System and method for unsleeving trays

Abstract

A system for unstrapping and unsleeving a tray is provided. The system comprises a tray-transport configured to transport a tray in the system, a strap cutter configured to cut a strap on the tray, a strap-removal portion configured to remove the strap cut by the strap cutter, and an unsleeving station configured to remove a sleeve from the tray. The unsleeving station is configured to remove the sleeve from the tray after the strap-removal portion removes the cut strap.

What is claimed is:  
     
         1 . A system for unstrapping and unsleeving a tray, comprising: 
 a tray-transport configured to transport a tray in the system;    a strap cutter configured to cut a strap on the tray;    a strap-removal portion configured to remove the strap cut by the strap cutter; and    an unsleeving station configured to remove a sleeve from the tray;    wherein the unsleeving station is configured to remove the sleeve from the tray after the strap-removal portion removes the cut strap.    
     
     
         2 . The system of  claim 1 , wherein the tray-transport comprises a tray-sizing station configured to determine the size of the tray.  
     
     
         3 . The system of  claim 2 , wherein the tray-sizing station comprises at least one sensor configured to determine the height of the tray.  
     
     
         4 . The system of  claim 3 , wherein at least one sensor is a photo-reflective zone sensor.  
     
     
         5 . The system of  claim 3 , wherein at least one sensor is a contact arm microswitch.  
     
     
         6 . The system of  claim 2 , wherein the tray-sizing station comprises at least one sensor configured to determine the length of the tray.  
     
     
         7 . The system of  claim 6 , wherein at least one sensor is a photo-reflective zone sensor.  
     
     
         8 . The system of  claim 6 , wherein at least one sensor is a contact arm microswitch.  
     
     
         9 . The system of  claim 1 , wherein the tray-transport comprises a traffic control device configured to regulate tray traffic in the system.  
     
     
         10 . The system of  claim 1 , further comprising a sleeve-transport conveyor configured to move empty sleeves.  
     
     
         11 . The system of  claim 1 , further comprising a safety enclosure configured to protect personnel from injury during system operation.  
     
     
         12 . The system of  claim 1 , further comprising a control system configured to control and monitor the system.  
     
     
         13 . The system of  claim 12 , wherein the control system comprises a computer.  
     
     
         14 . The system of  claim 1 , further comprising at least one emergency stop switch configured to stop the system.  
     
     
         15 . The system of  claim 1 , wherein the tray-transport comprises a powered roller.  
     
     
         16 . The system of  claim 15 , wherein the powered roller is a zero-pressure accumulation conveyor.  
     
     
         17 . The system of  claim 1 , wherein the tray-transport comprises a mail catcher configured to catch loose items.  
     
     
         18 . The system of  claim 1 , wherein the tray-transport comprises a tray centering guide configured to center the tray.  
     
     
         19 . The system of  claim 1 , wherein the strap-removal portion comprises a vacuum takeaway.  
     
     
         20 . The system of  claim 1 , further comprising a transfer device configured to push the destrapped tray onto the unsleeving station.  
     
     
         21 . The system of  claim 1 , wherein the strap cutter comprises a rotating saw blade and a flexible spatula.  
     
     
         22 . The system of  claim 1 , wherein the strap cutter comprises a hooked blade and a flexible spatula.  
     
     
         23 . The system of  claim 1 , wherein the strap cutter is configured to cut the strap above the tray and the strap-removal portion is configured to remove the cut strap below the tray.  
     
     
         24 . The system of  claim 1 , wherein the strap-removal portion is configured to remove the cut strap near the center of the cut strap.  
     
     
         25 . The system of  claim 1 , wherein the strap-removal portion comprises a strap chopping portion configured to chop the cut straps.  
     
     
         26 . The system of  claim 1 , wherein the unsleeving station comprises a sleeve-expander configured to lift the top of the sleeve.  
     
     
         27 . The system of  claim 26 , wherein the sleeve-expander comprises a gripper configured to grip the top of the sleeve.  
     
     
         28 . The system of  claim 27 , wherein the gripper comprises vacuum cups.  
     
     
         29 . The system of  claim 1 , wherein the unsleeving station comprises a push ram configured to push the tray out of the sleeve.  
     
     
         30 . The system of  claim 1 , further comprising a sleeve-sorting station configured to sort empty sleeves.  
     
     
         31 . The system of  claim 30 , wherein the unsleeving station comprises a sleeve-transport conveyor configured to transport empty sleeves to the sleeve-sorting station.  
     
     
         32 . The system of  claim 30 , wherein the sleeve-sorting station comprises at least one container.  
     
     
         33 . The system of  claim 32 , wherein the sleeve-sorting station further comprises at least one sleeve-ejector configured to sweep empty sleeves into the at least one container.  
     
     
         34 . The system of claim of  claim 33 , wherein at least one sleeve-ejector comprises at least one pusher paddle configured to flatten the empty sleeve before sweeping the empty sleeve into the at least one container.  
     
     
         35 . The system of  claim 32 , wherein the sleeve-sorting station comprises a floor fixture configured to position the container.  
     
     
         36 . The system of  claim 32 , wherein the sleeve-sorting station comprises a basket-full sensor configured to sense over-height stacking of the empty sleeves in the container.  
     
     
         37 . The system of  claim 29 , wherein the push ram comprises a sweeping device configured to remove loose mail from an empty sleeve.  
     
     
         38 . A method for removing a sleeve from a tray, the method comprising: 
 providing the system of  claim 1;     cutting the strap from the tray with the strap cutter;    removing the cut strap with the strap-removal portion; and    removing the sleeve from the tray with the unsleeving station.    
     
     
         39 . The method of  claim 38 , further comprising operating and monitoring the system with a control system.  
     
     
         40 . The method of  claim 38 , further comprising sorting the empty sleeve with a sleeve-sorting station.  
     
     
         41 . The method of  claim 38 , further comprising chopping the cut strap with a strap chopping portion.  
     
     
         42 . A device for destrapping a strapped sleeved tray comprising: 
 a strap cutter having a flexible spatula and a cutting blade next to said flexible spatula, said flexible spatula insertable between a strap and a sleeve over said strapped sleeved tray; and    a strap take-away system below said strap cutter.    
     
     
         43 . A device for shipping and routing items, the device comprising: 
 a tray-transport for receiving a strapped sleeved tray, said tray-transport including sensors for determining tray-size and sleeve size;    a destrapping station including a strap cutter and a strap take-away system;    an unsleeving station including a sleeve-expander and a ram, said unsleeving station separating said sleeves from said trays;    a sleeve-transport conveyor, wherein said sleeve-transport conveyor receives sleeves from said unsleeving station; and    a sleeve-stacking station, wherein said sleeve-stacking station sorts said sleeves according to sleeve size determined by the sensors into a plurality of containers.    
     
     
         44 . A method for separating a tray from a strap bound sleeve comprising the steps of: 
 receiving a strapped sleeved tray at a tray-transport station;    sizing said strapped sleeved tray at a tray-sizing station;    destrapping said strapped sleeved tray with a strap cutter;    removing said tray from said sleeve; and    sorting said sleeves according to size.