APPARATUS AND METHOD FOR FEEDING FLAT OBJECTS INTO A TRANSPORT CONTAINER

Abstract

A device and a method for feeding flat objects, in particular mail items such as envelopes or letters, in an upright position into a transport container. The device enables to achieve a high productivity and a high automation of the input of a plurality of flat objects and a safe guidance of the transport container by using a first transport device for transporting a transport container in a first transport direction, an input device for transporting flat objects along a second transport direction substantially opposite to the first transport direction, and a second transport device arranged below the first transport device for transporting the transport container in a third transport direction. Between the input device and the first and second transport device, a receiving device with a container receiver is arranged. The container receiver can be pivoted between a receiving position and a delivery position.

Claims

1. A device for feeding flat objects, such as mail items, envelopes or letters, in an upright position into a transport container, the device comprising: a first transport device for transporting a transport container in a first transport direction; an input device for transporting flat objects along a second transport direction substantially opposite to the first transport direction, and a second transport device for transporting the transport container in a third transport direction, the second transport device being arranged below the first transport device; a receiving device arranged between the input device and the first transport device and the second transport device and having a container receiving means for receiving a transport container, the container receiving means being pivotable from a receiving position for receiving a transport container from the first transport device into a delivery position for delivering the transport container to the second transport device.

2. The device according to claim 1, wherein at least one of the first transport device and the second transport device is designed for transporting transport containers in an upright position, in which a bottom of the transport container is at least substantially in a horizontal position or slightly inclined to horizontal plane, and the container receiving means is designed for positioning the transport container in an input position, in which the transport container is arranged obliquely or vertically upright.

3. The device according to claim 1, wherein the container receiving means is movable from the receiving position into an input position for inputting the flat objects, wherein in the input position an open side of the transport container faces in the direction of the input device.

4. The device according to claim 3, wherein the container receiving means is movable between an upper input position and a lower input position by means of a movement device.

5. The device according to claim 3, wherein the input device engages at least partially in a transport container in the input position of the container receiving means and/or the receiving position of the container receiving means.

6. The device according to claim 1, wherein the third transport direction is at least substantially parallel to the second transport direction, or the third transport direction and the second transport direction enclose an angle of less than 45?.

7. The device according to claim 1, wherein the container receiving means comprises a receiving base, on which a bottom of a transport container can be arranged, at least one lower contact wall on which a first side wall of a transport container can be arranged, and/or at least two lateral contact walls for guiding side walls of the transport container, and/or a suction device arranged on the receiving base, by means of which a transport container can be sucked in and fixed in the container receiving means.

8. The device according to claim 1, wherein the input device has at least one conveyor device for transporting the flat objects in singulated form or in a scaly overlapping arrangement.

9. The device according to claim 1, wherein the input device has at least two conveyor sections which can be operated independently of one another and/or at different speeds.

10. The device according to claim 9, wherein the input device has a retaining element being arranged for retaining at least briefly and/or scaling the flat objects transported by the input device between two conveying sections of the input device or for insertion of the flat objects between two conveyor sections of the input device.

11. The device according to claim 1, wherein at least one of the input device and the receiving device comprises at least one compression unit, the compression unit having at least one compression element which can be introduced into a transport container during the input of the flat objects and which serves for compressing a stack of flat objects inserted into a transport container.

12. The device according to claim 9, further comprising a movable base element adapted to be moved into a transport container located in the container receiving means, wherein the base element is serving as a support for a stack of flat objects produced by feeding a plurality of flat objects into the transport container, when the base element is arranged within the transport container located in the container receiving means.

13. A method for feeding flat objects in upright position into a transport container, the method comprising: transport of a transport container by a first transport device along a first transport direction; receiving the transport container by a container receiving means positioned in a receiving position; feeding of a plurality of flat objects into the transport container by an input device, which is designed for transporting a series of flat objects in the direction of a second transport direction, which is substantially opposite to the first transport direction; swiveling the container receiving means together with the transport container contained therein into a delivery position; delivery of the transport container being in the delivery position to a second transport device, which is arranged below the first transport device and is designed for transporting the transport container filled with the plurality of flat objects in the direction of a third transport direction.

