Note: Descriptions are shown in the official language in which they were submitted.
COIN SORTING HEAD AND COIN PROCESSING SYSTEM USING THE SAME
RELATED APPLICATION
[0001] This application claims the benefit of priority to U.S.
Continuation-in-Part
Application No. 16/224,246, entitled "Coin Sorting Head and Coin Processing
System
Using the Same" filed on December 18, 2018.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates generally to coin sorting
devices and, more
particularly, to coin sorters of the type which use a coin-driving member and
a coin-
guiding member or sorting head for sorting coins of mixed diameters.
BACKGROUND OF THE DISCLOSURE
[0003] This background information is provided to reveal information
believed by
the applicant to be of possible relevance. No admission is necessarily
intended, nor should
be construed, that any of the preceding information constitutes prior art or
forms part of
the general common knowledge in the relevant art.
[0004] Generally, disc-type coin sorters sort coins according to the
diameter of
each coin. Typically, in a given coin set such as the United States coin set,
each coin
denomination has a different diameter. Thus, sorting coins by diameter
effectively sorts
the coins according to denomination.
[0005] Disc-type coin sorters typically include a resilient pad
(disposed on a
rotating disc) that rotates beneath a stationary sorting head having a lower
surface
positioned parallel to the upper surface of the resilient pad and spaced
slightly therefrom.
The rotating, resilient pad presses coins upward against the sorting head as
the pad rotates.
The lower surface of sorting head includes a plurality of shaped regions
including exit slots
for manipulating and controlling the movement of the coins. Each of the exit
slots is
dimensioned to accommodate coins of a different diameter for sorting the coins
based on
diameter size. As coins are discharged from the sorting head via the exit
slots, the sorted
coins follow respective coin paths to sorted coin receptacles where the sorted
coins are
stored.
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[0006] Although coin sorters have been used for a number of years,
problems are
still encountered in this technology. For example, as coins are guided by the
sorting head,
portions of the sorting head and/or pad become worn due to friction between
the stationary
sorting head and the moving coins.
SUMMARY
[0007] The following presents a simplified summary of the general
inventive
concept(s) described herein to provide a basic understanding of some aspects
of the
invention. This summary is not an extensive overview of the invention. It is
not intended
to restrict key or critical elements of the invention or to delineate the
scope of the invention
beyond that which is explicitly or implicitly described by the following
description and
claims.
[0008] According to some embodiments of the present disclosure, a
coin
processing system for processing a plurality of coins of a mixed plurality of
denominations,
the coins of the plurality of denominations having a plurality of diameters,
comprises a
rotatable disc having a resilient pad coupled thereto for imparting motion to
the plurality
of coins, the resilient pad being generally circular and having an outer
periphery edge. The
system further comprises a stationary sorting head having a lower surface
generally parallel
to and spaced slightly away from the resilient pad, the lower surface forming
a coin path
for directing the movement of each of the coins and an exit slot area
comprising a plurality
of exit slots for discharging coins based on the diameter of each coin. The
coin path below
the exit slot area is positioned near the edge of the pad and coins travel
along the coin path
below the exit slot area having their radially outward edges aligned along a
common radius
positioned radially outward of the edge of the pad such that the outward edges
of the coins
extend beyond the edge of the pad. Each exit slot is associated with a given
diameter of
coin and the plurality of exit slots are arranged from upstream to downstream
to accept
coins in the order of increasing diameter, wherein each exit slot is sized to
permit coins of
an associated diameter to enter the exit slot while not permitting coins of
larger diameters
to enter the exit slot.
[0009] According to some embodiments of the present disclosure, a
method of
processing coins using a coin processing system for processing a plurality of
coins of a
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mixed plurality of denominations, the coins of the plurality of denominations
having a
plurality of diameters is provided. The coin processing system comprises a
rotatable disc
having a resilient pad coupled thereto for imparting motion to the plurality
of coins, the
resilient pad being generally circular and having an outer periphery edge and
the coin
processing system further comprises a stationary sorting head having a lower
surface
generally parallel to and spaced slightly away from the resilient pad, the
lower surface
forming a coin path for directing the movement of each of the coins and an
exit slot area
comprising a plurality of exit slots for discharging coins based on the
diameter of each
coin; wherein the coin path in the exit slot area is positioned near the edge
of the pad. The
method comprises the acts of receiving the coins traveling along the coin path
into the exit
slot area with their radially outward edges aligned along a common radius
positioned
radially outward of the edge of the pad such that the outward edges of the
coins extend
beyond the edge of the pad.
[0010]
According to some embodiments of the present disclosure, a U.S. coin
processing system for processing a plurality of coins of a mixed plurality of
U.S.
denominations, the coins of the plurality of U.S. denominations having a
plurality of
diameters, comprises a rotatable disc having a resilient pad coupled thereto
for imparting
motion to the plurality of coins, the resilient pad being generally circular
and having an
outer periphery edge. The system further comprises a stationary sorting head
having a
lower surface generally parallel to and spaced slightly away from the
resilient pad, the
lower surface forming a coin path for directing the movement of each of the
coins and an
exit slot area comprising a plurality of exit slots for discharging coins
based on the diameter
of each coin. The coin path below the exit slot area is positioned near the
edge of the pad
and coins travel along the coin path below the exit slot area having their
radially outward
edges aligned along a common radius positioned radially outward of the edge of
the pad
such that the outward edges of the coins extend beyond the edge of the pad.
Each exit slot
is associated with a given diameter of coin and the plurality of exit slots
are arranged from
upstream to downstream to accept coins in the order of increasing diameter.
Each exit slot
is sized to permit coins of an associated diameter to enter the exit slot
while not permitting
coins of larger diameters to enter the exit slot. Each exit slot comprises a
straight or nearly
straight downstream exit wall having a coin-driven length of less than 1 1/4
inch.
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100111 According to some embodiments of the present disclosure, a
coin chute for
receiving coins exiting from a coin sorting system comprises a rotatable disc
for imparting
motion to the plurality of coins, a stationary sorting head having a lower
surface generally
parallel to and spaced slightly away from the resilient pad, the lower surface
forming a coin
path for directing the movement of each of the coins, and a reject slot. Coins
exiting the
reject slot travel in a first generally horizontal direction. The coin chute
comprises a lower
tapered surface having a generally funnel shape having a larger perimeter at
its top than
near its bottom. The coin chute further comprises an upper generally vertical
wall having
an angled portion at an angle from the first horizontal direction coins exit
the reject slot,
the portion being positioned such that coins exiting the reject slot contact
the angled portion
and are directed in a generally horizontal second direction, the angle of the
angled portion
being an angle other than 900 from the first generally horizontal direction.
100121 According to some embodiments of the present disclosure, a
coin
processing system for processing a plurality of coins, comprises a rotatable
disc having a
resilient pad coupled thereto for imparting motion to the plurality of coins,
the resilient pad
being generally circular and having an outer periphery edge. The system
further comprises
a stationary sorting head having a lower surface generally parallel to and
spaced slightly
away from the resilient pad, the lower surface forming a coin path for
directing the
movement of each of the coins and a coin reject region for discharging coins.
The reject
region comprises a diverter pin. A coin to be rejected coin travels toward the
diverter pin
in a radial outward downward tilted manner.
