Note: Descriptions are shown in the official language in which they were submitted.
CA 02547271 2006-05-19
1 Title
2 Method and System for Sorting Mail
3
4 Inventor
Cameron Lanning Cormack
6
7 Field of the invention
8 The invention disclosed herein relates generally to methods and systems for
9 automated mail sorting and, more particularly, methods and systems for the
automated sorting of incoming mail.
11
12 Background
13 A number of mail sorting apparatus exist that can handle the sorting of
14 outgoing mail. Few machines exist that can effectively handle the
requirements of
incoming mail sorting. Quite often, outgoing mail sorting machines are used
for
16 incoming mail sorting. These machines have large footprints and are
considered
17 costly.
18 Usually when an organization has volumes of incoming mail that warrant an
19 incoming mail sorting apparatus, they also have a large number of required
sort
destinations, also known as mailstops, needed as delivery points across their
21 organization. Typically, an organization may have a large number of
mailstops
22 thereby requiring a large number of receiving bins in the mail sorting
machine. The
23 requirement for a large number of receiving bins increases the cost of
these machines.
24 These machines also have very large footprints when outfitted with a
substantial
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1 number of receiving bins, in comparison to the typical allotment of floor
space for
2 mail sorting. When the sorting apparatus has the same number of required
sort
3 destinations as it has receiving bins, then the sorting process can be
handled with a
4 single-pass of the mailpieces through the apparatus.
There are sorting apparatus that are better suited for incoming sorting when
6 cost and space constraints are a concern. These sorters often have fewer
receiving
7 bins then the number of required sort destinations. As a result, the
mailpieces need to
8 make multiple passes through the apparatus to get sorted to the proper
receiving bin.
9 There are a number of schemes available to maximize the sort process for
multi-pass
sorting apparatus. In a multi-pass apparatus, the common requirement is to
take a
11 portion of the mailpieces from the output end, then manually reload them
into the
12 input end of the machine and reprocess the mailpieces further. Multi-pass
machines
13 usually have smaller footprints because they have far fewer receiving bins
then their
14 single-pass counterparts. This also contributes to their lower cost.
The trade-off for the smaller and less-costly multi-pass machines is that they
16 are considerably slower and more costly to operate because of the labor and
time
17 required for processing the mailpieces more than once. Mailpieces in multi-
pass
18 machines experience more wear and tear then in a single-pass machine.
19 It is, therefore, desirable to provide a mail sorting method and system
having
the ability to sort incoming mailpieces using a single pass process with fewer
21 receiving bins than the number of mailstops being sorted.
22
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1 Summary
2 A method and system for sorting incoming mail is provided. An embodiment
3 of the system includes a fewer number of receiving bins than the required
number of
4 sort destinations or mailstops and can handle the mailpieces using a single-
pass sort
process. An embodiment of the method includes using sorting algorithms and the
6 automatic discharging of receiving bins to provide single-pass sorting of
mailpieces
7 with a fewer number of receiving bins than required sort destinations.
8 An embodiment of the system includes a mail singulation apparatus to receive
9 the mailpieces to be sorted and to present them to a mail scanning apparatus
one at a
time. The mail scanning apparatus scans the mailstop address affixed on the
11 mailpieces to identify the mailstop of each mailpiece. On the first
mailpiece received,
12 the mailstop is identified and assigned to one of a number of receiving
bins by a
13 control system operatively connected to the singulation apparatus and the
scanning
14 apparatus. A conveyor apparatus then carries the mailpiece along the
conveyor until
it reaches to the receiving bin assigned with its mailstop. The conveyor
apparatus
16 then deposits the mailpiece into the receiving bin. This process is
repeated with each
17 successive mailpiece until all of the receiving bins have been assigned
with a
18 mailstop. A control system including a general purpose computer controls
the
19 operation of the apparatuses of the system.
If and when a new mailpiece is received and scanned with a new mailstop that
21 is different from the mailstops already assigned to each of the receiving
bins, the
22 control system then makes a determination as to which of the receiving bins
is to be
23 emptied of its existing contents of mailpieces and be reassigned with the
new
24 mailstop. The control system uses an algorithm to make this determination.
