Method of measuring a condition in a mail processing machine using a diagnostic mail unit

1. A method of measuring a condition in a mail processing machine having a conveyor path through which mail pieces travel during processing, comprising:

feeding onto the conveyor path a diagnostic mail unit including a support having substantially the same shape as mail pieces being processed on the mail processing machine and sufficient flexibility to pass through the mail processing machine without causing a jam, and at least one sensor module mounted on the support configured to measure a condition during transit through the mail processing machine;

conveying the diagnostic mail unit along the conveyor path; and

measuring a condition in the mail processing machine with the sensor as the diagnostic mail unit moves along the conveyor path.

2. The method of claim 1 , wherein the mail pieces are letters and the conveyor path is formed by a pinch belt conveyor.

3. The method of claim 1 , wherein the diagnostic mail unit includes a microprocessor, a memory, a communications device and a power source, which microprocessor receives data concerning a measured condition from the sensor and stores in it the memory, and the method further comprises transmitting data from the communications device to an external decoder.

4. The method of claim 1 , further comprising the step of analyzing the data to identify abnormalities in the mail processing machine.

5. The method of claim 1 , further comprising the steps of: collecting particulate matter with the sensor as the diagnostic mail unit travels through the conveyor path; and analyzing the particulate matter for contaminants.

6. The method of claim 1 , further comprising the step of labeling the diagnostic mail unit with a destination code such that the diagnostic mail unit is directed along a specific path through the mail processing machine.

7. The method of claim 2 , wherein the sensor of the diagnostic mail unit detects conveyor belt scalloping.

8. The method of claim 1 , wherein the sensor of the diagnostic mail unit detects contaminants present in the conveyor path.

9. The method of claim 1 , wherein the sensor of the diagnostic mail unit measures transit time along the conveyor path.

10. The method of claim 1 , wherein the sensor of the diagnostic mail unit generates data used to measure relative velocity between belts.

11. A method of measuring a condition in a mail sorting machine having a pinch belt conveyor path through which mail pieces including letters travel during processing, comprising:

feeding onto the conveyor path a diagnostic mail unit including a support having substantially the same shape as letters being processed on the mail processing machine and sufficient flexibility to pass through the mail processing machine without causing a jam, and at least one sensor module mounted on the support configured to measure a condition during transit through the mail processing machine;

conveying the diagnostic mail unit along the conveyor path;

measuring a condition in the mail processing machine with the sensor as the diagnostic mail unit moves along the conveyor path; and

retrieving the diagnostic mail unit after it has traveled along the conveyor path.

12. The method of claim 11 , wherein the diagnostic mail unit includes a microprocessor, a memory, a communications device and a power source further comprising steps of:

receiving data from the sensor with the microprocessor concerning a measured condition; and

storing the data in the memory.

13. The method of claim 12 , further comprising transmitting data from the communications device to an external decoder via a wireless signal.

14. The method of claim 12 , further comprising:

after retrieval of the diagnostic unit, connecting the diagnostic mail unit to a decoder; and

downloading collected data to the decoder.

15. The method of claim 11 , further comprising:

labeling the diagnostic mail unit with a destination code;

sorting mail pieces transported by the pinch belt conveyor according to destination codes thereon; and

directing the diagnostic mail unit along a specific path through the mail sorting machine according to the destination code on the diagnostic mail unit.

16. The method of claim 12 , further comprising the step of analyzing the data to identify abnormalities in the mail sorting machine.

17. The method of claim 11 , further comprising detecting belt scalloping with the sensor.

18. The method of claim 11 , further comprising measuring transit time along the conveyor path with the sensor.

19. The method of claim 11 , further comprising measuring relative velocity between belts with the sensor.

20. A method of measuring a condition in a mail sorting machine having a conveyor path through which mail pieces travel during processing, comprising:

feeding onto the conveyor path a diagnostic mail unit including a support having substantially the same shape as mail pieces being processed on the mail sorting machine, and at least one sensor module mounted on the support configured to measure a condition during transit through the mail processing machine, which diagnostic mail unit further includes a microprocessor, a memory, a communications device and a power source for empowering components of the diagnostic mail unit;

conveying the diagnostic mail unit along the conveyor path;

measuring a condition in the mail sorting machine with the sensor as the diagnostic mail unit moves along the conveyor path;

receiving data from the sensor with the microprocessor concerning a measured condition;

storing the data in the memory;

analyzing the data; and

retrieving the diagnostic mail unit after it has traveled along the conveyor path.