100131 According to some embodiments of the present disclosure, a
coin
processing system for processing a plurality of coins of a mixed plurality of
denominations,
the coins of the plurality of denominations having a plurality of diameters,
comprises a
rotatable disc having a resilient pad coupled thereto for imparting motion to
the plurality
of coins, the resilient pad being generally circular and having an outer
periphery edge. The
system further comprises a stationary sorting head having a lower surface
generally parallel
to and spaced slightly away from the resilient pad, the lower surface forming
a coin path
for directing the movement of each of the coins and a coin reject region for
discharging
coins moving along the coin path satisfying one or more criteria. The reject
region
comprises a diverter pin, a reject slot having a reject wall, a lower surface,
and an elevated
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surface. The diverter pin has a retracted position at or above the elevated
surface and a
diverting position wherein the diverting pin extends below the elevated
surface toward the
resilient pad and into the path of coins traveling along the coin path. When
the diverting
pin is in the diverting position, a coin traveling along the coin path will
contact the diverter
pin and move in a radially outward direction. The coin path below the reject
region is
positioned near the edge of the pad. When coins travel along the coin path
below the reject
region their radially inward edges are aligned along a radius positioned near
the edge of
the pad such that the outward edges of the coins extend beyond the edge of the
pad. The
elevated surface is positioned radially inward of a portion of the lower
surface. When a
coin travels along the coin path toward the diverter pin it is pressed by the
pad upward
toward the sorting head such that the radially inner edge of the coin is
pressed into the
elevated surface and a portion of the coin contacts a portion of the lower
surface whereby
the coin travels toward the diverter pin in a radial outward downward tilted
manner.
[0014] According to some embodiments of the present disclosure, a
coin
processing system for processing a plurality of coins of a mixed plurality of
denominations,
the coins of the plurality of denominations having a plurality of diameters,
comprises a
rotatable disc having a resilient pad coupled thereto for imparting motion to
the plurality
of coins, the resilient pad being generally circular and having an outer
periphery edge. The
system further comprises a stationary sorting head having a lower surface
generally parallel
to and spaced slightly away from the resilient pad, the lower surface forming
a coin path
for directing the movement of each of the coins and a coin reject region for
discharging
coins moving along the coin path satisfying one or more criteria. The reject
region
comprises a diverter pin and a reject slot having a reject wall, the reject
wall being
downstream of the diverter pin. The diverter pin has a retracted position
whereat a coin
traveling along the coin path does not contact the diverter pin and the
diverting pin has a
diverting position whereat a coin traveling along the coin path will contact
the diverter pin
and move in a radially outward direction. When the diverter pin is in its
diverting position
and a rejected coin contacts the diverter pin, the resilient pad maintains
control over the
movement of the rejected coin at least until the rejected coin contacts the
reject wall.
[0015] According to some embodiments of the present disclosure, a
reject region
of a coin processing system for processing a plurality of coins of a mixed
plurality of
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denominations is provided. The coins of the plurality of denominations have a
plurality of
diameters. The coin processing system comprises a rotatable disc having a
resilient pad
coupled thereto for imparting motion to the plurality of coins, the resilient
pad being
generally circular and having an outer periphery edge. The coin processing
system further
comprises a stationary sorting head having a lower surface generally parallel
to and spaced
slightly away from the resilient pad. The lower surface forms a coin path for
directing the
movement of each of the coins and a coin reject region for discharging coins
moving along
the coin path satisfying one or more criteria. The reject region comprises a
diverter pin
having a generally cylindrical shape and having a bottom surface and generally
vertical
sides. The reject region further comprises a reject slot having a reject wall,
a lower surface,
and an elevated surface. The diverter pin has a retracted position at or above
the elevated
surface and a diverting position wherein the diverting pin extends below the
elevated
surface toward the resilient pad and into the path of coins traveling along
the coin path.
When the diverting pin is in the diverting position, a coin traveling along
the coin path will
contact the diverter pin and move in a radially outward direction. The coin
path below the
reject region is positioned near the edge of the pad wherein when coins travel
along the
coin path below the reject region they have their radially inward edges
aligned along a
radius positioned near the edge of the pad such that the outward edges of the
coins extend
beyond the edge of the pad. The elevated surface is positioned radially inward
of a portion
of the lower surface and wherein a coin traveling along the coin path toward
the diverter
pin is pressed by the pad upward toward the sorting head such that the
radially inner edge
of the coin is pressed into the elevated surface and a portion of the coin
contacts a portion
of the lower surface whereby the coin travels toward the diverter pin in a
radial outward
downward tilted manner. When the diverter pin is in its diverting position, a
coin contacts
the diverter pin while the coin is tilted in a radial outward downward tilted
manner.
100161 According to some embodiments of the present disclosure, a coin
processing system for processing a plurality of coins of a mixed plurality of
denominations,
the coins of the plurality of denominations having a plurality of diameters,
comprises a
rotatable disc having a resilient pad coupled thereto for imparting motion to
the plurality
of coins, the resilient pad being generally circular and having an outer
periphery edge and
a center. The system further comprises a stationary sorting head having a
lower surface
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generally parallel to and spaced slightly away from the resilient pad, the
lower surface
forming a coin path for directing the movement of each of the coins past a
coin re-gauging
area. The re-gauging area comprises a gauging block, a lower surface, and an
elevated
surface. The coin path below the re-gauging area is positioned near the edge
of the pad
and wherein coins travel along the coin path into the re-gauging area having
their radially
inward edges aligned along a radius positioned near the edge of the pad such
that the
outward edges of the coins extend beyond the edge of the pad. The rotation of
the pad
drives radial outward edges of the coins into contact with the gauging block.
The elevated
surface is positioned radially inward of a portion of the lower surface and
the gauging block
is positioned radially outward of the portion of the lower surface. When the
coins contact
the gauging block the coins are pressed by the pad upward toward the sorting
head such
that the radially inner edges of the coins are pressed into the elevated
surface and a portion
of the coins contacts a portion of the lower surface whereby the coins contact
the gauging
block in a radial outward downward tilted manner. The gauging block has a
gauging wall
having an upstream end and a downstream end, the downstream end of the gauging
wall
being positioned radially closer to the center of the pad than the upstream
end of the
gauging wall. The rotation of the pad drives the coins downstream along a
gauging wall
of the gauging block whereby the outer edges of the coins becomes radially
aligned and
wherein the coins are driven along the gauging wall in a radial outward
downward tilted
manner.
