Apparatus and method for coding and reading codes

Description Submit all comments and votes

IN THE DRAWINGS

FIG. 1 is a schematic diagram illustrating an article coding, reading and routing system which is particularly applicable to the routing of mail pieces and information bearing cards;

FIG. 2 is an end view of one type of conveyor for oblong flat articles of the type conveyed in FIG. 1;

FIG. 3 is a side view with parts broken away for clarity of a modified form of the feed and conveying means of FIG. 1;

FIG. 4 is a side view of one form of piece conveyed by the apparatus of FIGS. 1-3;

FIG. 5 is a side view of another form of piece conveyed by the apparatus of FIGS. 1-3; and

FIG. 6 is a fragmentary view of another form of piece which may be coded and conveyed by apparatus of the type described.

FIG. 7 is a side view with parts broken away for clarity of a portion of a wheel-device operative for recording series codes along a band area of a card, envelope, box, tape or other article.

FIG. 8 is an isometric view of an object on a conveyor being coded with a pulsed radiation beam and a schematic diagram of electronic means for controlling the operation of the radiation beam generating means to apply select codes to such objects as it is conveyed past the beam generating means.

FIG. 9 is an isometric view of an object on a conveyor in motion past a scanning station which includes television camera means for scanning the object both along a plurality of scanning paths and from a plurality of directions.

In FIG. 1 is shown part of a system for automatically coding and routing articles such as envelope and card mail pieces. However, the system illustrated in FIG. 1 is also applicable to the coding and routing of packages by utilizing most of the scanning, coding and conveying techniques provided therein.

The coding and sorting or routing system 10 includes a first means 11 such as a feeding bin or other suitable storage means for a plurality of mail pieces or cards which are individually designated by the alphabetical character E. The pieces E to be coded and routed may be horizontally or vertically stacked within the bin or feed magazine 11 in accordance with known designs, one such magazine illustrated in U.S. Pat. No. 2,891,467 contains means for feeding individual mail pieces to an outflow conveyor. In FIG. 1, the mail pieces E are fed in a horizontal stack and the endmost piece is disposed against a power-driven conveyor belt 12 which, cooperates with a feed mechanism 12 which is driven, together with the belt 13, by a controlled electric motor 14 which operates to feed individual mail pieces or cards intermittently onto a conveyor 15 leading to a conveyor 19 at the coding station 20. Conveyor 15, intermittently driven by a controlled electric motor 16, which like motor 14, is preferably a gear motor and has respective start and stop controls designated F and S which may comprise the inputs to a pulse operated bistable switch feeding electrical energy to the input of said motor. Motor 14 may be similarly operated, although in FIG. 1, it is illustrated as having a single control line input thereto for pulsing the motor control and comprising part of the unit 14, and such control is operative when so energized to cause the motor and the mechanism driven thereby to operate in a single cycle for releasing just one card or mail piece E from bin 11 to the conveyor 15 as provided, for example, in the Recordak 300 Stack-Reader for feeding cards to a reader.

The conveyor 15 is operative, as illustrated in greater detail in FIG. 2, to convey the lower edge 73 of a card or envelope along a predetermined path or line so that said lower edge will be properly disposed for applying a code recording or marking therealong such as on the border area adjacent said lower edge as will be hereafter described. Thus, regardless of the height and length of the envelope, all envelopes will contain a code sorting or destination recording along their lower edges or borders which may be easily read for sorting purposes by predeterminately positioning and conveying each piece with the lower edge thereof travelling the same path as the lower edges of all such pieces.

A photoelectric detector 17 is disposed immediately adjacent conveyor 15 and is operative to detect the leading edge 731 of a piece E travelling along conveyor 15. The photoelectric controller 18 for the cell or scanning system 17 is operative to generate an output pulse upon detecting such leading edge, which pulse is applied to the stop control S of motor 16 which temporarily stops conveyor 15 carrying the piece to be coded thereon while awaiting release of the piece downstream thereof which is being scanned and coded.

Coding and monitor station 20 includes a viewing screen 30 which provides an enlarged image of the address 75 on the face of the card or envelope E when the latter is disposed in the scanning field of a television camera 33 having its picture signal output 34 connected to the video receiver containing the monitor screen 30. Thus the operator of the station may easily view the state and city destination printed on written as part of the address 75 of the card, permitting him to properly code the lower edge of the card.