14. The method according to claim 13, further comprising a step of moving the container receiving means from the receiving position to an input position provided for delivering the plurality of flat objects by the input device into the transport container, wherein the container receiving means is moved together with the transport container contained therein from an upper input position to a lower input position, during feeding the flat objects into the transport container.

15. The method according to claim 13, further comprising a step of delaying and/or interrupting the transport of the flat objects by the input device towards the transport container and/or scaling up the flat objects transported by the input device during delivery of a transport container filled with a plurality of flat objects to the second transport device and/or during transport of an empty transport container by the first transport device into the container receiving means.

16. The method according to claim 13, wherein at least two independently drivable conveyor sections are arranged in front of a retaining element, which conveyor sections are operated at decreasing conveyor speed during a change of transport containers as viewed in the direction of the retaining element.

17. The method according to claim 13, further comprising a step of compressing the plurality of flat objects inserted into a transport container after or during feeding of the flat objects into the transport container, wherein the step of compressing comprises inserting a first compressing element into the transport container and/or inserting a second compressing element into the transport container, wherein the first compressing element is arranged at the input device and the second compressing element is arranged at the receiving device.

18. The method according to claim 17, wherein the step of compressing is performed during feeding of flat objects into the transport container and comprises: inserting the first compression element into the transport container, moving the container receiving means upwards, whereby a stack of flat objects inserted in the transport container is compressed by the first compression element, stopping the upward movement of the container receiving means, as soon as a predefined degree of compression of the stack of flat objects is reached, inserting the second compression element into the transport container on top of the compressed stack of flat objects, removing the first compression element from the transport container, further feeding of flat objects into the transport container and onto the second compression element, while the container receiving means is moved downwards, stopping the feeding of flat objects and removing the second compressing element from the transport container when a predefined filling level of the transport container with a plurality of flat objects is reached.

19. The method according to claim 13, wherein the container receiving means is moved from the delivery position into the receiving position for receiving an empty transport container after a filled transport container has been transferred to the second transport device.

20. The method according to claim 13, further comprising moving a base element into a transport container located in the container receiving means after the transport container has been received by the container receiving means, wherein feeding of flat objects into the transport container is performed by producing a stack of flat objects onto the bottom member inserted in the transport container.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0049] These and further features as well as advantages and effects of the device according to the invention as well as of the method according to the invention become clear from the following disclosure of embodiment examples described in more detail with reference to the accompanying drawings. The drawings show:

[0050] FIG. 1: Sketch of a device for feeding flat objects into a transport container in a side view;

[0051] FIGS. 2 to 16: Sketches of the device of FIG. 1 in different process stages of a method for feeding flat objects into a transport container;

[0052] FIG. 17: Illustration of a preferred embodiment of the device with a movable base element that can be inserted into a transport container located in the device in an input position, wherein in the Figure the base element is located outside the transport container in an extended position;

[0053] FIG. 18: Schematic illustration of a further embodiment of the device with a base element that can be inserted by a pivoting movement into a transport container located in an input position in the device;

[0054] FIGS. 19A and 19B: Schematic representation of a transport container in an input position in the device, with a base element located in the transport container and a stack of flat goods arranged on the base element, wherein the base element can be tilted relative to a horizontal plane and is shown in FIGS. 19A and 19B in two different tilting positions.

DETAILED DESCRIPTION

[0055] FIG. 1 shows an exemplary sketch of a device 1 according to the invention for feeding flat objects in an upright position into a transport container T. FIGS. 2 to 16 show reduced sketches of the device from FIG. 1 in individual and consecutive process steps of a method according to the invention for feeding the flat objects 5 into the transport container T, whereby individual components of the device 1 have been omitted in FIGS. 2 to 16 merely for the sake of clarity.

[0056] The device 1 for feeding flat objects 5 outlined in FIG. 1 comprises a first transport device 2 for transporting transport containers T along a first transport direction v1, a feed device 4 for transporting flat objects 5 along a second transport direction v2 essentially opposite to the first transport direction v1, and a second transport device 3 arranged below the first transport device 2 for transporting transport containers T in a third transport direction v3 running essentially parallel to the second transport direction v2. A receiving device 6 with a container receiving means 7 for receiving a transport container T is arranged between the input device 4 and the transport devices 2, 3.