The
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1 algorithm can be influenced by any number of parameters that includes but
are not
2 limited to the impending mailpieces to be sorted, historical information
related to the
3 sorting operation and operator preferences configured on the control
computer to
4 name but a few.
When the control system has determined which receiving bin is to be emptied
6 and reassigned, the control system issues a command to the receiving bin to
empty its
7 contents. In some embodiments, the control system can alert an operator that
the
8 receiving bin has been emptied. The control system will also inform the
operator of
9 the mailstop associated with the contents emptied from the receiving bin.
This can be
done in a number of ways. One is to print a piece of paper or tag with the
mailstop of
11 the contents and deposit the tag with the emptied contents. Another is to
dispense a
12 reusable token printed with the mailstop of the contents with the emptied
contents.
13 Yet another is to visually display the mailstop on a video display located
at the
14 receiving bin that has been emptied. Still another is to audibly broadcast
a message
containing the mailstop from an audio playback system. Upon identifying the
16 mailstop of the emptied contents, the control system then assigns the new
mailstop to
17 the emptied receiving bin and conveys the new mailpiece into that receiving
bin.
18 Broadly stated, one aspect of a method for sorting mailpieces in a single
pass
19 comprises the steps of. receiving a mailpiece with a mail singulation
apparatus, said
mailpiece having a mailstop affixed thereon; identifying said mailstop
associated with
21 said mailpiece; assigning said mailstop to one of a plurality of receiving
bins if said
22 mailstop has not already been assigned to a receiving bin, each of said
receiving bins
23 capable of emptying its contents upon receiving a command to empty its
contents; and
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1 conveying said mailpiece to the receiving bin assigned with said mailstop
associated
2 with said mailpiece and depositing said mailpiece into said receiving bin.
3 Broadly stated, one aspect of a system for sorting mailpieces in a single
pass
4 comprises: a mail singulation apparatus adapted for receiving a mailpiece
having a
5 mailstop affixed thereon; a mailpiece scanning apparatus for scanning and
identifying
6 said mailstop of said mailpiece, said scanning apparatus operatively coupled
to said
7 singulation apparatus; a plurality of receiving bins, each bin capable of
emptying its
8 contents upon receiving a command to empty its contents; a conveyor
apparatus
9 operatively coupling said singulation apparatus to said plurality of
receiving bins, said
conveyor apparatus adapted to carry a mailpiece from said singulation
apparatus to
11 any one of said plurality of receiving bins; and a control system
operatively coupled
12 to said singulation apparatus, to said scanning apparatus, to each of said
plurality of
13 receiving bins and to said conveyor apparatus, wherein said control system
is adapted
14 to assign said mailstop to any one of said plurality of receiving bins,
said control
system further adapted to cause said conveyor apparatus to carry said
mailpiece to the
16 receiving bin assigned with said mailstop, said control system further
adapted to cause
17 said conveyor apparatus to carry said mailpiece to the receiving bin
assigned with said
18 mailstop and deposit said mailpiece into said receiving bin.
19 Broadly stated, one aspect of a system for sorting mail comprises: first
means
for receiving a plurality of mailpieces having mailstops affixed thereon and
for
21 presenting said mailpieces one at a time; second means for identifying the
mailstop of
22 each mailpiece present by said first means, said second means operatively
connected
23 to said first means; third means for assigning a mailstop identified by
said second
24 means to one of a plurality of receiving bins if said mailstop has not
already been
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1 assigned to a receiving bin, said third means operatively connected to said
first and
2 second means; fourth means for conveying a mailpiece whose mailstop has been
3 identified by said second means and assigned to a receiving bin by said
third means to
4 said assigned receiving bin and depositing said mailpiece therein, said
fourth means
operatively connected to said first, second and third means; and a plurality
of
6 receiving bins, each receiving bin adapted to receive mailpieces from said
fourth
7 means.
8
9 Brief Description of the Drawings
Figure 1 is a flowchart depicting an embodiment of a method for sorting
11 mailpieces.
12 Figure 2 is a perspective view depicting an embodiment of a system for
13 sorting mailpieces.
14 Figure 3 is a perspective view depicting the system of Figure 2 depositing
a
mailpiece into the first receiving bin.