The monitor station 20 includes a console 20C having, in addition to the monitor screen 30, a single pushbutton cycle control switch 29 and a panel 26 containing a plurality of pushbutton coding switches 26S. By properly depressing the banks of coding switches 26S, parallel destination codes are generated on the outputs 27 thereof which extend to a shift register 28 for converting the parallel codes to a series code which is held therein until an input 32' to the shift register is energized, after which the series code is applied to activate a recording device 24 which records the series code along the lower border or edge of the piece E.

Upon activating a cycle control switch 29, a control signal is generated on a plurality of circuits including a circuit extending to the control for the motor-operated device 14 for releasing the next piece from the bin 11, the start control F of motor 16 for driving the piece held upon conveyor 15 to conveyor 19, the start control F of motor 25 for driving conveyor 19 to remove the previously coded piece therefrom onto continuously driven conveyor 35 and a delay relay 32 in the line 34' leading to the trigger input of the shift register 28. A delay in the operation of the shift register is thus provided to permit the leading edge of the piece E to be coded to be driven past the recording transducer 24. After recording is effected, the piece is transferred from conveyor 19 to conveyor 35 which extends to a plurality of branch conveyors, designated 40, 41, etc., onto one of which the piece is conveyed or transferred by means to be described.

Edge or border coding of each piece on the conveyor 19 may be effected in one of a number of manners depending upon the marking or recording system provided. In FIG., 1, an automatic, motor-operated applicator 21 for recording material has its output closely disposed to the path along which each piece is conveyed on conveyor 19 and is operated by a signal generated by a time delay relay 31, which is activated when the cycle start control switch 29 is activated. In other words, at some time after the piece E has started its movement towards conveyor 19 from conveyor 15, the applicator device 21 dispenses a recording material by spraying or rolling same along the lower edge or border of the mail piece as it passes said applicator. In one form of the invention, the recording material may comprise magnetic oxide which is roller or spray coated along said edge or border or is otherwise applied thereto as the piece is fed past the applicator on conveyor 19.

A photoelectric detector 22 detects the leading edge of the piece E and its control 23 generates a pulse output to the stop control S of motor 25 which predeterminately positions the piece in the scanning field of the video camera 33. The operator of the station 20 reads the address 75 on the face of the piece E and, either mentally, or by reference to a chart, generates the necessary address or selection code by properly operating selected of the switches 26S of the control panel 26. Thereafter, the cycle is repeated when the operator depresses start cycle control switch 29 after which the recording transducer 24, which may comprise a magnetic recording head, is engaged or rolled against the edge or border of the piece E containing the recording material provided by device 21. The motor 25 is operated to remove the piece E from conveyor 19 to transfer it to conveyor 35 until the photoelectric detector 22 detects the leading edge of the next card whereupon motor 25 is stopped by pulsing the stop input S thereof.

The piece E may be stored downstream of conveyor 19 in the event that it is a card to be edge coded or, if it is a mail piece it may be conveyed on conveyor 35 past a magnetic reproduction transducer 36 which is operative to operably engage the magnetic recording material applied to the lower edge or border thereof and to reproduce the code provided as a recorded pulse train along such lower portion of the piece. The output of reproduction transducer 36 is passed to an amplifier 37 which generates a series code on its output, which output extends to a logical switching circuit controller 38 which controls a servo 39 operating gate deflection means 39' for properly transferring the piece to one of a plurality of branch conveyors 40, 41, etc. for properly routing the piece E along that path which is indicated by the code provided along its lower edge and reproduced by reproduction transducer 36.

In FIG. 1, notation PS refers to a power supply for electrically powering the switches, controls and motor device 30 associated with the monitor and coding switch controller 20C for generating the described control and code signals on the outputs thereof. It is assumed that suitable power supplies are provided on the proper sides of all switches, controls and motors illustrated in FIG. 1, such not having been illustrated therein for the purpose of simplifying the drawings.