[0017]
According to some embodiments of the present disclosure there is provided
a coin processing system for processing a plurality of coins of a mixed
plurality of
denominations where the coins of the plurality of denominations have a
plurality of
diameters. The coin processing system comprises a rotatable disc having a
resilient pad
coupled thereto for imparting motion to the plurality of coins where the
resilient pad is
generally circular and has an outer periphery edge a center, and an upper
surface. There is
provided a stationary sorting head which has a lower surface generally
parallel to and
spaced slightly away from the resilient pad where the lower surface forms a
coin path for
directing the movement of each of the coins past a coin re-gauging area. The
re-gauging
area comprises a gauging block, a lower surface, and an elevated surface and
wherein the
coin path below the re-gauging area is positioned near the edge of the pad and
wherein
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when coins travel along the coin path into the re-gauging area they have their
radially
inward edges aligned along a radius positioned near the edge of the pad such
that the
outward edges of the coins extend beyond the edge of the pad. The rotation of
the pad
drives radial outward edges of the coins into contact with the gauging block,
wherein the
elevated surface is positioned radially inward of a portion of the lower
surface and the
gauging block is positioned radially outward of the portion of the lower
surface and
wherein when the coins contact the gauging block the coins are pressed by the
pad upward
toward the sorting head such that the radially inner edges of the coins are
pressed into the
elevated surface and a portion of the coins contacts a portion of the lower
surface whereby
the coins contact the gauging block in a radial outward downward tilted
manner. And,
wherein the gauging block has a gauging wall which has an upstream end and a
downstream end, the downstream end of the gauging wall is positioned radially
closer to
the center of the pad than the upstream end of the gauging wall; and wherein
the rotation
of the pad drives the coins downstream along a gauging wall of the gauging
block whereby
the outer edges of the coins becomes radially aligned and wherein the coins
are driven
along the gauging wall in a radial outward downward tilted manner with the
radially
inward, lower edges of the coins are above the upper surface of the pad.
[0018] In another aspect, in accordance with some embodiments, there
is provided
a method of processing coins using a coin processing system for processing a
plurality of
coins of a mixed plurality of denominations, the coins of the plurality of
denominations
having a plurality of diameters, the coin processing system comprising a
rotatable disc
having a resilient pad coupled thereto for imparting motion to the plurality
of coins, the
resilient pad being generally circular and having an outer periphery edge, a
center, and an
upper surface, the coin processing system further comprising a stationary
sorting head
having a lower surface generally parallel to and spaced slightly away from the
resilient pad,
the lower surface forming a coin path for directing the movement of each of
the coins past
a coin re-gauging area, the re-gauging area comprising a gauging block, a
lower surface,
and an elevated surface, wherein the coin path in the re-gauging area is
positioned near the
edge of the pad, wherein the elevated surface is positioned radially inward of
a portion of
the lower surface and the gauging block is positioned radially outward of the
portion of the
lower surface, the method comprising the acts of:
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receiving coins traveling along the coin path into the re-gauging area with
their
radially inward edges being aligned along a radius positioned near the edge of
the pad
such that the outward edges of the coins extend beyond the edge of the pad;
driving radial outward edges of the coins into contact with the gauging block
via
the rotation of the pad;
pressing the coins, by the pad, upward toward the sorting head while the coins
contact the gauging block such that the radially inner edges of the coins are
pressed
into the elevated surface and a portion of the coins contacts a portion of the
lower
surface whereby the coins contact the gauging block in a radial outward
downward
tilted manner;
wherein the gauging block has a gauging wall having an upstream end and a
downstream end, the downstream end of the gauging wall being positioned
radially
closer to the center of the pad than the upstream end of the gauging wall;
driving the coins, via the rotation of the pad, downstream along a gauging
wall of
the gauging block whereby the outer edges of the coins becomes radially
aligned and
wherein the coins are driven along the gauging wall in a radial outward
downward
tilted manner with the radially inward, lower edges of the coins being above
the upper
surface of the pad.
[0019]
According to some embodiments of the present disclosure there is provided
a coin processing system for processing a plurality of coins of a mixed
plurality of
denominations where the coins of the plurality of denominations have a
plurality of
diameters. The coin processing system comprises a rotatable disc having a
resilient pad
coupled thereto for imparting motion to the plurality of coins where the
resilient pad is
generally circular and has an outer periphery edge, a center, and an upper
surface. There
is also provided a stationary sorting head which has a lower surface generally
parallel to
and spaced slightly away from the resilient pad where the lower surface forms
a coin path
for directing the movement of each of the coins past a coin re-gauging area.
The re-gauging
area comprises a gauging block, a lower surface, and an elevated surface and
the rotation
of the pad drives radial outward edges of the coins into contact with the
gauging block,
wherein the elevated surface is positioned radially inward of a portion of the
lower surface
and the gauging block is positioned radially outward of the portion of the
lower surface.
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When the coins contact the gauging block the coins are pressed by the pad
upward toward
the sorting head such that the radially inner edges of the coins are pressed
into the elevated
surface and a portion of the coins contacts a portion of the lower surface
whereby the coins
contact the gauging block in a radial outward downward tilted manner. The
gauging block
has a gauging wall having an upstream end and a downstream end where the
downstream
end of the gauging wall is positioned radially closer to the center of the pad
than the
upstream end of the gauging wall; and wherein the rotation of the pad drives
the coins
downstream along a gauging wall of the gauging block whereby the outer edges
of the
coins become radially aligned and wherein the coins are driven along the
gauging wall in
a radial outward downward tilted manner with the radially inward, lower edges
of the coins
being above the upper surface of the pad.
100201 In another aspect, in accordance with some embodiments, there
is provided
a method of processing coins using a coin processing system for processing a
plurality of
coins of a mixed plurality of denominations where the coins of the plurality
of
denominations have a plurality of diameters. The method comprises providing a
coin
processing system comprising a rotatable disc having a resilient pad coupled
thereto for
imparting motion to the plurality of coins, the resilient pad being generally
circular and
having an outer periphery edge, a center, and an upper surface, the coin
processing system
further comprising a stationary sorting head having a lower surface generally
parallel to
and spaced slightly away from the resilient pad, the lower surface forming a
coin path for
directing the movement of each of the coins past a coin re-gauging area, the
re-gauging
area comprising a gauging block, a lower surface, and an elevated surface,
wherein the
elevated surface is positioned radially inward of a portion of the lower
surface and the
gauging block is positioned radially outward of the portion of the lower
surface, the method
comprising the acts of:
receiving coins traveling along the coin path into the re-gauging area with
their
radially inward edges being aligned along a radius;
driving radial outward edges of the coins into contact with the gauging block
via
the rotation of the pad;
pressing the coins, by the pad, upward toward the sorting head while the coins
contact the gauging block such that the radially inner edges of the coins are
pressed
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into the elevated surface and a portion of the coins contacts a portion of the
lower
surface whereby the coins contact the gauging block in a radial outward
downward
tilted manner;
wherein the gauging block has a gauging wall having an upstream end and a
downstream end, the downstream end of the gauging wall being positioned
radially
closer to the center of the pad than the upstream end of the gauging wall;
driving the coins, via the rotation of the pad, downstream along a gauging
wall of
the gauging block whereby the outer edges of the coins becomes radially
aligned and
wherein the coins are driven along the gauging wall in a radial outward
downward
tilted manner with the radially inward, lower edges of the coins being above
the upper
-
surface of the pad.
100211 In some embodiments, there is provide a method of processing
coins using
a coin processing system for processing a plurality of coins of a mixed
plurality of
denominations where the coins of the plurality of denominations have a
plurality of
diameters. The method comprises providing a coin processing system comprising
a
rotatable disc having a resilient pad coupled thereto for imparting motion to
the plurality
of coins, the resilient pad being generally circular and having an outer
periphery edge, a
center, and an upper surface, the coin processing system further comprising a
stationary
sorting head having a lower surface generally parallel to and spaced slightly
away from the
resilient pad, the lower surface forming a coin path for directing the
movement of each of
the coins past a coin re-gauging area, the re-gauging area comprising a
gauging block, a
lower surface, and an elevated surface, the method comprising the acts of:
receiving coins traveling along the coin path into the re-gauging area with
their
radially outward edges being at first radii;
pressing the coins, by the pad, upward toward the sorting head such that the
radially
inner edges of the coins are pressed into the elevated surface and a portion
of the coins
contacts a portion of the lower surface whereby the coins are driven radially
inward
while being oriented in a radial outward downward tilted manner with the
radially
inward, lower edges of the coins being above the upper surface of the pad such
that
coins move from having with their radially outward edges being at first radii
to having
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with their radially outward edges being at second radii, wherein the second
radii are
located radially inward of the first radii.