[0057] The first and second transport devices 2, 3 each comprise a motor-driven conveyor device, in particular an endless conveyor belt, on which transport containers T can be transported along the first transport direction v1 and the second transport direction v2, respectively, in a substantially upright transport container position.

[0058] Viewed in the second transport direction v2, the input device 4 has several conveyor sections arranged one behind the other, namely a first conveyor section M1, a second conveyor section M2, a third conveyor section M3, a fourth conveyor section M4 and a fifth conveyor section M5. The conveyor sections M1 to M5, which in particular can each comprise endless conveyor belts rotating around driving and deflection rollers, can be driven independently of one another. Via the first conveyor section M1, the flat objects 5 are fed towards the input device 4, in particular from an infeed system (not shown here) connected upstream of the input device 4. Through the downstream fifth conveying section M5, the flat objects 5 are fed into a transport container T arranged in the container receiving means 7. In the present embodiment example, the first to fourth conveying sections M1 to M4 run essentially in a horizontal plane. The fifth conveying section M5 is slightly inclined downward. This favors an input of the flat objects 5 into a transport container T. In the region of the fifth conveying section M5, a first compression element 12 movable substantially along the second conveying direction v2 and insertable into a transport container T arranged in the container receiving means 7 is provided. The first compression element 12 is coupled to a drive (not shown) for performing a movement towards a transport container T placed in the container receiving means 7. Further, the input device 4 has a retaining element 11 arranged above the fourth conveying section M4, which can be brought in and out of engagement (e.g. by an up and down movement) by a first actuator A1 between the third and the fourth conveying sections M3, M4.

[0059] The container receiving means 7 of the receiving device 6 has at least one lower contact wall 8 and a receiving base 9, wherein a transport container T inserted into the container receiving means 7 rests with a front side wall against the contact wall 8 and rests with its bottom on the receiving base 9. Preferably, the container receiving means 7 has lateral contact walls, not shown in FIG. 1, for a secure lateral guiding of the transport container T. Via a second actuator A2, the container receiving means 7 can be rotated or pivoted about a pivot axis 14. In an alternative embodiment, it is also conceivable that the entire receiving device 6 is designed to be pivotable, i.e. that further components of the receiving device 6 are also pivoted together with the container receiving means 7.

[0060] Via a movement device 10, the container receiving means 7 can be moved between an upper position described in more detail below and a lower position. Further, the receiving device 6 comprises a second compression element 13 which can be inserted into a transport container T arranged in the container receiving device 7. The second compression element 13 is mounted in such a way that it is moved together with the container receiving means 7, in particular during an upward and downward movement, by the movement device 10. In an alternative embodiment not shown here, it is also conceivable that the second compression element 13 is attached to the receiving device 6 in such a way that it is also pivoted together with the container receiving device 7 when the latter is pivoted.

[0061] In the following, considering FIGS. 2 to 16, an example of a method according to the invention for feeding the flat objects 5 into the transport container T is described. The method outlined in FIGS. 2 to 16 is carried out in the device 1 of FIG. 1. However, the method according to the invention is not limited to the described embodiment and, in particular, need not to be executed in a device according to FIG. 1. Merely for the sake of clarity, the movement element 10 and the second actuator A2 in FIGS. 2 to 16 as well as the reference signs of the receiving device 6, the contact wall 8, the receiving base 9 and the pivot point 14 are not drawn in FIGS. 2 to 16.

