously, the modular links thus allow a degree of longitudinal freedom to the conveyor belt. More specifically, the provision of the modular links allows the conveyor belt to compress differentially along the cross rods sideways as well as up and down, thus facilitating smooth traversal of a bend and/or an incline/decline by the conveyor belt even when supported at an angle to the horizontal. The modular links, including side links formed with the inclusion of depending arms and integral locking tabs, as well as cooperating guide means, are more fully explained in the issued U. S.

Patents Nos. 4,953,693 and 5,031,757, which are hereby incorporated by reference.

The conveyor belt guide means of the present invention travels in an endless path that defines a carousel, with a plurality of distribution stations being positioned around the same. In accordance with an important aspect of the present invention, the guide means is positioned on the frame of the system such that the plane of the conveyor belt forms an angle to the horizontal plane, thus providing support for the packages during transportation to the selected distribution station, while at the same time limiting the overall size or footprint of the sortation system.

The angle formed depends upon the particular application and specifications of the sortation system, and can be between 10° and 80° to the

horizontal plane. The preferred embodiment is illustrated as approximately 60°.

A stationary ledge is positioned adjacent the lower edge of the conveyor belt for further supporting the packages. It is contemplated that the ledge extends completely around the periphery of the carousel forming a track for support of the edge of each package. A plurality of transverse pushers extend across the upper surface of the conveyor belt and work with the ledge to guide and properly position the packages for eventual discharge. Advantageously, the ledge provides sufficient frictional drag to retard the packages, and thus assure alignment of the trailing edge of each package so as to engage the corresponding pushers. This relationship provides alignment of the ejector with the trailing edge of the package. The belt and pushers are monitored so that there is always registration with the distribution stations.

A driver for the belt includes a drive motor, shaft and multiple sprockets to impart motion across the full width. A scanner is placed near the conveyor belt for reading the coded parameters from each passing package. A controller receives the signal for processing. The selected parameter on the package determines the proper distribution station for ejection.

In another important aspect of the present

invention, the distribution stations each include an ejector having a pivotal blade and a corresponding actuator for extending the blade outwardly to cut across the angled plane of the conveyor belt for positively discharging the packages from the carousel.

A plurality of valves control the actuators in response to the controller. The discharged packages are collected at the individual distribution stations in receptacles supported by laterally extending support arms mounted on the frame adjacent the ledge.

In a further aspect of the invention, in accordance with its objects and purposes, a method of sorting coded packages according to a selected parameter for distribution includes the steps of positioning the packages in a plane at an angle to the horizontal plane on a continuous conveyor belt capable of side and elevational flexing action, driving the belt in an endless path, providing a plurality of distribution stations around the path, scanning the packages to determine the selected parameter and ejecting each package at its determined distribution station.

The method also includes the steps of monitoring the position of the conveyor belt around the endless path and controlling the ejection of the packages dependent upon the scanning step and the monitoring step. The monitoring step is accomplished by sensing the presence of the transverse pushers

moving around the path and a home indicator. Based on the location of the pushers and the speed at which the conveyor belt is driven, the controller determines the appropriate time to eject the packages at the distribution stations.

Still other objects of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments, and its several details are capable of modifications in carious, obvious aspects all without departing form the invention.

Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

Brief Description of the Drainas The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention. In the drawings: Figure 1 is a perspective view of the package sortation system of the preferred embodiment of the present invention having the center portion

broken away; Figure 2 is an end view of the sortation system of the preferred embodiment; Figure 3 is a cross sectional view of the package sortation system at the broken away mid- section showing a driver and a distribution station; Figure 4A is a top view, partially broken away, and showing a coded package approaching a distribution station and an ejector in the normal position; Figure 4B is an illustration showing the ejector partially extended across the angled plane of the conveyor belt and contacting the lower portion of the coded package; Figure 4C is an illustration showing an ejector returning to a home position and a coded package dropping away from the ledge into a collection receptacle; Figure 5 is a partial and enlarged perspective view showing a modular link conveyor, upward extending fins forming the pusher for engaging a package and two distribution stations ; and Figure 6 is a schematic block diagram of the control circuit of the sortation system.

Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.