16 Figure 4 is a perspective view depicting the system of Figure 2 depositing
a
17 mailpiece into the second receiving bin.
18 Figure 5 is a perspective view depicting the system of Figure 2 depositing
a
19 mailpiece into the third receiving bin.
Figure 6 is a perspective view depicting the system of Figure 2 depositing a
21 mailpiece into the fourth receiving bin.
22 Figure 7 is a perspective view depicting the system of Figure 2 emptying
the
23 contents of the third receiving bin.
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1 Figure 8 is a perspective view depicting the system of Figure 2 depositing a
2 new mailpiece into the third receiving bin that has been reassigned with the
mailstop
3 of the new mailpiece.
4
Detailed Description of Embodiments
6 The following is a detailed description of the embodiments of a method and
7 system for sorting mailpieces as shown in the attached figures. For the
purposes of
8 this specification, the term "mailpieces" shall refer to all forms of mail
including but
9 not limited to envelopes and parcels. Wherever possible, the same reference
numbers
shall be used throughout to refer to the same or similar elements.
11 Briefly, Figure 1 is a flow chart depicting an embodiment of a method for
12 sorting mailpieces. Figures 2 through 8 are sequential drawings that depict
an
13 example of a typical mail sorting process in accordance with an embodiment
of a
14 system for sorting mailpieces. Figures 3 through 6 illustrate the process
of assigning
receiving bins to receive mailpieces belonging to specific mailstops. Figure 7
16 illustrates the introduction of a unique mailstop after all receiving bins
have been
17 assigned with a mailstop whereupon one receiving bin is being emptied so as
to be
18 assigned with the new mailstop. Figure 8 illustrates a new mailpiece being
deposited
19 into a receiving bin that has been reassigned with a mailstop of the new
mailpiece.
Figure 1 illustrates a flow chart setting out process 200 that describes an
21 embodiment of a method for sorting mailpieces. Process 200 starts at step
204 and is
22 followed by step 208 where a mailpiece is passed by a mail scanner to
create an image
23 of the mailpiece. At step 212, the image is processed to determine the
mailstop
24 address affixed on the mailpiece. The mailstop address may be printed on
the
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1 mailpiece itself or printed on a label attached to the mailpiece. At step
216, a
2 determination is made if the mailstop has been assigned to a receiving bin.
If "yes",
3 then process 200 proceeds to step 252 where the mailpiece is conveyed to its
4 receiving bin and deposited therein, following which process 200 returns to
step 208
where another mailpiece is passed through the scanner.
6 If the answer at step 216 is "no", the mailstop is added to the mailstop
queue
7 at step 220. A mailstop is selected from the queue at step 224 for
assignment to a
8 receiving bin. The determination of which mailstop is selected can be made
in
9 accordance with any number of predetermined criteria. For example, the
determination can be made according to an operator's preferences in
configuring the
11 control system. The determination can also be made by the control system
basing its
12 decision on the outcome of running an algorithm to select the mailstop. The
13 algorithm can be based on monitoring at least one piece of information
associated
14 with the incoming mailpieces, such as their mailstop address.
Alternatively, the
algorithm can be based on monitoring at least one piece of information
associated
16 with the receiving bins such as the volume of mailpieces being deposited
into them.
17 Another criteria can be historical information relating to the past
mailpieces received
18 and sorted. Yet another criteria can be based on the position of each
mailpiece within
19 the sorting system itself. The algorithm can easily be derived by a person
skilled in
the art once the criteria has been chosen for selecting mailstops.
21 Upon the control system selecting a mailstop, the mailstop is removed from
22 the queue at step 228. At step 232, the control system selects a receiving
bin to be
23 assigned with the mailstop. As in selecting the mailstop from the mailstop
queue, the
24 control system makes a selection upon operator preferences or upon the
outcome of
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1 processing an algorithm using any number of external criteria or parameters
in
2 making a determination as to which receiving bin to select. It should also
be obvious
3 to a person skilled in the art that the control system can embody a neural
network
4 approach to learn and to adapt as process 200 operates over time in
selecting both
mailstops and receiving bins.