The recording material device 21 may be subject to a number of variations depending on the coding, recording and scanning apparatus used in the system. For example, device 21 may adhesively apply coded or uncoded tape, such as magnetic recording tape, along a selected band area such as near or parallel to the lower edge of member E. Printed or other optically scannable tapes or recording material may be applied by suitable roller applying means comprising part of device 21 which may also contain recording means for the code operatively connected to the code generating means described herein. Device 21 may also comprise a printing wheel for magnetic material or ink for applying machine readable characters or codes along the piece E as it is driven therepast. Device 21 or the transducer 22 may also comprise a laser and means for pulse modulating its output with code signals for burning a code along or parallel to the lower edge of members E or containers fed therepast.

It is also noted that reading device 36 may be a photoelectric reading system such as employing a light reflected off an electro-optically readable code applied by one of the means defined herein.

The automatic scanning means for identifying the document, envelope or package and/or determining its destination, so as to provide a coded electrical signal for controlling recording as described, may comprise a conventional electro-optical character reader is adpated to read all lines of the address or label 75 and, by logical circuit or other means, determines the destination and/or other characteristics of the document for coding purposes. In a preferred form, means may be provided for the reader to read just the last line of characters and preferably the last portion 75Z thereof which may comprise the zip code. Suitable optical scanning means may be provided, such as an electron beam scanning means to scan laterally from or near the bottom edge of the envelope upwardly until the last line of characters is identified and is operable to generate a pulse output upon detecting such last line to control the positioning of the line scanning means so as to only scan said last line. If the envelope is fed lateral to its longitudinal edge 73 such edge by means provided in my U.S. Pat. No. 3,309,669, then the activation of any one of a plurality of photoelectric detectors, scanning the face of the envelope and disposed in a line parallel to edge 73, may generate a control signal when the last line 75Z of characters is scanned and such control signal may be employed to stop the means driving the envelope and initiate the operation of the scanning disc or beam to cause it to scan such last line, which may comprise characters defining the town and city or may be the mail zip code per se. If such last line is defined by the zip code, the code signals output by the scanner may define a series of binary codes indicative of the zip code which may be recorded, as described, along the recording area of the envelope or may be electronically converted to a single binary series code indicative of the zip code number prior to applying same to modulate the recording transducer. A suitable time delay relay may be employed to initiate the motor driving the envelope from the reader onto, for example, a conveyor of the type described such as edge travelling conveyor 35.

If an electron beam scanning means is operable to read the zip code 75Z, suitable logical switching circuitry may be provided to detect the last line or zip code portion of the address 75 and cause the read beam of the scanning means to read such last line or zip code or control a gate to pass the modulated analog signal output generated when the read beam thereof scans said last line of characters or code, to a suitable means for converting such analog signal to a suitable signal form which may be used to modulate and control the described magnetic or optical recording means. If the zip code comprises the last line of printed matter, it may be read per se and the resulting signals may be applied to the recording transducer. If such zip code is not part of the last line of the address being read, beam scanning may be effected which initiates at the end of the line containing such code until the gap is detected between the zip code and end of the printing defining the address portion of the last line which scanning may be used to generate signals defining such zip code number.

Thus it is seen that the apparatus defined in FIG. 1 may be operated either by a person viewing individual mail pieces when said mail pieces contain a variety of addresses in printed or handwritten form and disposed at various locations or may be automatically effected if the mail piaces and their printed addresses are uniform and capable of being electro-optically scanned. Switch 42 in the output line 34, may be manually operated to define either automatic or manual operation of the scanning and coding operation.

The automatic scanning system defined by scanner 33 and computing circuitry 43 may be operated in accordance with known address scanning and recognition equipment or that provided in application Ser. No. 622,650 which provides a rotating disc for reading a select line of a document driven past the scanner or by moving the scanner past the document.

FIG. 2 illustrates a conveyor for edgewise conveying thin oblong members E, such as cards and envelopes, to be coded. The features shown in FIG. 2 may be applied to any or all of the conveyors 15, 19 and 35 of FIG. 1. The oblong card or mail piece E is disposed in a channel-like guideway defined by longitudinally aligned conveyor wheels 54 having outer surfaces which taper sharply inwardly, as illustrated, to provide V-shaped wells for the cards or envelopes resting on the upper surfaces thereof. A plurality of longitudinally aligned wheels 54 are rotationally supported in spaced-apart relationship by a channel-like member 50, the side walls 51 and 53 of which contain ball bearings B which rotationally support the shafts 54S of the wheels 54.

