Dual mode stacking system and method of use

Abstract

An apparatus and method for orienting a container. The apparatus includes a frame moveable between a lowered position and a raised, substantially vertical position. A container cradle is pivotably connected to the frame and selectively positionable to a substantially vertical stacking position or a substantially horizontal stacking position when the frame is in the raised, substantially vertical position. The method includes, amongst other features, orienting the container into a horizontal stacking position or maintaining the container in a same orientation as the frame when in the raised vertical position. In the latter orientation, product or other objects can be stacked in a vertical orientation.

1 . An apparatus for orienting a container, comprising: 
 a frame moveable between a lowered position and a raised position; and    a cradle pivotably connected to the frame, the cradle selectively positionable to a substantially vertical stacking position when the frame is moved to the raised position.    
   
   
       2 . The apparatus of  claim 1 , further comprising an actuator mounted to the frame for moving the frame between the lowered position and the raised position.  
   
   
       3 . The apparatus of  claim 1 , further comprising a stop positioned proximate a leading edge of the cradle, the stop selectively provides a stopping position of the cradle.  
   
   
       4 . The apparatus of  claim 1 , wherein the cradle includes a pivot joint on opposing sides thereof, and partly forms a four bar linkage pivotably mounted to the frame which selectively rotates the cradle as the frame is moved between the lowered position and the raised position.  
   
   
       5 . The apparatus of  claim 1 , further comprising an intake conveyor and an exit conveyor at opposing ends of the frame for moving a container towards and away, respectively, the frame.  
   
   
       6 . The apparatus of  claim 1 , further comprising a fail safe stop which stops motion of the frame upon a loss of power.  
   
   
       7 . The apparatus of  claim 1 , further comprising a vertical edge stop which supports a position of a container when the cradle is in the substantially vertical stacking position.  
   
   
       8 . The apparatus of  claim 1 , further comprising: 
 a synchronizer bar actuated by movement of the frame; and    a stop system which is actuated by the synchronizer bar to an extended position and a retracted position by movement of the frame into the raised position and lowered position, respectively.    
   
   
       9 . The apparatus of  claim 8 , wherein the stop system comprises a backstop to retain product in a container during vertical stacking of product when the cradle is in the substantially vertical stacking position.  
   
   
       10 . The apparatus of  claim 8 , wherein the product stop system comprises a container support to support a container when the frame is in the raised position and the cradle is in the substantially vertical stacking position.  
   
   
       11 . The apparatus of  claim 1 , wherein the cradle holds a container having mail pieces stacked therein.  
   
   
       12 . An apparatus for stacking product, comprising: 
 a conveyor support structure;    a conveyor tilt frame moveable between a lowered position and a raised position;    a conveyor actuator coupled to the conveyor support structure and the conveyor tilt frame, the conveyor actuator moving the conveyor tilt frame between the lowered position and the raised position;    a container cradle pivotably coupled to the conveyor tilt frame; and    a system extending between the container cradle and the conveyor support structure to position the container cradle in a substantially vertical stacking orientation when the conveyor tilt frame is in the raised position.    
   
   
       13 . The apparatus of  claim 12 , further comprising a synchronizer and a stop mechanism, the synchronizer moving the stop mechanism to an extended position when the container cradle is moved to the substantially vertical stacking orientation and the conveyor tilt frame is moved to the raised position.  
   
   
       14 . The apparatus of  claim 13 , wherein the stop mechanism comprising: 
 a four-bar linkage controllable by movement of the synchronizer;    a container support; and    a product stop,    the container support and the product stop are opened to the extended position in synchronization by movement of the four-bar linkage.    
   
   
       15 . The apparatus of  claim 14 , wherein the container support and the product stop are opened to the extended position when the container cradle is moved to the substantially vertical stacking orientation position, and retracted when the container cradle is moved to a lowered position.  
   
   
       16 . The apparatus of  claim 12 , wherein the system is a four-bar linkage system mounted between the conveyor support frame and the container cradle.  
   
   
       17 . The apparatus of  claim 12 , wherein the container cradle supports a container for stacking mail pieces therein.  
   
   
       18 . The apparatus of  claim 12 , wherein the conveyor tilt frame further comprises: 
 a first pivot joint to provide container orientation depending on whether a container is being transferred into or out of the container cradle;    a second pivot joint positioning the container cradle in either a horizontal stacking position or the substantially vertical stacking orientation; and    a third pivot joint providing a mounting point for the conveyor actuator.    
   
   
       19 . An apparatus for orienting a container, comprising: 
 a frame moveable between a lowered position and a raised, substantially vertical position; and    a container cradle pivotably connected to the frame and selectively positionable to a vertical stacking position or a horizontal stacking position when the frame is in the raised, substantially vertical position.    
   
