Embodiments of a system and method for sorting and sequencing articles in a processing facility are disclosed. Delivery endpoints are divided and grouped into stop groups. A first sorter sorts items according to stop group and outputs the items to trays. The output trays from the first sorter are loaded to a second sorter in stop group order. The second sorter sorts items for each stop group into separate lanes. Each lane can then be sorted into output bins in delivery sequence order.

Embodiments of a system and method for unloading articles from a container of items for use in an automatic stack feeder are disclosed. The automatic stack feeder may comprise a belt, a moveable lower paddle, and a moveable upper paddle, wherein the lower paddle is configured to partially extend through a belt of the automatic stack feeder. The movement of the belt, the lower paddle, and the upper paddle are coordinated such that there is no need to interrupt the operation of the automatic stack feeder to unload the container.

According to some embodiments, a stacking assembly accepts mail-pieces traveling from a re-direct mechanism in a first direction and urges a leading edge portion of a mail-piece toward a registration wall of a sortation bin. The stacking assembly may include a plurality of neighboring cam shafts, each with at least one cam, arranged along the first direction, such that rotation of the cam shafts results in synchronized rotation of the cams to guide an incoming mail-piece. Rotation of the cam shafts may also urge a previously stacked mail-piece away from the cams, and into the sortation bin, in a second direction perpendicular to the first direction.

Embodiments of a system and method for sorting and sequencing articles in a processing facility are disclosed. Delivery endpoints are divided and grouped into stop groups. A first sorter sorts items according to stop group and outputs the items to trays. The output trays from the first sorter are loaded to a second sorter in stop group order. The second sorter sorts items for each stop group into separate lanes. Each lane can then be sorted into output bins in delivery sequence order.

A mail singulator system determines a position of an optical panel to automatically adjust a loading conveyor speed to prevent stacked and overlapped mailpieces in the singulator and large gaps between mailpieces. The optical panel is configured between the front mailpiece of a mail stack on the loading conveyor and the optical sensor. The optical panel changes position with the pressure exerted by the mail stack and provides signals to the controller to adjust the conveyor speed. An optical sensor may detect a far threshold position or limit distance to increase the speed of the conveyor and may detect a near threshold position of limit distance to reduce the speed of the conveyor. The optical panel may have a low friction surface to allow the mail to slide into the conveyor and an optical surface to allow reliable optical sensor detection of the optical panel position.

According to some embodiments, a stacking assembly accepts mail-pieces traveling from a re-direct mechanism in a first direction and urges a leading edge portion of a mail-piece toward a registration wall of a sortation bin. The stacking assembly may include a plurality of neighboring cam shafts, each with at least one cam, arranged along the first direction, such that rotation of the cam shafts results in synchronized rotation of the cams to guide an incoming mail-piece. Rotation of the cam shafts may also urge a previously stacked mail-piece away from the cams, and into the sortation bin, in a second direction perpendicular to the first direction.

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.

Embodiments of a system and method for sorting and sequencing articles in a processing facility are disclosed. Delivery endpoints are divided and grouped into stop groups. A first sorter sorts items according to stop group and outputs the items to trays. The output trays from the first sorter are loaded to a second sorter in stop group order. The second sorter sorts items for each stop group into separate lanes. Each lane can then be sorted into output bins in delivery sequence order.

A mail singulator system determines a position of an optical panel to automatically adjust a loading conveyor speed to prevent stacked and overlapped mailpieces in the singulator and large gaps between mailpieces. The optical panel is configured between the front mailpiece of a mail stack on the loading conveyor and the optical sensor. The optical panel changes position with the pressure exerted by the mail stack and provides signals to the controller to adjust the conveyor speed. An optical sensor may detect a far threshold position or limit distance to increase the speed of the conveyor and may detect a near threshold position of limit distance to reduce the speed of the conveyor. The optical panel may have a low friction surface to allow the mail to slide into the conveyor and an optical surface to allow reliable optical sensor detection of the optical panel position.

A mail singulator system determines a position of an optical panel to automatically adjust a loading conveyor speed to prevent stacked and overlapped mailpieces in the singulator and large gaps between mailpieces. The optical panel is configured between the front mailpiece of a mail stack on the loading conveyor and the optical sensor. The optical panel changes position with the pressure exerted by the mail stack and provides signals to the controller to adjust the conveyor speed. An optical sensor may detect a far threshold position or limit distance to increase the speed of the conveyor and may detect a near threshold position of limit distance to reduce the speed of the conveyor. The optical panel may have a low friction surface to allow the mail to slide into the conveyor and an optical surface to allow reliable optical sensor detection of the optical panel position.