The single concave, wedge shaped roller 54 of FIG. 2 may also be replaced or supplemented by a plurality of cylindrical rollers disposed with their peripheral surfaces properly angled to the horizontal with alternate rollers of an array of said rollers angled and power rotated to provide the same lower edge aligning, guiding and driving effect as the single rollers 54 illustrated in FIG. 2.

Other conveying means may also be provided to predeterminately align and guide the lower longitudinal edges of each envelope or card along a predetermined path for coding and reading same as described. For example, the horizontally angled surfaces defined by the inwardly tapering conical portions of the rollers 54 of FIG. 2, may be replaced by a pair of power driven flexible belts each angled upwardly and driven in the same direction at the same speed with their lower edges disposed close to each other or they may be shaped wherein the lower edge of one abuts the upper surface of the other so as to provide a guideway for the lower edge of each mailpiece. A single belt or pulley of resilient material, folded or having a V-shaped upper surface may also be utilized.

In the embodiment of FIG. 2, it is noted that said wheel shaft 54 extends outwardly through the bearings from the wall 51 and contains pulleys 58 on the ends thereof which are rotated by a chain or belt 58' driven by a pulley or sprocket on the shaft of motor 16 so that all wheels 54 rotate simultaneously to drive the piece E therealong.

Cantileverly supported on the sidewalls 51 and 53 of the channel 50 and extending upwardly therefrom are a plurality of pairs of leaf spring members designated 55 and 55', each of which supports a pillow block denoted 56 and 56', which rotationally support respective wheels 57 and 57', the peripheries of which are spaced apart a degree greater than the thickness of the average piece E, although possibly less than the thickness of the heaviest gauge or thickest mail piece. Thus, while some degree of lateral movement of the mail piece E may be effected between the rollers 57 and 57' such mail piece will be guided thereby and, if such wheels are power rotated by means such as that rotating the wheels 54, further means will be provided for power driving the member E along its guided path.

Since the lower edge of all pieces E is determined by the path defined by the low point of the radian groove or recess formed in the wheels 54, various devices such as the described magnetic recording and reproduction transducers, recording material application means and edge detection means may be provided between adjacent wheels 54 as illustrated in FIG. 2 wherein a recording device 59 is supported by the bottom wall 52 of the channel 50 and is removably secured thereto by means of adjusting nuts 59' which retain same in a hole extending vertically through the bottom wall 52. If the exterior wall of member 59 is threaded, the transducer 59T which is secured thereby may be vertically adjusted and held by adjusting and tightening such adjustment nuts 59' against the wall 52 of the channel. The transducer head 59T illustrated in FIG. 2 is operative to scan or record signals along the lower edge of the piece E although it may be so shaped to scan or record along other border areas of E. Similarly, the transducer, photo-electric detector or recording material application means may be adjustably supported by either or both side walls 51 and 53 of the channel 50.

FIG. 3 shows details of a modified form of feeding bin 60 operable for individually feeding mail pieces or cards to a conveyor extending to a monitor and coding station as described. Whereas in FIG. 1 the feeding bin 11 is operative to stack the mail pieces or cards E so that they may be fed from a stacked array therefrom, such bin may contain cards disposed in a horizontal stack or at an angle to the horizontal for coding with the cards disposed as in FIG. 1 lying on their sides. The feeding means 60 of FIG. 3 includes a bin 61, the side walls of which are preferably made of tubed metal sheet containing a plurality of tube formations 62 each with a passageway 63 interconnected with the passageways of the other tube formations for feeding pressurized air from an inlet 67 through a plurality of holes 64 which are angularly drilled in the walls of the bin so as to direct when gas pressuring a plurality of air streams against the uppermost piece of a stack of mail to force said stack against the lower or far end wall 66 of the bin so that the lowermost piece E' is directed against a controlled belt conveyor 68 driven by motor 14. Thus, whenever motor 14 is energized for a predetermined period of time, piece E' will be carried thereby between the power operated conveyor belts 69 and 70 which comprise a conveyor 15' corresponding to the first output conveyor 15 of FIG. 1. Notation 71 refers to a deflection plate for aligning and guiding one edge of each mail piece fed to the conveyor 15'. Each piece E' may be forced by gravity or by means of wheels riding thereagainst to contact the plate 71 as it is driven onto the conveyor 15' so as to align the edges of all pieces thereagainst to permit coding to be effected as described. From conveyor 15' the pieces are fed to a conveyor 19' corresponding to conveyor 19 of FIG. 1 and comprising a pair of power-driven endless belts 72 and 72' between which edge mail piece E is driven. Disposed adjacent the edges of belts 72 and 72' are devices 21', 22' and 24' corresponding in function to the recording material applicator 21, the photoelectric detector 22 and the recording transducer 24 of FIG. 1, each of which is so mounted to align its output with the edge or border of the card driven therepast as the conveyor 19' operates. The conveyors 68, 15' and 19' are intermittently and sequentially operated as described in the description on the apparatus of FIG. 1.