Detailed Description of the Preferred Embodiment With reference to the perspective view of FIG. 1, there is shown a preferred embodiment of a package sortation system 10 for sorting coded packages P according to a selected parameter. In one important aspect of the present invention, the sortation system 10 includes a continuous, modular conveyor belt 11 capable of side and elevational flexing action supported by a frame, generally designated by reference numeral 12. The plane of the conveyor belt is at an angle 6 of approximately sixty degrees (60°), to the horizontal plane H. In accordance with the broadest aspects of the present invention, it is contemplated that the angle can be selectively established at any suitable angle, but preferably approximately 60°, as illustrated.

The frame 12 in the preferred embodiment is elongated, and overall is generally rectangular in shape. Vertically extending legs 14 and a conveyor belt guide means 15 form a part of the frame. This results in the conveyor belt 11 being supported along an endless path and defines a carousel, including two elongated sides and two frustoconical ends which generate side and elevational flexing movement of the conveyor belt 11. It is contemplated that in accordance with the broadest aspects of the present invention, the length of the sides and the radius of the ends can be adjusted to fit the particular use. A

plurality of distribution stations DS are located along the sides, as well as at the curved ends, if necessary. The shape of the sortation system 10 can be selected to accommodate any turns and to include any number of sides and ends for additional sorting capacity.

As shown in FIG. 2, braces 17,18 are attached at both ends and along the sides of the frame 12. These braces form a part of the frame 12, as well as support suitable receptacles or containers for the packages. These receptacles define the distribution stations DS and will be described in more detail below.

The frame 12 includes two guide rails 21,22 to guide the conveyor belt 11 at its lateral edges around the carousel. As is apparent, both longitudinal and transverse beams 23 are provided as a part of the frame (see Figures 1 and 2). The guide rails are fixed at the desired lateral spacing for the belt 11. Frustoconical support assemblies 24 of the frame 12 positioned at each end of the system 10 are operative to cause the conveyor belt 11 to turn and define the ends of the carousel.

The conveyor belt 11 includes a plurality of transverse pushers 13 in the form of raised fins (see Figure 5) extending across the upper surface of the belt to engage and drive the packages P around the carousel. In the preferred embodiment of the present

invention, a ledge 25 is mounted on the frame 12 adjacent the lower edge of the conveyor belt to provide a stationary support surface or track for the bottom edge of the packages P. The ledge provides a frictional drag sufficient to retard the packages to assure contact with the transverse pushers 13 for registration, as will be discussed more fully below.

In accordance with another important aspect of the present invention, the conveyor belt 11 in the preferred embodiment is formed by a plurality of interconnecting modular links 26 and a plurality of transverse connectors 27 to hold the modular links together. Advantageously, the modular links 26 allow the required degree of freedom to the conveyor belt.

More specifically, the provision of the modular links 26 allows the conveyor belt 11 to compress differentially for side and elevational flexing action. This action facilitates smooth traversal of the sides, as well as the frustoconical ends by the conveyor belt 11, even given the fact that it is supported at the angle 6 to the horizontal plane H.

The belt 11 includes modular center links 26 and side links 28 (see Figure 5), the later being formed by the inclusion of depending arms and integral locking tabs (not numbered). The side links 28 engage the guide rails 21,22 in the preferred embodiment, as more fully explained in the issued U. S. Patents Nos.

4,953,693 and 5,031,757 owned by the assignee of the

present application and previously incorporated by reference above.

Also, in the preferred embodiment as shown in FIGS. 1 and 3, dual synchronized drivers 30 provide the driving force for the conveyor belt 11. Each driver 30 includes a motor 31 connected to a drive shaft 32. Depending on the width of the conveyor belt 11, at least two conveyor belt engaging sprockets 33 are utilized on the drive shaft 32 to impart the motion to the belt 11. By placing the drivers at the terminal ends of the side runs, the belt 11 is assured of being tensioned along said side runs and allowed to compress as necessary around the frustoconical ends.

In accordance with the broadest aspects of the present invention, other motor, drive shaft and sprocket combination meeting this basic criteria can be used.