   
       20 . The apparatus of  claim 19 , further comprising an actuator mounted to the frame for moving the frame between the lowered position and the raised, substantially vertical position.  
   
   
       21 . The apparatus of  claim 19 , wherein the frame is a first degree of freedom motion and the container cradle is a second degree of freedom motion.  
   
   
       22 . The apparatus of  claim 19 , wherein the container cradle includes a container power transfer assembly which is in a flow stream of a load conveyor and a remove conveyor.  
   
   
       23 . The apparatus of  claim 19 , further comprising stops located at the trailing edge and leading edge of the container cradle, respectively.  
   
   
       24 . The apparatus of  claim 23 , wherein: 
 the stops are moveable in both an upward direction and downward direction; and    in the upright position, one of the stops positions and supports the container at the leading edge when the container cradle is in either the vertical stacking position or the horizontal stacking position.    
   
   
       25 . The apparatus of  claim 23 , wherein: 
 the stops are a leading edge pop-up stop and a trailing edge pop-up stop; and    at least one sensor includes at least one of: 
 (i) a leading edge pop-up stop position sensor which senses when the leading edge pop-up stop has reached its up position;  
 (ii) a leading edge pop-up stop retract position sensor which senses when the leading edge pop-up stop is required to drop down, and senses that the leading edge pop-up stop has reached its down position;  
 (iii) a trailing edge pop-up stop, up position sensor which senses when the trailing edge pop-up stop is required to actuate up and senses that the trailing edge pop-up stop has reached its up position; and  
 (iv) a trailing edge pop-up stop, retract position sensor which senses when the trailing edge pop-up stop is required to drop down and senses when the trailing edge pop-up stop has reached its down position.  
   
   
   
       26 . The apparatus of  claim 19 , further comprising at least one of: 
 (i) a container-in-position sensor which monitors the presence of a container on the container cradle;    (ii) an orientation sequencing mode selector position sensor which determines that a predetermined sequencing mode has been selected;    (iii) a frame position sensor which determines when the frame has reached the lowered position and the raised, substantially vertical position;    (iv) a frame actuator sensor which controls a speed of the frame to minimize impact at an end of travel position; and    (v) a product jam sensor for detecting the movement of product.    
   
   
       27 . The apparatus of  claim 26 , wherein the container-in-position sensor controls a stop to register the container in the container cradle.  
   
   
       28 . The apparatus of  claim 19 , wherein the container cradle includes a pivot joint to provide a mounting pivot point for a linkage mechanism, the linkage mechanism selectively positions the container cradle between the vertical stacking position and the horizontal stacking position when the frame is moved to the raised, substantially vertical position.  
   
   
       29 . The apparatus of  claim 28 , wherein the linkage mechanism is a four bar linkage mechanism including two parallel bars, a portion of the container cradle and a portion of a mode selector.  
   
   
       30 . The apparatus of  claim 19 , further comprising a mode selector to selectively provide an orientation of the container cradle to either the vertical stacking position or the horizontal stacking position.  
   
   
       31 . The apparatus of  claim 19 , wherein the container cradle holds a container having product stacked therein.  
   
   
       32 . An apparatus for stacking product, comprising: 
 a conveyor tilt frame moveable between a lowered position and a raised, substantially vertical position;    a conveyor actuator coupled to the conveyor tilt frame to move the conveyor tilt frame between the lowered position and the raised, substantially vertical position;    a container cradle pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation within the container; and    a linkage system extending between the container cradle and a support structure of the conveyor tilt frame to position the container cradle to a substantially horizontal stacking orientation or maintain the container cradle in a substantially same orientation as the conveyor tilt frame is moved in the raised, substantially vertical position for vertical stacking.    
   
   
       33 . The apparatus of  claim 32 , further comprising a mode selector selectively engaging the linkage system to provide a stacking orientation of the container.  
   
   
       34 . The apparatus of  claim 32 , wherein the linkage system is a four-bar linkage system.  
   
   
       35 . The apparatus of  claim 32 , wherein the conveyor tilt frame further comprises: 
 a first pivot joint to provide container orientation depending on whether the container is being transferred into or out of the container cradle;    a second pivot joint positioning the container cradle for stacking product in the horizontal stacking orientation; and    a third pivot joint providing a mounting point for the conveyor actuator.    
   
   
       36 . The apparatus of  claim 32 , wherein the product is mail pieces.  
   