[0062] FIG. 2 and FIG. 3 show the transport of a transport container T by the first transport device 2 along the first transport direction v1 and the transfer of the transport container T into the container receiving means 7. For this purpose, the container receiving device 7 is moved to a receiving position shown in FIG. 2 and FIG. 3 for receiving the transport container T provided by the first transport device 2. When the container receiving means 7 is in the receiving position, the first transport device 2 is driven and the transport container T is conveyed along the first transport direction v1 into the container receiving means 7. Subsequent transport containers T, T are already located in series on the first transport device 2. In the present case, however, the first transport device 2 is driven only during the transfer of the front transport container T and is then stopped until the next transport container T shall be transferred to the container receiving means 7. In addition to the design shown, other designs of the first transport device 2 are also conceivable, for example a transport of transport containers T in the first transport device 2 using gravity alone and the provision of a limiting element at the end of the first transport device 2 pointing in the direction of the container receiving means 7, which can be introduced in front of one of the following transport containers T, T in order to retain the following transport containers T, T and which can be released for the transfer of the next transport container T to the container receiving means 7, in order to allow a movement of the next transport container T in the first transport direction v1.

[0063] FIG. 4 and FIG. 5 show the movement of the container receiving means 7 from the receiving position shown in FIG. 2 and FIG. 3 to the upper input position shown in FIG. 5. For this purpose, the container receiving means 7 is first pivoted towards the input device 4, as shown in FIG. 4, and then moved upward by the movement device 10 shown in FIG. 1. As shown in FIG. 4 and FIG. 5, when the container receiving means 7 is moved to the upper input position shown in FIG. 5, the second compression element 13 attached to the receiving device 6 moves upwardly together with the container receiving means 7. The first and the second compression elements 12, 13 are configured and arranged in such a way that they do not interfere with each other, in particular not during an upward and downward movement of the container receiving device 7. For example, the compression elements 12, 13 can comprise compressing pins or compressing fingers arranged one behind the other.

[0064] As can be seen from FIGS. 2 to 5, while the transport container T is being picked up by the first transport device 2 and the container receiving means 7 is positioned in the upper input position, the retaining element 11 is in a lower position and thereby is blocking the conveyance of flat objects 5 by the input device 4 towards the container receiving means 7.

[0065] As shown in FIG. 6, when the container receiving means (and the transport container T contained therein) is in the upper input position, the retaining element 11 is moved upward by the first actuator A1 to a release position and the series of flat objects 5 is moved by the conveying sections M1 to M5 of the conveying device in the second transport direction v2 and is finally fed into the transport container T via the fifth conveying section M5. The conveying sections M1 to M5 are thereby preferably all driven at the same conveying speed. The flat objects 5 are thus conveyed serially into the transport container T and stacked flat on top of each other in the transport container T to produce a stack S of flat objects therein, as can be seen in FIGS. 6 and 7.

[0066] As the filling level of the transport container T increases, the container receiving means 7 is moved downward in steps or continuously, as shown in FIG. 7, to ensure a compact input of the plurality of flat objects 5, in particular a compact stacking of the flat objects 5 on the stack S of flat objects developing inside the transport container T.

[0067] As soon as a certain filling level of the container T is reached, the first compression element 12 arranged on the input device 4 is moved into the transport container T, as shown in FIG. 8. For this purpose, the first compression element 12 is coupled to a drive element that is not shown here. Subsequently, as shown in FIG. 9, a compression of the stack S of flat objects 5 placed in the transport container T takes place by moving the container receiving means 7 upward by means of the movement device 10 (shown in FIG. 1). Here, the compression of the stack S is achieved by pressing the flat objects 5 in the transport container T against the stationary first compression element 12 arranged on the input device 4. As soon as a certain compression is reached, at which in particular the second compression element 13 is at the same height level as the first compression element 12, the movement of the container receiving means 7 is stopped.

[0068] As shown in FIG. 10, the second compression element 13 attached to the receiving device 6 is then introduced into the transport container T, and the first compression element 12 subsequently is removed therefrom. The second compression element 13 introduced into the transport container T ensures that the compression of the stack S of flat objects 5 achieved by the first compression element 12 is upheld. Subsequently, or if necessary, also during the described compression process, further flat objects 5 are inserted serially by the input device 4 into the transport container T, specifically on top of the stack S and above the second compression element 13, as shown in FIG. 10. The container receiving means 7 is then again movedtogether with the second compression element 12downwards in the direction of the lower input position, shown in FIG. 11, in order to obtain an optimal input or placement of further the flat objects 5 on the stack S placed in the transport container T. Contrary to the illustration in the figures, the first and in particular the second compressing elements 12, 13 are preferably designed as thin as possible, for example as thin metal sheets or thin tines of a rake, in order to cause an optimized stacking under an optimal use of the receiving contingent of the transport container T.