[0022] The above summary of the present disclosure is not intended to
represent
each embodiment, or every aspect, of the present disclosure. Additional
features and
benefits of the present disclosure will become apparent from the detailed
description,
figures, and claims set forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Several embodiments of the present disclosure will be
provided, by way of
examples only, with reference to the appended drawings, wherein:
[0024] FIG. 1A is a perspective view of a coin processing system or
coin sorter,
according to some embodiments of the present disclosure, with portions thereof
broken
away to show the internal structure.
[0025] FIG. 1B is a functional block diagram of a control system for
the coin
processing system shown in FIG. 1A.
[0026] FIG. 2 is a bottom plan view of a first sorting head for use
with the system
of FIGS. 1A and 1B.
[0027] FIG. 3 is a bottom plan view of a second sorting head for use
with the system
of FIGS. 1A and 1B embodying concepts and features of the present disclosure.
[0028] FIG. 4A is a bottom plan view of a reject region of the
sorting head of FIG.
2.
[0029] FIG. 4B is a bottom plan view of a reject region of the
sorting head of FIG.
3.
[0030] FIG. 4C is a bottom plan view of the reject area of the
sorting head of FIG.
3 illustrating the passage of a non-rejected coin.
[00311 FIG. 5A is a bottom plan view of reject region or area of
sorting head of
FIG. 2 with representations of coins in the reject region.
[0032] FIG. 5B is a bottom plan view of reject region or area of
sorting head of
FIG. 3 with representations of coins in the reject region.
[0033] FIG. 6A is a partial cross-sectional view of the reject region
of FIG. 5A in
a location near a diverter pin.
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[0034] FIG. 6B is a partial cross-sectional view of the reject region
of FIG. 5B in a
location near a diverter pin.
[0035] FIG. 7A is a partial cross-sectional view of the reject region
of FIG. 5A at
two locations near a diverter pin illustrating the tilt of exemplary coins (US
100, 250, and
500 coins) in the reject region.
[0036] FIG. 7B is a partial cross-sectional view of the reject region
of FIG. 5B at
two locations near a diverter pin illustrating the tilt of exemplary coins (US
100, 250, and
500 coins) in the reject region.
[0037] FIG. 7C is a bottom plan view of a reject region of the
sorting head of FIG.
2 illustrating the range and hence the duration of "pad controlled drive" of a
rejected dime
from first pin contact to end of pad-to-disc grip.
[0038] FIG. 7D is a bottom plan view of a reject region of the
sorting head of FIG.
3 illustrating the range and hence the duration of "pad controlled drive" of a
rejected dime
from first pin contact to end of pad-to-disc grip.
[0039] FIG. 7E is an enlarged, cross-sectional view of a rejected
coin abutting an
outside, lower corner of a diverter pin in the reject region of FIG. 4A.
[0040] FIG. 7F is an enlarged, cross-sectional view of a rejected
coin abutting an
outside, lower corner of a diverter pin in the reject region of FIG. 4B.
[0041] FIG. 7G illustrates the hold areas for a dime in the reject
regions of sorting
heads of FIG.2 and FIG. 3.
[0042] FIG. 8A is a bottom plan view of a re-gauging area of the
sorting head of
FIG. 2.
[0043] FIG. 8B is a bottom plan view of a re-gauging area of the
sorting head of
FIG. 3.
[0044] FIG. 9A is a bottom plan view of the re-gauging area of the
sorting head of
FIG. 2 with representations of coins in the re-gauging area.
[0045] FIG. 9B is a bottom plan view of the re-gauging area of the
sorting head of
FIG. 3 with representations of coins in the re-gauging area.
[0046] FIG. 10A is a partial cross-sectional view the re-gauging area
of FIG. 9A
illustrating the tilt of exemplary coins (US 100, 250, and 500 coins) in the
re-gauging area.
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[0047] FIG. 10B is a partial cross-sectional view the re-gauging area
of FIG. 9B
illustrating the tilt of exemplary coins (US 100, 250, and 500 coins) in the
re-gauging area.
[0048] FIG. 10C is a partial cross-sectional view the re-gauging area
of FIG. 9B
illustrating the tilt of an exemplary coin (US 500 coin) in the re-gauging
area.
[0049] FIG. 10D is a partial cross-sectional view an alternative re-
gauging area
from that of FIGS. 9B and 10C illustrating the tilt of an exemplary coin (US
500 coin) in
the alternative re-gauging area.
[0050] FIG. 10E is a bottom plan view of the alternative re-gauging
area of FIG.
10D.
[0051] FIG. 11A is a bottom plan view of the re-gauging area of the
sorting head
of FIG. 2 illustrating radial displacement of exemplary coins (US 100, 50, 10,
$1, 250, and
500 coins) as the coins pass through the re-gauging area.
[0052] FIG. 11B is a bottom plan view of the re-gauging area of the
sorting head
of FIG. 3 illustrating radial displacement of exemplary coins (US 100, 50, 10,
$1, 250, and
500 coins) as the coins pass through the re-gauging area.
[0053] FIG. 12A is a partial bottom plan view of an exit slot area of
the sorting
head of FIG. 2.
100541 FIG. 12B is a partial bottom plan view of an exit slot area of
the sorting
head of FIG. 3.
[0055] FIG. 12C is an upward perspective view of a first exit slot of
the sorting
head of FIG. 3.
[0056] FIG. 13A is a partial cross-sectional view of a first exit
slot shown in FIG.
12A.
[0057] FIG. 13B is a partial cross-sectional view of a first exit
slot shown in FIG.
12B.
[0058] FIG. 14 is a flowchart illustrating a Container Limit Stop
Routine according
to some embodiments.
[0059] FIG. 15A is a bottom plan view of a variation of the sorting
head of FIG. 3
overlaying exit slots of sorting head of FIG. 2 according to some embodiments.
[0060] FIG. 15B is a bottom plan view of a variation of sorting head
of FIG. 3
according to some embodiments.
3030P-CPS-CAD I 14
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[0061] FIG. 16 is a top plan view and FIG. 17 is a downward
perspective view of
a reject chute according to some embodiments.
[0062] FIG. 18 is a bottom plan view of the first sorting head of
FIG. 2 with
indications of the coin-driven length of exit slots.
[0063] FIG. 19 is a bottom plan view of the second sorting head of
FIG. 3 with
indications of the coin-driven length of exit slots.