In FIG. 3, notation 65 refers to holes provided in the sidewalls of bin 61 operable for laterally exhausting air downwardly through the interior of bin 61 against the stack of mail pieces or cards through the holes 64.

FIGS. 4 and 5 illustrate mail piece or card structures employing different types of recordings along the edge or border portion thereof. In FIG. 4, the piece E is illustrated as an envelope or card having multiple address lines 75 containing written or printed name and destination characters, and return address lines 75' disposed near the upper left hand corner thereof. Disposed adjacent to the lower edge 73 of the piece E along the margin or border portion 74 thereof, is a strip, tape or coating of magnetic recording material which may be applied thereto when the card or envelope is first fabricated, when it is addressed or by the means provided in FIG. 1 which may comprise a spray nozzle, roller coating wheel or applicator for a short length of magnetic tape; the magnetic recording material being generally defined by the notation 76 and illustrated as extending from the leading edge 73' of the piece E a sufficient distance along the lower marginal border 74 to permit the longest serial code to be recorded thereon.

In FIG. 5 is shown an elongated record member 75, such as an envelope or card containing address lines 75 of characters on one face thereof and a code 77 in the form of a plurality of spaced-apart, optically scannable marks 78 of predetermined height and separated by spaces 79 which, when scanned, also define a portion of the printed code. The marks 78 printed along the border portion 74 of the piece E' of FIG. 5, may be provided along the lower margin and/or across the lower edge 73 thereof by one or more selective recording means including a selectively operable array of rotary mark printing devices, such as selectively projectable and retractable printing cuts disposed at the ends of the spokes of a wheel, the periphery of which rides against the edge 73 or border portion 74 of the member to be coated. The marks 78 may also be applied in the form of a code by the controlled pulsing of a solenoid which projects a printing cut or wheel against the record member and away from such lower edge or border 73 or by the selective operation of a valve disposed in the inlet of a small spray nozzle operative to spray apply printing ink or magnetic recording material to selected areas of the members E' such as the areas defined by marks 78. The recording transducer may also include (c) a variable mask which is operated by bi-stable solenoids connected directly to the outputs 27 of the pushbutton panel 26 which mask may receive mark printing material from a spray head or roller coating means applied thereagainst to provide the necessary coded array or marks; (d) a modulated intense radiation beam generating means such as an electron gun or laser generating an intense beam employed to either burn select portions of the border or margin 74 of the envelope or select portions of a recording material such as 76 so disposed to provide the necessary scannable code recording. The latter described beam recording means may be controlled, for example, by the series code signal generated by shift register 28 of FIG. 1 to provide a series code which is optically scannable.

