Thickness measuring device for use within a mail handling system, and a method of using the same

A conveyor system for depositing a predetermined number of articles, having a predetermined cumulative thickness dimension, into a storage bin having a predetermined storage capacity, comprising:

• a storage bin having a predetermined storage capacity for accommodating therein a predetermined number of articles having a predetermined cumulative thickness dimension such that the predetermined number of articles can be stored within said storage bin;
• an article conveyor for conveying a plurality of articles along a predetermined conveyor path toward said storage bin, wherein each one of the conveyed articles has a predetermined thickness dimension;
• a mounting bracket;
• a rotary encoder mounted upon said mounting bracket and comprising a rotary shaft;
• a lever arm movably mounted upon said rotary shaft of said rotary encoder and having a first end portion thereof disposed adjacent to said predetermined conveyor path so as to engage each one of the articles being conveyed along said predetermined conveyor path, whereupon said first end portion of said lever arm encountering an article being conveyed along said predetermined conveyor path, said lever arm will movably deflect a predetermined amount and cause a corresponding rotation of said rotary shaft of said rotary encoder such that said rotary encoder emits data which is indicative of the thickness dimension of the article being conveyed along said predetermined conveyor path;
• and
• means operatively connected to said article conveyor for correlating said thickness dimension data of each article being conveyed along said predetermined conveyor path with said predetermined storage capacity of said storage bin such that when the cumulative thickness dimension of a plurality of articles being conveyed along said predetermined conveyor path, as indicated by said thickness dimension data emitted by said rotary encoder, comprises a predetermined value with respect to said storage capacity of said storage bin, operation of said article conveyor will be terminated so as not to deposit any additional articles into said storage bin.

A method for depositing a predetermined number of articles, having a predetermined cumulative thickness dimension, into a storage bin having a predetermined storage capacity, comprising:

• providing a storage bin having a predetermined storage capacity for accommodating therein a predetermined number of articles having a predetermined cumulative thickness dimension such that the predetermined number of articles can be stored within said storage bin;
• providing an article conveyor for conveying a plurality of articles along a predetermined conveyor path toward said storage bin, wherein each one of the conveyed articles has a predetermined thickness dimension;
• positioning a rotary encoder, having a rotary shaft, adjacent to said article conveyor;
• movably mounting a lever arm upon said rotary shaft of said rotary encoder wherein a first end portion of said lever arm is disposed adjacent to said predetermined conveyor path so as to engage each one of the articles being conveyed along said predetermined conveyor path, whereupon said first end portion of said lever arm encountering an article being conveyed along said predetermined conveyor path, said lever arm will movably deflect a predetermined amount and cause a corresponding rotation of said rotary shaft of said rotary encoder such that said rotary encoder will emit data which is indicative of the thickness dimension of the article being conveyed along said predetermined conveyor path;
• providing means for correlating said thickness dimension data of each article being conveyed along said predetermined conveyor path with said predetermined storage capacity of said storage bin;
• and
• controlling the operation of said article conveyor in such a manner that when the cumulative thickness dimension of a plurality of articles being conveyed along said predetermined conveyor path of said article conveyor, as indicated by said thickness dimension data emitted by said rotary encoder, comprises a predetermined value with respect to said storage capacity of said storage bin, operation of said article conveyor will be terminated so as not to deposit any additional articles into said storage bin.

A system for measuring the thickness dimension of an article being conveyed along a predetermined conveyor path, comprising:

• a mounting bracket;
• a rotary encoder mounted upon said mounting bracket and comprising a rotary shaft;
• a lever arm movably mounted upon said rotary shaft of said rotary encoder and having a first end portion thereof disposed adjacent to the predetermined conveyor path so as to engage an article being conveyed along the predetermined conveyor path, whereupon said first end portion of said lever arm encountering an article being conveyed along the predetermined conveyor path, said lever arm will movably deflect a predetermined amount and cause a corresponding rotation of said rotary shaft of said rotary encoder which is indicative of the thickness of the article being conveyed along the predetermined conveyor path;
• first biasing means fixedly mounted at a first end portion thereof and operatively connected at a second end portion thereof to said first end portion of said lever arm for generating a first predetermined biasing force for normally resisting said movement of said lever arm in response to said engagement of said first end portion of said lever arm with the article being conveyed along the predetermined conveyor path, and for generating a second biasing force tending to return said lever arm to its non-deflected position;
• and
• second biasing means fixedly mounted at a first end portion thereof and operatively connected at a second end portion thereof to a second end portion of said lever arm for generating a first predetermined biasing force for normally resisting said movement of said lever arm in response to said engagement of said first end portion of said lever arm with the article being conveyed along the predetermined conveyor path, and for generating a second biasing force tending to return said lever arm to its non-deflected position.