[0064] While the disclosure is susceptible to various modifications
and alternative
forms, specific embodiments will be shown by way of example in the drawings
and will
be desired in detail herein. It should be understood, however, that the
disclosure is not
intended to be limited to the particular forms disclosed. Rather, the
disclosure is to cover
all modifications, equivalents and alternatives falling within the spirit and
scope of the
inventions as defined by the appended claims.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS
[0065] Turning now to the drawings and referring first to FIG. 1A, a
disc-type coin
processing system or coin sorter 100 according to some embodiments of the
present
disclosure is shown. FIG. 1A is a perspective view of a coin processing system
or coin
sorter, according to some embodiments of the present disclosure, with portions
thereof
broken away to show the internal structure. The coin processing system 100
includes a
hopper 110 for receiving coins of mixed denominations that feeds the coins
through a
central opening in an annular sorting head 112. As the coins pass through this
opening,
they are deposited on the top surface of a rotatable disc 114. This rotatable
disc 114 is
mounted for rotation on a shaft (not shown) and driven by an electric motor
116. The disc
114 typically comprises a resilient pad 118, preferably made of a resilient
rubber or
polymeric material, bonded to the top surface of a solid disc 120. While the
solid disc 120
is often made of metal, it can also be made of a rigid polymeric material.
[0066] According to some embodiments, coins are initially deposited
by a user or
operator in a coin tray (not shown) disposed above the coin processing system
100 shown
in FIG. 1A. The user lifts the coin tray which funnels the coins into the
hopper 110. A
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coin tray suitable for use in connection with the coin processing system 100
is described in
detail in U.S. Patent No. 4,964,495 entitled "Pivoting Tray For Coin Sorter".
[0067] As the disc 114 is rotated, the coins deposited on the
resilient pad 118 tend
to slide outwardly over the surface of the pad 118 due to centrifugal force.
As the coins
move outwardly, those coins which are lying flat on the pad 118 enter the gap
between the
surface of the pad 118 and the sorting head 112 because the underside of the
inner periphery
of the sorting head 112 is spaced above the pad 118 by a distance which is
about the same
as the thickness of the thickest coin the coin sorter 100 is designed to sort.
As is further
described below, the coins are processed and sent to exit stations or channels
where they
are discharged. The coin exit stations or channels may sort the coins into
their respective
denominations and discharge the coins from the sorting head 112 corresponding
to their
denominations.
[0068] FIG. 1B is a functional block diagram of a control system for
the coin
processing system 100 shown in FIG. 1A which may be employed with the sorting
heads
212, 312 to be subsequently described. FIG. 1B illustrates a system controller
180 and its
relationship to the other components in the coin processing system 100. More
details
regarding a system controller 180 and its relationship to the other components
in the coin
processing system 100 are described in U.S. Patent No. 7,743,902. But briefly,
an operator
of system 100 communicates with the coin processing system 100 via an operator
interface
182 which is configured to receive information from the operator and display
information
to the operator about the functions and operation of the coin processing
system 100. The
controller 180 monitors the angular position of the disc 114 via an encoder
184 which sends
an encoder count to the controller 180 upon each incremental movement of the
disc 114.
Based on input from the encoder 184, the controller 180 determines the angular
velocity at
which the disc 114 is rotating as well as the change in angular velocity, that
is, the
acceleration and deceleration, of the disc 114. The encoder 184 allows the
controller 180
to track the position of coins on the sorting head 212 or 312 after being
sensed. According
to some embodiments of the coin processing system 100, the encoder has a
resolution of
40,000 pulses per revolution of the disc 114.
[0069] The controller 180 also controls the power supplied to the
motor 116 which
drives the rotatable disc 114. When the motor 116 is a DC motor, the
controller 180 can
3030P-CPS-CAD I 16
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reverse the current to the motor 116 to cause the rotatable disc 114 to
decelerate. Thus,
the controller 180 can control the speed of the rotatable disc 114 without the
need for a
braking mechanism. If a braking mechanism 186 is used, the controller 180 also
controls
the braking mechanism 186. Because the amount of power applied is proportional
to the
braking force, the controller 180 has the ability to alter the deceleration of
the disc 114 by
varying the power applied to the braking mechanism 186.
[0070] According to some embodiments of the coin processing 100 and
as will be
described further below such as in reference to FIGS. 2 and 3, the controller
180 also
monitors coin counting sensors 271-276 which are disposed in each of the coin
exit slots
261-266 of the sorting head 212 (or just outside the periphery of the sorting
head 212). As
coins move past one of these counting sensors 271-276, the controller 180
receives a signal
from the counting sensor 271-276 for the particular denomination of the
passing coin and
adds one to the counter for that particular denomination within the controller
180. The
controller 180 and memory 188 maintain a counter for each denomination of coin
that is to
be sorted. In this way, each denomination of coin being sorted by the coin
processing
system 100 has a count continuously tallied and updated by the controller 180.
According
to some embodiments, the controller 180 is able to cause the rotatable disc
114 to quickly
terminate rotation after "n" number (i.e., a predetermined number n) of coins
have been
discharged from an exit slot, but before the "n+1" coin has been discharged.
For example,
it may be necessary to stop the discharging of coins after a predetermined
number of coins
have been delivered to a coin receptacle, such as a coin bag, so that each bag
contains a
known number of coins, or to prevent a coin receptacle from becoming
overfilled.
Alternatively, the controller 180 can cause the system to switch between bags
in
embodiments having more than one coin bag corresponding to each exit slot. For
embodiments of sorting head 312 employing coin counting sensors similar to
sensors 271-
276 in or near exit slots 361-366, the above description related to the use of
sensors 271-
276 would also apply. In some embodiments employing either sorting head 212 or
312,
the controller 180 and memory 188 maintain a counter for each denomination of
coin that
is to be sorted without the use of exit slot sensors 271-276 such as by using
a trigger sensor
and monitoring the rotation of the pad 118 and tracking the location of the
coins as they
travel under and out from under the sorting heads 212,312.
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[0071] The controller 180 also monitors the output of a coin
discrimination sensor
234, 334 and compares information received from the discrimination sensor 234,
334 to
master information stored in a memory 188 of the coin processing system 100
including
information associated with known genuine coins. If the received information
does not
favorably compare to master information stored in the memory 188, the
controller 180
sends a signal to a voice coil 190 causing a diverting pin 242, 342 to move to
a diverting
position. According to some embodiments of the coin processing system 100, as
described
in more detail in U.S. Patent No. 7,743,902, after a coin moves past a trigger
sensor 236,
336 the coin discrimination sensor 234, 334 begins sampling the coin and the
controller
180 then compares the coin's signature to a library of "master" signatures
associated with
known genuine coins stored in the memory 188 and the controller 180 determines
whether
to reject a coin. After determining that a coin is invalid, the controller 180
sends a signal
to activate a voice coil 190 for moving a diverting pin 242, 342 to a
diverting position.
OVERVIEW OF SORTING HEADS
[0072] To better appreciate some of the features and aspects
associated with a
sorting head according to the present disclosure, a first sorting head 212 and
the manner in
which it guides coins will be discussed in conjunction with FIG. 2 and then an
embodiment
of a second sorting head 312 incorporating various features and aspects of the
present
disclosure and the manner in which it guides coins will be discussed in
conjunction with
FIG. 3. Then differences between various aspects and features of sorting head
212 and 312
will be discussed in more detail in conjunction with subsequent figures.