6 At step 236, the control system will check if the selected receiving bin has
7 already been assigned with a mailstop. If "yes", the control system issues a
command
8 to the receiving bin at step 240 to empty its contents. At step 244, the
control system
9 identifies the emptied contents to the operator whereupon the operator can
retrieve the
contents and forward the contents to its mailstop destination. Process 200
then
11 proceeds to step 248 whereupon the receiving bin is assigned with the new
mailstop.
12 If the answer at step 236 is "no", the process 200 proceeds from step 236
to step 248.
13 After step 248, process 200 proceeds to step 252 whereupon the mailpieces
deposited
14 into the receiving bin. Process 200 then returns to step 208 to process
another
mailpiece.
16 Referring to Figure 2, sorting system 100 is shown. In this figure, system
100
17 is configured as a simple linear mail sorting machine with only four
receiving bins
18 109a to 109d and a reject bin 104 located at the end of a conveyor path 106
consisting
19 of static conveyor sections 110 and gated conveyor sections 115a to 115d.
This
embodiment is shown only as an illustration of the system and not as a
limitation of
21 the system. It should be obvious to a person skilled in the art that the
concepts
22 described herein can be applied to mail sorting devices or machines of all
types and
23 configurations, not just the simple linear embodiment shown in the attached
figures
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1 including mail sorting machines where mailpieces can be conveyed or "looped"
past
2 the receiving bins repeatedly.
3 System 100 comprises feeding unit 107 that feeds mailpieces 101 into
4 singulation unit 102 where the mailpieces are placed on a conveyor one at a
time and
5 with the address label facing upwards so it can be scanned. Mailpieces 101
are then
6 fed into scanning unit 103 so that an image can be taken of each mailpiece.
An image
7 processing computer 120 is operatively attached to scanning unit 103 with
link 123 to
8 control the operation of scanning unit 103 and to process the images taken
of
9 mailpieces 101 to determine their mailstop addresses. Image processing
computer
10 120 is a general purpose computer running optical recognition software that
works
11 with scanning unit 103 to process the images of scanned mailpieces to
determine their
12 mailstop. Such systems and software are well known to those skilled in the
art.
13 System 100 further comprises distribution unit 108 which consists of
conveyor
14 sections 105a to 105d and 110, receiving bins 109a to 109d and receptacles
116a to
11 6d. Static conveyor sections 110 remain fixed in orientation and transport
the mail
16 laterally along its belts. Gated conveyor sections 105a to 105d are hinged
on one end
17 so that the other end can lift up to expose a receiving bin underneath, and
allow a
18 mailpiece to drop therein. A gated conveyor section is positioned above
each
19 receiving bin. Receptacles 116a to 116d are positioned beneath receiving
bins 109a to
109d, respectively. A printer 122 is operatively attached to system 100 for
printing
21 tags, the purpose of which shall be discussed in further detail below. A
system
22 control computer 121 is operatively attached to system 100 by a link 124 to
control
23 the operations of the sub components of system 100. System control computer
121 is
24 a general purpose computer having a computer memory with a program code
segment
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1 stored thereon. The program code segment is adapted to control the operation
of
2 system control computer 121 and the operations of system 100 in accordance
with
3 process 200 as shown in Figure 1. The program code segment is further
adapted to
4 receive the mailstops of mailpieces identified by scanning unit 103 and
assigning
these mailstops to receiving bins 109a to 109d. Upon assigning a mailstop to a
6 receiving bin, the program code segment causes system control computer 121
to
7 operate distribution unit 108 to convey the mailpieces to a receiving bin
according to
8 their mailstop. When system 100 first starts a sorting process, no receiving
bin will
9 be assigned a mailstop until a first mailpiece is processed by scanning unit
103 and
image processing computer 120 to determine its mailstop.
11 Referring to Figure 3, mailpiece 111 is shown having already passed through
12 feeding unit 107 and scanning unit 103. In this example, mailpiece 111 has
been
13 determined to belong to mailstop "28". System control computer 121 has
assigned
14 this mailstop to receiving bin 109a to hold mailpieces belonging to
mailstop "28". As
mailpiece 111 travels along conveyor path 106, gated conveyor section 105a
opens to
16 receive mailpiece 111. System 100 will continue to deposit all mailpieces
destined to
17 mailstop "28" in receiving bin 109a until such time receiving bin 109a is
no longer
18 assigned to mailstop "28".
