Method for optimally loading objects into storage/transport containers

A method for stacking mailpieces having variable thickness characteristics in a mailpiece container/tray, comprising the steps of:

• conveying mailpieces along a transport;
• coordinating the spatial relationship and movement of the mailpieces on the transport with a thickness measurement device;
• measuring thickness dimensions of each mailpiece at predetermined locations as the mailpiece passes the thickness measurement device;
• calculating a cumulative thickness profile of a plurality of mailpieces, the cumulative thickness profile being developed by summing the respective thickness dimensions of each mailpiece at the predetermined locations;
• determining a maximum thickness value from the cumulative thickness profile in connection with the thickness dimensions at each of the plurality of predetermined locations;
• comparing the maximum thickness value to a maximum fill value for each mailpiece container to determine an overfill condition;
• and
• stacking mailpieces in the mailpiece container based on the overfill condition,
• wherein the step of measuring the thickness dimensions is performed by measuring the displacement of an arm engaging the face surface of the mailpiece,
• wherein the step of measuring the thickness dimensions is performed by an image sensor for optically viewing an image strip disposed in combination with the displacement arm, and
• wherein the image sensor includes a linear array of photosensitive sensors and an illumination device, wherein the image strip includes regions which absorb and reflect light energy, the regions forming an abrupt transition line which is displaced by movement of the pivot arm, and wherein the photosensitive sensors detect the movement of transition line when illuminated by the illumination device to measure the thickness of the mailpiece.

A method for stacking objects in a container, comprising the steps of:

• measuring thickness dimensions of each object at a plurality of predetermined locations, wherein the measuring the thickness dimensions includes measuring multiple thickness measurements across a plurality of same points along an entire length for the each object to produce an array of thickness dimensions for the each object at the same points;
• calculating a cumulative thickness profile of a plurality of stacked objects, the cumulative thickness profile being developed by summing the respective thickness dimensions of each object at each of the predetermined locations;
• determining a maximum thickness value from the cumulative thickness profile in connection with the thickness dimensions at each of the plurality of predetermined locations;
• comparing the maximum thickness value to a maximum fill value for each container to determine an overfill condition;
• stacking objects in the container based on the overfill condition;
• and
• storing the array of thickness dimensions for the each of the plurality of objects as measured at the plurality of same points for the each object.