[0073] Referring now to FIG. 2, a bottom plan view of the underside
of a first
sorting head 212 for use with the system of FIGS. 1A and 1B is shown. The coin
sets for
any given country are sorted by the sorting head 212 due to variations in the
diameter size.
The coins circulate between the sorting head 212 and the pad 118 (FIG. 1A) on
the rotatable
disc 114 (FIG. 1A). The pad 118 has a circular surface with a center at C. The
sorting
head 212 has a circular portion centered at point C2 which corresponds with
the center C
of pad 118. The coins are deposited on the pad 118 via a central opening 202
and initially
enter an entry area 204 formed in the underside of the sorting head 212. It
should be kept
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in mind that the circulation of the coins in FIG. 2 appears counterclockwise
as FIG. 2 is a
view of the underside of the sorting head 212.
[0074] An outer wall 206 of the entry area 204 divides the entry area
204 from the
lowermost surface 210 of the sorting head 212. The lowermost surface 210 is
preferably
spaced from the pad 118 by a distance that is less than the thickness of the
thinnest coins
the coin sorter is designed to sort. Consequently, the initial outward radial
movement of
all the coins is terminated when the coins engage the outer wall 206, although
the coins
continue to move more circumferentially along the wall 206 (in the
counterclockwise
direction as viewed in FIG. 2) by the rotational movement imparted to the
coins by the pad
118 of the rotatable disc 114.
[0075] In some cases, coins may be stacked on top of each other ¨
commonly
referred to as "stacked" coins or "shingled" coins. Stacked coins which are
not against the
wall 206 must be recirculated and stacked coins in contact against the wall
206 must be
unstacked. To unstack the coins, the stacked coins encounter a stripping notch
208
whereby the upper coin of the stacked coins engages the stripping notch 208
and is
channeled along the stripping notch 208 back to an area of the pad 118
disposed below the
central opening 202 where the coins are then recirculated. The vertical
dimension of the
stripping notch 208 is slightly less the thickness of the thinnest coins so
that only the upper
coin is contacted and stripped. While the stripping notch 208 prohibits the
further
circumferential movement of the upper coin, the lower coin continues moving
circumferentially across stripping notch 208 into a queuing channel 220.
[0076] Stacked coins that may have bypassed the stripping notch 208
by entering
the entry area 204 downstream of the stripping notch 208 are unstacked after
the coins
enter the queuing channel 220 and are turned into an inner queuing wall 222 of
the queuing
channel 220. The upper coin contacts the inner queuing wall 222 and is
channeled along
the inner queuing wall 222 while the lower coin is moved by the pad 118 across
the inner
queuing wall 222 into a region defined by surface 214 wherein the lower coin
engages a
wall 215 and is recirculated. Other coins that are not properly aligned along
the inner
queuing wall 222, but that are not recirculated by wall 215, are recirculated
by recirculating
channel 217.
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[0077] As the pad 118 continues to rotate, those coins that were initially
aligned
along the wall 206 (and the lower coins of stacked coins moving beneath the
stripping
notch 208) move across a ramp 223 leading to the queuing channel 220 for
aligning the
innermost edge of each coin along the inner queuing wall 222. In addition to
the inner
queuing wall 222, the queuing channel 220 includes a first rail 226 that forms
the outer
edge of surface 228 and a second rail 227 that forms the outer edge of beveled
surface 229.
The beveled surface 229 transitions downward from first rail 226 to second
rail 227. A flat
surface 239x is located radially outward of the second rail 227. The surfaces
228 and 229
are sized such that the width of surface 228 is less than that of the smallest
(in terms of the
diameter) coins and the combined width of surfaces 228 and 229 is less than
that of the
largest coin. As a result, because surface 228 has a width less than that of
the smallest
diameter coin the sorting head is configured to sort, each coin has a portion
thereof which
extends beyond the outer periphery 118a of the rotating pad 118 as they enter
a
discrimination region 230.
100781 The coins are gripped between one of the two rails 226, 227 and the
pad 118
as the coins are rotated through the queuing channel 220. The coins, which
were initially
aligned with the outer wall 206 of the entry area 204 as the coins moved
across the ramp
223 and into the queuing channel 220, are rotated into engagement with inner
queuing wall
222. Because the queuing channel 220 applies a greater amount of pressure on
the outside
edges of the coins, the coins are less likely to bounce off the inner queuing
wall 222 as the
radial position of the coin is increased along the inner queuing wall 222.
[0079] It can be seen that the queuing channel 220 is generally "L-shaped."
The
queuing channel 220 receives the coins as the coins move across the ramp 223
and into the
queuing channel 220. The coins exit the queuing channel 220 as the coins turn
a corner
222a of the L-shaped queuing channel 220 and are guided down ramp 224. L-
shaped
queuing channels are discussed in more detail in U.S. Pat. 7,743,902. As the
pad 118
continues to rotate, the coins move along the queuing channel 220 and are
still engaged on
the inner queuing wall 222. The coins move across a ramp 224 as the coins
enter the
discrimination region 230 and the inner queuing wall 222 transitions to an
inner alignment
wall 232. The discrimination region includes a discrimination sensor 234
for
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discriminating between valid and invalid coins and/or identifying the
denomination of
coins.
[0080] As the pad 118 continues to rotate, the L-shape of the queuing
channel 220
imparts spacing to the coins which are initially closely spaced, and perhaps
abutting one
another, as the coins move across the ramp 223 into the queuing channel 220.
As the coins
move along the queuing channel 220 upstream of corner 222a, the coins are
pushed against
inner queuing wall 222 and travel along the inner queuing wall 222 in a
direction that is
transverse to (i.e., generally unparallel) the direction in which the pad 118
is rotating. This
action aligns the coins against the inner queuing wall 222. However, as the
coins round
the corner 222a of the queuing channel 220, the coins are turned in a
direction wherein they
are moving with the pad (i.e., in a direction more parallel to the direction
of movement of
the pad). A coin rounding the corner 222a is accelerated as the coin moves in
a direction
with the pad; thus, the coin is spaced from the next coin upstream. Put
another way, the
queuing channel 220 receives coins from the entry area 204 and downstream of
corner 222a
the queuing channel 220 is disposed in an orientation that is substantially
more in the
direction of movement of the rotatable disc 114 for creating an increased
spacing between
adjacent coins. Accordingly, the coins moving out of the queuing channel 220
are spaced
apart. According to some embodiments of the present disclosure, the coins are
spaced apart
by at least about 10 mm or 0.40 inches when the sorting head 212 has an eleven
inch
diameter and the pad 118 rotates at a speed of approximately three hundred
revolutions per
minute (300 rpm) such as at approximately 320 rpm.
[0081] The coins move across ramp 224 and transition to a flat
surface 239 of the
discrimination region 230 as the pad 118 continues to rotate. Put another way,
the two
surfaces 228, 229 of the queuing channel 220 transition into the flat surface
239 of the
discrimination region 230. The pad 118 holds each coin flat against the flat
surface 239 of
the discrimination region 230 as the coins are moved past the discrimination
sensor 234.
[0082] The sorting head 212 includes a cutout for the discrimination
sensor 234.