19 When a mailpiece enters singulation unit 102 having a mailstop that is
different than the mailstop assigned to receiving bin 109a, system 100 will
then assign
21 the mailstop to an available receiving bin. Referring to Figure 4,
mailpiece 112 has
22 been determined by scanning unit 103 and image processing computer 120 to
belong
23 to mailstop "33". As mailpiece 112 moves along conveyor path 106, gated
conveyor
24 section 105b opens and will allow mailpiece 112 to drop into receiving bin
109b.
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1 System 100 will continue to deposit all mailpieces destined to mailstop "33"
in
2 receiving bin 109b until such time receiving bin 109b is no longer assigned
to
3 mailstop "33".
4 Referring to Figure 5, mailpiece 113 has been determined to belong to
mailstop "17". In this instance, system control computer 121 has assigned
mailstop
6 "17" to receiving bin 109c. As mailpiece 113 move along conveyor path 106,
gated
7 conveyor section 105c opens and will allow mailpiece 113 to drop into
receiving bin
8 109c. System 100 will continue to deposit all mailpieces destined for
mailstop "17"
9 into receiving bin 109c until such time receiving bin 109c is no longer
assigned to
mailstop "17".
11 Referring to Figure 6, mailpiece 114 has been determined to belong to
12 mailstop "59". In this instance, system control computer 121 has assigned
mailstop
13 "59" to receiving bin 109d. As mailpiece 114 moves along conveyor path 106,
gated
14 conveyor section 105d opens and will allow mailpiece 114 to drop into
receiving bin
109d. System 100 will continue to deposit all mailpieces destined to mailstop
"59"
16 until such time receiving bin 109d is no longer assigned to mailstop "59".
17 When a mailpiece with a fifth unique mailstop is presented to system 100,
as
18 shown in the figures herein, system control computer 121 will assign the
new
19 mailstop to a receiving bin. To do so will require that a receiving bin
already
assigned with a mailstop empty its contents so that it can be reassigned with
the new
21 mailstop and receive mailpieces destined for the new mailstop. This is
shown in
22 Figures 7 and 8.
23 Referring to Figure 7, mailpiece 115 is passed through scanning unit 103
and
24 has been determined to belong to mailstop "43" by system control computer
121. As
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1 all of receiving bins 109a to 109d have been assigned, system control
computer 121
2 makes the determination as to which receiving bin it will reassign to
receive mailpiece
3 115. In this instance, system control computer 121 has selected receiving
bin 109c to
4 be reassigned as mailstop "43". In doing so, the program code segment stored
on
system control computer 121 causes it to issue a command to receiving bin 109c
to
6 empty its contents into receptacle 116c. In one embodiment, system control
computer
7 121 issues a tag indicating the mailstop of the contents in receptacle 116c.
This is
8 accomplished by system control computer 121 causing printer 122 to print a
piece of
9 paper or tag with the mailstop assigned to receiving bin 109c, mailstop
"17", and
deposit the tag onto conveyor section 110. The tag is then conveyed along path
106
11 and deposited into receiving bin 109c which, in turn, is emptied into
receptacle 116c.
12 In this manner, the operator retrieving the contents from receptacle 116c
will see the
13 tag and direct the contents to the mailstop printed on the tag. Printer 122
can be a
14 then-no printer although it should be obvious to a person skilled in the
art that any
comparable printing device will work. In another embodiment, system control
16 computer 121 can additional alert an operator that receiving bin 109c has
emptied its
17 contents although this is not essential nor is it necessary.