   
       37 . The apparatus of  claim 32 , further comprising: 
 a mode selector mounted to the conveyor tilt frame, the mode selector including: 
 a first position to selectively orient the container cradle in the horizontal stacking orientation when the conveyor tilt frame is in the raised, substantially vertical position, and  
 a second position to selectively maintain the container cradle at the vertical stacking orientation when the conveyor tilt frame is in the raised, substantially vertical position;  
   wherein the linkage system is a a four bar linkage which: 
 rotates the container cradle to the horizontal stacking orientation when the mode selector is in the first position and the conveyor tilt frame is the raised, substantially vertical position, and  
 maintains the container cradle in a same orientation as the conveyor tilt frame for vertical stacking when the conveyor tilt frame is in the raised, substantially vertical position and the mode selector is in the second position;  
   a product stop mechanism; and    a synchronizer mounted between the product stop mechanism and the mode selector, the synchronizer moving the product stop mechanism to an extended position when the container cradle is moved to the vertical stacking orientation and the conveyor tilt frame is in the raised, substantially vertical position.    
   
   
       38 . An apparatus for stacking product in a horizontal orientation or a vertical orientation, comprising: 
 a conveyor tilt frame moveable from approximately a horizontal position to a vertical position;    a conveyor actuator coupled to the conveyor tilt frame to move the conveyor tilt frame from the approximately the horizontal position to the vertical position;    a container cradle pivotably coupled to the conveyor tilt frame for stacking product in either a horizontal stacking orientation or a vertical stacking orientation when the conveyor tilt frame is positioned to approximately the vertical position;    a mode selector including: 
 a first position to selectively orient the container cradle in the horizontal stacking orientation, and  
 a second position to selectively maintain the container cradle and the conveyor tilt frame at substantially a same orientation when the conveyor tilt frame is positioned to approximately the vertical position;  
   a four bar linkage which: 
 rotates the container cradle to the horizontal stacking orientation when the mode selector is in the first position and the conveyor tilt frame is positioned to approximately the vertical position; and  
 maintains the container cradle in the substantially same orientation when the conveyor tilt frame is positioned to approximately the vertical position and the mode selector is in the second position for vertical stacking;  
   a product stop mechanism; and    a synchronizer selectively controlled by the mode selector, the synchronizer moving the product stop mechanism to an extended position when the container cradle is moved to the substantially vertical stacking orientation.    
   
   
       39 . The apparatus of  claim 38 , wherein the product stop mechanism comprises: 
 a four-bar linkage controllable by movement of the synchronizer;    a container support; and    a product stop,    the container support and the product stop are opened to the extended position in synchronization by movement of the four-bar linkage.    
   
   
       40 . The apparatus of  claim 38 , wherein the substantially horizontal position to the vertical position is approximately 0° to 70°.  
   
   
       41 . A method of stacking mail, comprising: 
 inserting an empty container into a pivotably mounted cradle;    raising the cradle from a first height to a raised height;    rotating the cradle to a substantially vertical stacking position;    inducting mail into the container when the cradle is in the substantially vertical position; and    lowering the cradle to the first height and rotating the cradle into a substantially horizontal orientation after a predetermined amount of mail has been inducted into the container.    
   
   
       42 . The method of  claim 41 , further comprising transporting a non-empty container out of the cradle and transporting an empty container out of the cradle.  
   
   
       43 . A method of stacking mail in either a horizontal orientation or a vertical orientation, comprising: 
 placing a container on a container cradle;    if the mail is to be stacked in the vertical stacking orientation, rotating a conveyor frame to a substantially vertical orientation while maintaining the container cradle in a substantially same orientation as the conveying frame; and    if the mail is to be stacked in the horizontal stacking orientation, rotating the conveyor to the substantially vertical position and rotating the container cradle to a substantially, raised horizontal orientation;    inducting mail into the container; and    when the mail has reached a predetermined height or weight in the container or no further mail is available then: 
 if the mail was stacked in the vertical stacking orientation, rotating the conveyor frame into a substantially horizontal position while maintaining the maintaining the container cradle in a same orientation as the conveying frame; and  
 if the mail was stacked in the horizontal stacking orientation, rotating the conveyor frame to the substantially vertical position and rotating the container cradle to an original, lowered horizontal orientation.  
   
   
   
       44 . The method of  claim 43 , further comprising determining when the container has reached the predetermined height or weight of mail or no further mail is available.  
   
   
       45 . The method of  claim 43 , further comprising actuating a leading edge pop-up stop when the container is placed on the container cradle.  
   
   
       46 . The method of  claim 43 , further comprising triggering a container-in-position sensor when the container is positioned on the container cradle.  
   
   
       47 . The method of  claim 46 , further comprising, in response to the triggering step, beginning the induction of the mail.  
   
   
       48 . The method of  claim 43 , further comprising sensing the position of the container in the container cradle.  
   
   
       49 . The method of  claim 43 , further comprising moving a stop into an up position after the container has been placed on the container cradle and lowering the stop after the container cradle has been moved to its original, lowered horizontal orientation such that the container can be ejected therefrom.  
   
   
       50 . The method of  claim 43 , further comprising sensing whether the is being stacked in the vertical stacking orientation or the horizontal stacking orientation in the container.