The discrimination sensor 234 is disposed flush with the flat surface 239 of
the
discrimination region 230 or recessed slightly within the sorting head just
above the flat
surface 239 of the discrimination region 230. Likewise, a coin trigger sensor
236 is
disposed just upstream of the discrimination sensor 234 for detecting the
presence of a
3 03 OP-CPS-CAD I 21
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coin. Coins first move over the coin trigger sensor 236 (e.g., a photo
detector or a metal
proximity detector) which sends a signal to a controller (e.g., controller
180) indicating that
a coin is approaching the coin discrimination sensor 234. According to some
embodiments,
the sensor 236 is an optical sensor which may employ a laser to measure a
chord of passing
coins and/or the length of time it takes the coin to traverse the sensor 236
and this
information along with the information from the coin discrimination sensor is
used to
determine the diameter, denomination, and validity of a passing coin.
Additional
description of such embodiments may be found in U.S. Pat. No. 7,743,902.
[0083] According to some embodiments, the coin discrimination sensor
234 is
adapted to discriminate between valid and invalid coins. Use of the term
"valid coin" refers
to coins of the type the sorting head is designed or configured to sort. Use
of the term
"invalid coin" refers to items being circulated on the rotating disc that are
not one of the
coins the sorting head is designed to sort. Any truly counterfeit coins (i.e.,
a slug) are
always considered "invalid." According to another alternative embodiment of
the present
disclosure, the coin discriminator sensor 234 is adapted to identify the
denomination of the
coins and discriminate between valid and invalid coins.
[0084] Some coin discrimination sensors suitable for use with the
disc-type coin
sorter shown in FIGS. 1A-3 are described in detail in U.S. Patent Nos.
7,743,902;
5,630,494; and 5,743,373. Another coin discrimination sensor suitable for use
with the
present disclosure is described in detail in U.S. Patent No. 6,892,871.
[0085] As discussed above according to one alternative embodiment of
the present
disclosure, the discrimination sensor 234 discriminates between valid and
invalid coins.
Downstream of the discrimination sensor 234 is a diverting pin 242 disposed
adjacent inner
alignment wall 232 that is movable to a diverting position (out of the page as
viewed in
FIG. 2) and a home position (into the page as viewed in FIG. 2). In the
diverting position,
the diverting pin 242 directs coins off of inner alignment wall 232 and into a
reject slot
249. The reject slot 249 includes a reject surface 243 and a reject wall 244
that rejected
coins abut against as they are off-sorted to the periphery of the sorting head
212. Off-
sorted coins are directed to a reject area (not shown). Coins that are not
rejected (i.e., valid
coins) eventually engage an outer wall 252 of a gauging channel or region 250
where coins
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are aligned on a common outer radius for entry into a coin exit station or
exit slot area 260
as is described in greater detail below.
[0086] According to some embodiments of the present disclosure, the
diverting pin
242 is coupled to a voice coil 190 (not shown in FIG. 2, see FIG. 1B) for
moving the
diverting pin 242 between the diverting position and the home position. More
details on
diverting pins such as diverting pins 242 and 342 and voice coils are
discussed in U.S. Pat.
7,743,902. Other types of actuation devices can be used in alternative
embodiments of the
present disclosure instead of voice coils. For example, a linear solenoid or a
rotary solenoid
may be used to move a pin such as diverting pin 242 between a diverting
position and a
home position.
[0087] As the pad 118 continues to rotate, those coins not diverted
into the reject
slot 249 continue to the gauging region 250. The inner alignment wall 232
terminates just
upstream of the diverter pin 242; thus, the coins no longer abut the inner
alignment wall
232 at this point. The radial position of the coins is maintained, because the
coins remain
under pad pressure, until the coins contact an outer wall 252 of the gauging
region 250.
According to some embodiments, the sorting head 212 includes a gauging block
254 which
has an outer wall 252 extending beyond the outer periphery 118a of the
rotating pad 118.
[0088] The gauging wall 252 extends radially inward in the
counterclockwise
direction as viewed in FIG. 2 so as to align the coins along a common outer
radius 256
which is positioned inboard of the outer periphery 118a of the rotating pad
118 and the
outer periphery 212a of the sorting head 212 as the coins approach a series of
coin exit
slots 261-266 which discharge coins of different denominations. The first exit
slot 261 is
dedicated to the smallest diameter coin to be sorted (e.g., the dime in the
U.S. coin set).
Beyond the first exit slot 261, the sorting head 212 shown in FIG. 2 forms
five more exit
slots 262-266 which discharge coins of different denominations at different
circumferential
locations around the periphery of the sorting head 212. Thus, the exit slots
261-266 are
spaced circumferentially around the outer periphery 212a of the sorting head
212 with the
innermost edges 261a-266a of successive channels located progressively closer
to the
center C2 of the sorting head 212 so that coins are discharged in the order of
increasing
diameter. The number of exit slots can vary according to alternative
embodiments.
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[0089] The innermost edges 261a-266a of the exit slots 261-266 are
positioned so
that the inner edge of a coin of only one particular denomination can enter
each channel
261-266. The coins of all other denominations reaching a given exit slot
extend inwardly
beyond the innermost edge of that particular exit slot so that those coins
cannot enter the
channel and, therefore, continue on to the next exit slot under the
circumferential
movement imparted on them by the pad 118. To maintain a constant radial
position of the
coins, the pad 118 continues to exert pressure on the coins as they move
between successive
exit slots 261-266.
[0090] According to some embodiments of the sorting head 212, each of
the exit
slots 261-266 includes a coin counting sensor 271-276 for counting the coins
as coins pass
through and are discharged from the coin exit slots 261-266. In embodiments of
the coin
processing system utilizing a discrimination sensor 234 capable of determining
the
denomination of each of the coins, it is not necessary to use the coin
counting sensors 271-
276 because the discrimination sensor 234 provides a signal that allows the
controller 180
to determine the denomination of each of the coins. Through the use of the
system
controller 180 (FIG. 1B), a count is maintained of the number of coins
discharged by each
of the exit slots 261-266.
[0091] Now that a first sorting head 212 has been described, an
embodiment of a
second sorting head 312 incorporating various features and aspects of the
present
disclosure and the manner in which sorting head 312 guides coins will be
discussed in
conjunction with FIG. 3. Similar reference numerals will be used for similar
features (e.g.,
the last two digits of reference numerals of similar features are the same).
[0092] Referring now to FIG. 3, the underside of a sorting head 312
is shown. The
coin sets for any given country are sorted by the sorting head 312 due to
variations in the
diameter size. The coins circulate between the sorting head 312 and the pad
118 (FIG. 1A)
on the rotatable disc 114 (FIG. 1A). The pad 118 has a circular surface with a
center at C.
The sorting head 312 has a circular portion centered at point C3 which
corresponds with
the center C of pad 118. The coins are deposited on the pad 118 via a central
opening 302
and initially enter an entry area 304 formed in the underside of the sorting
head 312. It
should be kept in mind that the circulation of the coins in FIG. 3 appears
counterclockwise
as FIG. 3 is a view of the underside of the sorting head 312.
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[0093] An outer wall 306 of the entry area 304 divides the entry area
304 from the
lowermost surface 310 of the sorting head 312. The lowermost surface 310 is
preferably
spaced from the pad 118 by a distance that is less than the thickness of the
thinnest coins
the coin sorter is designed to sort. Consequently, the initial outward radial
movement of
all the coins is terminated when the coins engage the outer wall 306, although
the coins
continue to move more circumferentially along the wall 306 (in the
counterclockwise
direction as viewed in FIG. 3) by the rotational movement imparted to the
coins by the pad
118 of the rotatable disc 114.