As further shown in FIG. 1, a plurality of ejectors 35 are positioned along at least the two sides of the carousel for ejecting the moving packages P at one of the plurality of distribution stations DS, DSn as shown by action arrows A (some distribution stations not shown in the cut-away area of FIG. 1 for clarity).

In the preferred embodiment of the present invention and as shown most clearly in FIG. 5, each distribution station DS, DSn includes a pair of laterally extending support arms 36 positioned adjacent the lower edge of the conveyor belt 11. A

receptacle, such as bag 37, is removeably attached to the support arms 36 for receiving the ejected package P. Each bag has an upper portion that folds over and is secured to the adjacent support arm 36 by a rod 38 and a clamp 39 in the form of a plastic tube with an open side. As is apparent, the upper portion of the bag 37 is folded over each adjacent rod 38 and the clamp 39 is then slipped and snapped over it due to the inherent resiliency of the tube to provide the clamping action.

As will be discussed in greater detail below, a controller 39 (shown schematically in FIG. 6) activates the ejectors 35 in response to the selected parameter on the package P at the proper distribution station DS, DSn around the carousel. In the preferred embodiment of the present invention as shown in FIG.

2, a scanner 40 is provided spaced from the conveyor belt 11 for reading the coded label L that identifies the selected destination parameter. Preferably, the label L is a UPC label and the scanner 40 can be one of several available capable of locating and reading the code. It should be realized that each label L on the coded package P activates the controller 20 during continuous movement of the packages P around the carousel and the packages are ejected on the fly in accordance with the selected parameter. The scanner 40 may be mounted on a cantilever arm 41 above the conveyor belt 11. The scanner 40 may be mounted at

any location around the carousel and in any manner sufficient to allow proper scanning of the coded packages P. In accordance with the broadest aspects of the present invention, manual input by a keyboard can be used (not shown).

As best shown in the top partial cutaway view of FIG. 4A, each ejector 35 includes a pivotal blade 43 and a corresponding actuator in the form of a cylinder 44,44n for extending the blade outwardly to cut across the angled plane of the conveyor belt 11 for ejecting the packages P at the selected distribution station. More specifically, the pivotal blade 43 is mounted to the frame 12 on a pivot pin 45.

It is positioned at the upstream end of each distribution station DS, DSn and in juxtaposition to the support surface of the ledge 25. This arrangement allows for a sweeping action across the ledge engaging the bottom or lower edge of the package P.

In accordance with the preferred embodiment of the present invention and as illustrated in FIG.

4A, each actuator 44 includes a pneumatic cylinder having a clevis 46 attached to the pivotal blade 43.

As sequentially shown in FIGS. 4A-4C and with <BR> <BR> <BR> reference to Figure 6, actuation of each cylinder 44,<BR> <BR> <BR> <BR> <BR> 44n by the controller 39 is in response to valves 53, 53n that apply the air pressure at the correct level to rapidly pivot the blade 43 about the pivot pin 45.

The close, rapid sweeping action of the blade across

the support surface of the ledge 25 kicks the lower end of the package P off the ledge. From this point, the package P simply falls by gravity into the selected bag 37. Advantageously, this minimal contact with the packages limits the amount of energy added to the packages P during ejection. In turn, there is improved control as the package P enters the bag.

In operation, the pivotal blade 43 is retracted as the package P, pushed by the transverse pusher 13, approaches the distribution station DS (see action arrows C in FIG. 4A indicating the direction of the approaching packages). As shown in FIG. 4B, as the controller 39 activates the cylinder 44 (see action arrow D) the blade 43 pivots outwardly (see action arrow E), thereby contacting and kicking the package P off of the ledge 25, as shown by action arrows F. Then, as shown in FIG. 4C, the package P falls lower end first into the bag 37 (see action arrows I) as the blade 43 returns to the normal position (see action arrow G) to await the next package in-line.

In accordance with the method of the sortation system 11 of the present invention, the packages are first positioned on the conveyor belt 11 at a loading station LS, just upstream of the first distribution station DS. The loading can be manual or by any of the known automatic arrangements. The UPC label L may be in any outwardly facing orientation

since the scanner 40 locates and then reads it. Also, it is contemplated that any size package P, or similar article, can be used to practice the method greatly enhancing the adaptability of the system. Typically, any packages P, from a single letter size envelope to a bulk box mailer, and in any combination, are used to practice the invention.