[0069] Shortly before a transport container T reaches a predetermined (or maximum) filling level, as shown in FIG. 12, the restraining element 11 is moved downward by the first actuator A1 into a blocking position. Thereby, the serial flow of flat objects 5 conveyed by the input device 4 to the transport container T is interrupted. The flat objects 5 which are on the fourth and fifth conveying sections M4, M5, so downstream of the restraining element 11, are still fed into the transport container T, as shown in FIG. 13. Preferably, the conveying speed of the fourth and fifth conveying sections M4, M5 can be increased for a short time for this purpose, in order to shorten the duration of the required stopping of the serial flow of flat objects 5 arranged in upstream of the retaining element 11.

[0070] When none of the flat objects 5 is located on the downstream conveying sections M4 and M5 anymore, the downstream conveying sections M4, M5 can be stopped to save power. For the time that the restraining element 11 is in its blocking position, the conveying speed of the conveying sections M1 to M3 arranged upstream of the restraining element 11 can be reduced. Preferably, the speed at which the conveying sections M2 and M3 are driven preferably is gradually reduced, in particular in such a way that the conveying speed of the third conveying section M3 is lower than the conveying speed of the second conveying section M2. The first conveying section M1 can maintain its conveying speed, so that there is no effect on an infeed system arranged upstream of the input device 4, which feeds the series of flat objects 5 to the input device 4. Due to the retaining element 11 being in its lower blocking position and the described control of the conveying sections M1 to M3, an increasing scaling of the flat objects 5 arranged upstream of the retaining element 11 takes place, as indicated in FIGS. 12 to 16.

[0071] As soon as the transport container T is completely filled (up to a maximum filling level), the second compression element 13 is moved out of the transport container T, as shown in FIG. 14, the container receiving means 7 is swivelled into the delivery position shown in FIG. 15 and the transport container T is delivered to the second transport device 3. Then, as shown in FIG. 16, the container receiving means 7 is moved back to the receiving position, shown in FIG. 2, to receive the next transport container T. The filled transport container T meanwhile is transported away by the second transport device 3 along the third transport direction v3.

[0072] An exemplary device and an exemplary method for feeding flat objects 5 in an upright position into a transport container T is described herein. The invention is not limited to the described example embodiment. Thus, among other things, other control of the restraining element 11, the conveying sections M1 to M5 and the transport devices 2, 3 is possible. For example, the retaining element 11 can be controlled in such a way that it is already moved upwards shortly before a transport container T is in the upper input position, shown in FIG. 5, so that immediately when the container receiving means 7 has reached the upper input position, flat objects 5 are already fed into the container T. This prevents an unnecessary delay or loss of time.

[0073] Furthermore, it is also conceivable that the second compression element 13 is arranged on the receiving device 6 in such a way that the receiving device 6 is pivoted together with the container receiving device 7 and, for example, is only brought out of the latter after the container receiving device 7 is in the delivery position. Depending on the positioning of the transport devices 2, 3 and the input device 4, the sequence of movement of the container receiving means 7 can also differ. For example, the container receiving means 7 can already be in the upper input position when pivoting from the receiving position to the input position and/or can be both pivoted and moved upwards when moving from the delivery position to the receiving position. It is also conceivable that the container receiving means 7 is pivoted and moved downward during movement from the lower input position to the delivery position. Further, the device may also have sensors for detecting the filling level. Furthermore, a multiple compression by the first compression element 12 and the use of a plurality of second compression elements 13 is also conceivable.