18 In addition to the mailstop information, the tag can contain other
information
19 such as the number of pieces contained and the route identification number
for
delivery of the mailpieces. The information printed on the tag can be
controlled by
21 predefined settings entered into system control computer 121 by an
operator. In other
22 embodiments, printer 122 can be replaced with a token dispenser (not shown)
where
23 reusable tokens (not shown) preprinted with mailstop numbers are dispensed
onto
24 path 106 to be deposited into the receiving bin with the sorted mailpieces
to indicate
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1 the mailstop destination to an operator. In other embodiments, visual
displays (not
2 shown) or audible play back systems (not shown) can be used in place of
printer 122
3 or token dispensers. The visual display provides visual information as to
the mailstop
4 destination for mailpieces emptied into a receptacle. Alternatively, an
audible
playback system can audibly inform an operator, using a voice synthesizer, of
the
6 mailstop destination and other relevant information. Once receiving bin 109c
has
7 been emptied, receiving bin 109c is then available to be reassigned with a
new
8 mailstop. In alternate embodiments, the operator is alerted to the fact that
receiving
9 bin 109c has been emptied.
In another embodiment, system control computer 121 alerts the operator to
11 manually empty receiving bin 109c. In yet another embodiment, the operator
can
12 manually empty receiving bin 109c on his own accord upon which system
control
13 computer 121 is informed of which receiving bin has been emptied, either by
sensors
14 (not shown) located on distribution unit 108 detecting that a bin is empty
or by the
operator manually inputting which bin was emptied by pressing a button (not
shown)
16 or using a keyboard attached to system control computer 121.
17 In another embodiment, receiving bin 109c is removed from distribution unit
18 108 and replaced with a new empty bin instead of being emptied. In yet
another
19 embodiment, a replacement bin associated with the new mailstop being
assigned by
system control computer 121 (not shown) is provided to replace receiving bin
109c.
21 The replacement bin may be empty or may contain mailpieces addressed to the
new
22 mailstop being assigned to the bin location where receiving bin 109c was
located.
23 This bin replacement process can be performed manually by the operator or
it can be
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CA 02547271 2010-06-15
1 that is controllable by system control computer 121. In some embodiments,
system
2 100 can further comprise a mailpiece bundling device (not shown) as well
known to
3 those skilled in the art for bundling the mailpieces emptied from receiving
bin 109c,
4 along with any additional printed tag or token that may be deposited with
the
5 mailpieces prior to being emptied.
6 Referring to Figure 8, system control computer 121 has reassigned receiving
7 bin 109c as mailstop "43". In this instance, mailpiece 115 is conveyed along
path 106
8 as gate conveyor section 105c is opened. Mailpiece 115 is then deposited
into
9 receiving bin 109c.
10 The method and system described herein is shown with only four receiving
11 bins although it should be obvious to a person skilled in the art that any
number of
12 receiving bins can be used. The number of receiving bins does not have to
be equal to
13 or greater than the number of mailstops contained within a group of
mailpieces being
14 sorted, rather, the number of receiving bins can be less than the number of
mailstops
15 given the ability of the system to dynamically assign and reassign "m"
number of
16 mailstops to "n" number of receiving bins where "m" is greater than "n".
17 It is also noted that relationships exist between: a) the number of
receiving
18 bins; b) the number of required mailstops contained within the group of
mailpieces
19 being sorted; and c) the average number of mailpieces emptied from a
receiving bin
when it is being reassigned with a new mailstop.
21 The quotient consisting of a number of required mailstops divided by the
22 number of receiving bins is inversely proportional to the average number of
23 mailpieces emptied from a receiving bin when being reassigned. Furthermore,
the
24 average number of mailpieces emptied from a receiving bin is inversely
proportional
to the frequency of emptying cycles of the receiving bins, at a given input
rate of
26 mailpieces. These relationships indicate that the mail sorting system must
have at
27 least one receiving bin and that the number of receiving bins does not
affect the
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1 ability of the system to sort mailpieces. However, the number of receiving
bins
2 required by the system is a function of an operator's requirements regarding
the
3 average number of mailpieces to be emptied from a receiving bin and on how
frequent
4 the receiving bins are to be emptied.
Although a few preferred embodiments have been shown and described, it will
6 be appreciated by those skilled in the art that various changes and
modifications might
7 be made without departing from the scope of the invention. The terms and
8 expressions used in the preceding specification have been used herein as
terms of
9 description and not of limitation, and there is no intention in the use of
such terms and
expressions of excluding equivalents of the features shown and described or
portions
11 thereof, it being recognized that the scope of the invention is defined and
limited only
12 by the claims that follow.
13
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