The coding and sorting apparatus hereinabove described and illustrated in the accompanying drawings may be modified to code and sort articles of manufacture, such as boxes or containers of rectangular configuration or a configuration having at least one straight edge, which may be predeterminately disposed as described with respect to both the code marking or recording means and the code scanning or reproduction means. In FIG. 6, is shown a container 80 of rectangular configuration having a side wall 81 preferably, although not necessarily, containing an address label 75'. The container 80 may comprise, for example, a boxed mail piece, product container or pallet. Means, such as illustrated in application Ser. No. 468,418, may be provided for conveying the container 80 with its lower surface 83 disposed against a flight conveyor and the side wall 81 extending a predetermined vertical plane so that the edge defined by the intersection of walls 81 and 83 will travel a predetermined lineal path. By such means, all containers having rectangular parallelepiped configurations, regardless of the height, width and depth of said containers, may be so conveyed that the lower edge of each container may travel the same line path, thus predeterminately positioning the lower borders of each container with respect to a stationary coating or marking means. Such coating or marking means may comprise any of the described magnetic recording, printing, spray applying or modulated beam burning means. In FIG. 6 is shown a wheel 88 which is rotationally supported at the side of the belt conveyor 87 carrying the container 80 and positioned such that the periphery of such wheel rides against a band-like portion 85 of the side wall 81 of the container adjacent the lower edge 84 thereof. Radially movable within the wheel 88 are a plurality of printing cuts or mark applicating devices 89, each of which is operated by a separate bi-stable solenoid disposed within the wheel. Each of such solenoids is operatively connected to a respective of the outputs 27 of the bank of code switches 26S of FIG. 1, so that the printing cuts may be selectively projected and retracted to apply marks in a coded array along the recording area 86 of the border 85 as the wheel 88 is rotated and either moves longitudinally along the wall of the container or rotates as the container is conveyed therepast.

Located downstream of the code applying wheel 88 is provided a magnetic or optical scanning transducer supported closely adjacent the conveyor 87 and operable to scan a series or paralled code applied to the border 85 adjacent edge 84 of the container 80. The output of such transducer may be connected to means for transferring the container 80 to a selected of a plurality of branch conveyors, such as the means provided in FIG. 1 for routing envelopes or cards. The code wheel 88 of FIG. 6 may be replaced by a code modulated radiation beam generating means of the type described which is operative to discolor or burn portions of the container wall or a recording material 86 disposed adjacent the edge 84 of the container.

Further details of the code applying wheel 88 of FIG. 6 are illustrated in FIG. 7. The printing wheel 88 comprises a disc-shaped hollow housing having upper and lower disc-shaped walls 96 and 97 separated by a spacer ring 98 having a plurality of holes 98H extending radially therethrough. The printing devices 89 comprise a plurality of bi-stable solenoids 90 which are mounted on the bottom plate 97 inwardly of the ring 98 and have their shafts 91 extending radially to holes 98H. Secured to each shaft 91 of each solenoid 90 is a retainer 92 for a printing cut 93, which printing material may be retracted so that its outermost surface is below the peripheral surface 88' of the wheel 88 when the solenoid 90 is retracted in one of its two bi-stable states. When the solenoid is pulsed or switched to its other bi-stable state, the printing cut 93 protrudes outwardly from the peripheral surface 88' of the wheel 88 and provides means for applying a code mark to a surface against which the peripheral surface 88' of the wheel is rolled. Each of the solenoids 90 has an input wire pair 94 extending radially inwardly and along the interior of a hollow shaft 95 on which the wheel is mounted, said shaft extending to a drive means such as a rotary solenoid or motor which power rotates such wheel against a surface, such as any of the band areas 76, 78 or 86 of an envelope, card or container such as shown in FIGS. 4, 5 and 6. The wires 94 may extend to an array of commutator and brush elements located on the shaft 95 or directly to respective code signal generating output means such as the outputs 27 of the binary code generating pushbutton switches 26S of the bank 26 illustrated in FIG. 1. The solenoid energizing lines 94 may be connected to a computer or the circuits of the hereinabove described means for automatically reading the alphanumeric address 75 on the envelope or card or other means identifying the article being coded. If the rotary solenoid is provided and coupled to shaft 95 so as to rotate the wheel 88, it may be activated, for example, by the signal generated on the output of delay relay 31 or a means such as the photoelectric scanner 22 which is operative for detecting the leading edge of the card assuming that the conveyor along which the card is driven is operated thereafter for a sufficient time interval to permit the wheel 88 to effect a cycle of operation against the member being coded. In an alternate form of the invention, the wheel 88 may be translated and rotated relative to the envelope, card or container while the latter is held stationary during a coding cycle.

The printing material 93 located at the end of the solenoid shaft may