[0074] FIGS. 17 and 18 show embodiments of the device with a movable base element 15 that can be inserted into a transport container T located in the receiving device 6 in an input position, wherein the base element 15 in FIGS. 17 and 18 is located outside the transport container T in an extended position. These embodiments of the device are specifically intended for use with transport containers T having inclined side walls. In the case of such transport containers T, in which at least two opposing side walls form an angle of more than 90? with the bottom of the transport container, there is a risk that a stack S of flat objects stacked in the transport container T, which is in the input position in the device, may slip out of the transport container due to the inclined side walls, in particular the front side wall of the transport container which is at the bottom in the input position. To prevent this, the movable base element 15 is retracted into the transport container T before flat objects 5 are inserted. In this position of the base element 15, which is shown schematically in FIGS. 19A and 19B, the base element 15 serves as a support, arranged at least substantially horizontally or preferably perpendicularly to the bottom of the transport container T, for supporting the stack S of flat objects stacked in the transport container T by serially feeding a plurality of flat objects 5 thereon.

[0075] In the embodiment shown in FIG. 17, the base element 15 is designed as a linearly movable plate which is coupled to a drive by means of which the plate of the base element 15 can be retracted into a transport container T located in the container receiving means 7 in the input position, and can be extended again out of the transport container T. In the retracted position of the base element 15, shown in FIGS. 19A and 19B, the plate is in contact with and at least substantially perpendicular to the bottom of the transport container T. In this position of the base element 15, the flat objects can be stacked on the plate of the base element 15, with the generated stack S of flat objects being supported on the one hand by the plate of the base element 15 and on the other hand by the (inclined) bottom of the transport container T. The stack S of flat objects thereby is supported by the plate of the base element 15. This prevents the stack S from slipping out of the transport container T during stacking.

[0076] In particular, when stacking of flat objects 5 with different thicknesses on a front side and a rear side, such as envelopes or mail items packed in an envelope, there is a risk of a stack formed by the (filled) envelopes being built up at an angle, if the items are always stacked in the same orientation on the stack S (i.e., for example, always with the thicker front side facing the bottom of the transport container T). This effect is shown schematically in FIG. 19A. As a result, there is a risk that the entire stack S or at least the upper layers of the stack will slip out of the transport container T during stacking, as indicated by an arrow in FIG. 19A. In order to prevent this, the inclination of the base element 15, in particular of the plate which can be moved into the transport container T, can preferably be adjusted relative to a horizontal plane. For this purpose, the plate is hinged to a frame of the base element 15 so as to be pivotable about an axis extending in a horizontal plane, for example. During stacking of the flat objects 5, the inclination of the plate of the base element 15 relative to the horizontal plane can thereby be adjusted so that the upper side of the stack S runs at least substantially horizontally or is inclined downwardly in the direction of the bottom of the transport container T, as shown in FIG. 19B, so that the flat objects 5 in the upper layers of the stack S cannot slip out.

[0077] FIG. 18 shows another embodiment of the device with a movable base element 15, wherein the base element 15 in this embodiment can be introduced into a transport container T located in an input position in the device by a pivoting movement. For this purpose, the base element 15 comprises at least one pivotable plate. Preferably, in this embodiment, the base element 15 comprises a first plate pivotally arranged laterally on a first side of the receiving device 6 and a second plate pivotally arranged laterally on a second side of the receiving device 6 opposite to the first side. The first and second plates are thereby coupled to a pivot drive, by means of which the two plates can be pivoted into and out of the transport container, as shown schematically in FIG. 18 by the arrow symbolizing the pivoting movement of one plate. When the two plates of the base element 15 are pivoted into the transport container T, the plates form a support for a stack S with a support surface formed by the top of the two plates, wherein the support surface is at least substantially perpendicular to the bottom of the transport container T (as shown in FIG. 19A). It is convenient that the inclination of the two plates with respect to a horizontal plane or with respect to the bottom of the transport container, as in the embodiment of FIG. 17, is adjustable by means of an inclination drive (as schematically shown in FIG. 19B). Instead of two plates, the base element may also comprise only a single plate, which is pivotally attached to the side of the receiving device 6. However, the design of the base element 15 by two plates has the advantage that the extension of the device in a lateral direction (perpendicular to the transport directions v1, v2, v3) is smaller when the base element 15 is folded out, whereby the device is more compactly constructed.