To initiate the operation of the method, the packages P are placed one at a time on the conveyor belt 11 with the bottom edge resting on the ledge 25.

Preferably, the belt 11 is mounted so as to be at an angle 6 (preferably 60°) to the horizontal plane H (see Figure 2). The conveyor belt 11 is modular, formed of the plastic links 26,28 to form an upper conveying surface with low tribological (frictional) characteristics. The shifting of the links allow the side and elevational flexing action, as set forth above. As the conveyor belt 11 is driven in an endless path defining the carousel, the side links slide easily along the guide rails 21,22, which may include a plastic wear strip (see Figure 5). The packages P are presented in turn to the scanner 40 for detection of the code, and delivered to the proper distribution stations DS, DSn in a smooth and efficient fashion. The operation of the conveyor belt 11 in this manner thus provides for maximum speed, as well as exceptional reliability. The modular conveyor belt 11 is particularly well suited for accommodating

the shifting and turning of the links as the endless path to deliver the packages P is traversed.

To assist the registration of the packages P relative to the belt 11 and with respect to the stations DS, DSn it is necessary for the trailing edge to abut the adjacent pusher 13. To do this according to the invention, the ledge 25 forming the track around the carousel is fabricated of stainless steel or the like, and thus provides a frictional drag greater than the conveying surface of the plastic links 26,28. As such, the differential drag is sufficient to slightly retard the packages as they leave the loading station LS (see Figure 1). In other words, the trailing edge of each package slides back against the corresponding transverse pusher 13 before reaching the first in-line distribution station DS (see action arrow S in Figure 1). This allows desirable random positioning of the package P between the pushers 13 and still accomplish registration for proper ejection at the proper distribution station DS.

Also to insure proper registration, the position of the conveyor belt 11 around the carousel is monitored. In particular, sensors 51 are provided near the upstream end of each side of the carousel in order to detect each passing transverse pusher 13 (see FIG. 1). As each pusher 13 passes and lifts the sensing finger, the respective sensor 51 sends a signal to the controller 39 (see FIG. 6).

Additionally, a home position sensor 52 is activated by a low profile cam 52a that clears the sensing finger of the sensor 51 but is operative to engage the sensing finger of said sensor 52. In response, a home position signal is sent to the controller 39 each time the conveyor belt 11 completes a revolution around the carousel, thus further monitoring the operation of the conveyor belt 11.

The scanned parameters for each individual package P are continually transmitted to the controller 39 for processing. Dependent upon the predetermined selected parameter, and in timed registration with the conveyor belt position as determined by the sensors 51,52, the controller 39 initiates the ejection of the selected package P at the appropriate distribution station DS. As set forth above, the ejection is accomplished by actuating the corresponding blade 43. The controller 39 includes a memory module to store the signals from the scanner 40 and the sensors 51,52, so as to allow the ejection of multiple packages at any number of distribution stations DS, DSn simultaneously as the belt 11 continuously moves around the carousel.

In summary, numerous benefits result from employing the concepts of the present invention. The sortation system 10 gains substantial benefits from use of the modular conveyor belt 11 capable of side and elevational flexing action. The belt moves in an

endless path to form a carousel with the multiple distribution stations DS, DSn positioned around it.

The ledge 25 forms a track around the carousel to support the bottom edge of the packages P. From the loading station LS to the first in-line distribution station DS, the ledge 25 provides sufficient differential frictional drag to retard the packages and assure alignment with the adjacent pusher 13.

This action in combination with the signals from the sensors 51,52, allows the controller 39 to provide proper registration between the packages P and the distribution stations DS, DSn. The scanner 40 reads the UPC information on the labels L to allow the controller 39 to determine the proper station for ejection of each package. The bags 37 are held on the arms 36 by the rod 38 and clamp 39 combination for easy, but secure installation and removal. In essence, a simple and inexpensive sortation system 11, that is also capable of more efficient and economical operation is the result.

The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best application to thereby enable one of

ordinary skill in the art to utilize the invention i various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.