[0094] In some cases, coins may be stacked on top of each other ¨
commonly
referred to as "stacked" coins or "shingled" coins. Stacked coins which are
not against the
wall 306 must be recirculated and stacked coins in contact against the wall
306 must be
unstacked. To unstack the coins, the stacked coins encounter a stripping notch
308
whereby the upper coin of the stacked coins engages the stripping notch 308
and is
channeled along the stripping notch 308 back to an area of the pad 118
disposed below the
central opening 302 where the coins are then recirculated. The vertical
dimension of the
stripping notch 308 is slightly less the thickness of the thinnest coins so
that only the upper
coin is contacted and stripped. While the stripping notch 308 prohibits the
further
circumferential movement of the upper coin, the lower coin continues moving
circumferentially across stripping notch 308 into a queuing channel 320.
[0095] Stacked coins that may have bypassed the stripping notch 308
by entering
the entry area 304 downstream of the stripping notch 308 are unstacked after
the coins
enter the queuing channel 320 and are turned into an inner queuing wall 322 of
the queuing
channel 320. The upper coin contacts the inner queuing wall 322 and is
channeled along
the inner queuing wall 322 while the lower coin is moved by the pad 118 across
the inner
queuing wall 322 into a region defined by surface 314 wherein the lower coin
engages a
wall 315 and is recirculated. Other coins that are not properly aligned along
the inner
queuing wall 322, but that are not recirculated by wall 315, are recirculated
by recirculating
channel 317.
[0096] As the pad 118 continues to rotate, those coins that were
initially aligned
along the wall 306 (and the lower coins of stacked coins moving beneath the
stripping
notch 308) move across a ramp 323 leading to the queuing channel 320 for
aligning the
3030P-CPS-CAD I 25
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innermost edge of each coin along the inner queuing wall 322. In addition to
the inner
queuing wall 322, the queuing channel 320 includes a first rail 326 that forms
the outer
edge of surface 328 and a second rail 327 that forms the outer edge of beveled
surface 329.
The beveled surface 329 transitions downward from first rail 326 to second
rail 327. A flat
surface 339x is located radially outward of the second rail 327. The surfaces
328 and 329
are sized such that the width of surface 328 is less than that of the smallest
(in terms of the
diameter) coins and the combined width of surfaces 328, 329 is less than that
of the largest
coin. As a result, because surface 328 has a width less than that of the
smallest diameter
coin the sorting head is configured to sort, each coin has a portion thereof
which extends
beyond the outer periphery 118a of the rotating pad 118 as they enter a
discrimination
region 330.
[0097] The coins are gripped between one of the two rails 326, 327
and the pad 118
as the coins are rotated through the queuing channel 320. The coins, which
were initially
aligned with the outer wall 306 of the entry area 304 as the coins moved
across the ramp
323 and into the queuing channel 320, are rotated into engagement with inner
queuing wall
322. Because the queuing channel 320 applies a greater amount of pressure on
the outside
edges of the coins, the coins are less likely to bounce off the inner queuing
wall 322 as the
radial position of the coin is increased along the inner queuing wall 322.
[0098] It can be seen that the queuing channel 320 is generally "L-
shaped." The
queuing channel 320 receives the coins as the coins move across the ramp 323
and into the
queuing channel 320. The coins exit the queuing channel 320 as the coins turn
a corner
322a of the L-shaped queuing channel 320. L-shaped queuing channels are
discussed in
more detail in U.S. Pat. 7,743,902. As the pad 118 continues to rotate, the
coins move
along the queuing channel 320 and are still engaged on the inner queuing wall
322. The
coins move across a ramp 324 as the coins enter the discrimination region 330
and the inner
queuing wall 322 transitions to an inner alignment wall 332. The
discrimination region
330 includes a discrimination sensor 334 for discriminating between valid and
invalid coins
and/or identifying the denomination of coins.
[0099] As the pad 118 continues to rotate, the L-shape of the queuing
channel 320
imparts spacing to the coins which are initially closely spaced, and perhaps
abutting one
another, as the coins move across the ramp 323 into the queuing channel 320.
As the coins
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move along the queuing channel 320 upstream of corner 322a, the coins are
pushed against
inner queuing wall 322 and travel along the inner queuing wall 322 in a
direction that is
transverse to (i.e., generally unparallel) the direction in which the pad 118
is rotating. This
action aligns the coins against the inner queuing wall 322. However, as the
coins round
the corner 322a of the queuing channel 320, the coins are turned in a
direction wherein they
are moving with the pad (i.e., in a direction more parallel to the direction
of movement of
the pad). A coin rounding the corner 322a is accelerated as the coin moves in
a direction
with the pad; thus, the coin is spaced from the next coin upstream. Put
another way, the
queuing channel 320 receives coins from the entry area 304 and downstream of
corner 322a
the queuing channel 320 is disposed in an orientation that is substantially
more in the
direction of movement of the rotatable disc 114 for creating an increased
spacing between
adjacent coins. Accordingly, the coins moving out of the queuing channel 220
are spaced
apart. According to some embodiments of the present disclosure, the coins are
spaced apart
by at least about 10 mm or 0.40 inches when the sorting head 312 has an eleven
inch
diameter and the pad 118 rotates at a speed of approximately three hundred
revolutions per
minute (300 rpm) such as at approximately 320 rpm.
[00100] The coins move across ramp 324 and transition to a flat surface 339 of
the
discrimination region 330 as the pad 118 continues to rotate. Put another way,
the two
surfaces 328, 329 of the queuing channel 320 transition into the flat surface
339 of the
discrimination region 330. The pad 118 holds each coin flat against the flat
surface of the
discrimination region 330 as the coins are moved past the discrimination
sensor 334.
1001011 The sorting head 312 includes a cutout for the discrimination sensor
334.
The discrimination sensor 334 is disposed flush with the flat surface 339 of
the
discrimination region 330 or recessed slightly within the sorting head 312
just above the
flat surface 339 of the discrimination region 330. Likewise, a coin trigger
sensor 336 is
disposed just upstream of the discrimination sensor 334 for detecting the
presence of a
coin. Coins first move over the coin trigger sensor 336 (e.g., a photo
detector or a metal
proximity detector) which sends a signal to a controller (e.g., controller
180) indicating that
a coin is approaching the coin discrimination sensor 334.
According to some
embodiments, the sensor 336 is an optical sensor which may employ a laser to
measure a
chord of passing coins and/or the length of time it takes the coin to traverse
the sensor 336
3030P-CPS-CAD I 27
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and this information along with the information from the coin discrimination
sensor is used
to determine the diameter, denomination, and validity of a passing coin.
Additional
description of such embodiments may be found in U.S. Pat. No. 7,743,902.
[00102] According to some embodiments, the coin discrimination sensor 334 is
adapted to discriminate between valid and invalid coins. Use of the term
"valid coin" refers
to coins of the type the sorting head is designed or configured to sort. Use
of the term
"invalid coin" refers to items being circulated on the rotating disc that are
not one of the
coins the sorting head is designed to sort. Any truly counterfeit coins (i.e.,
a slug) are
always considered "invalid." According to another alternative embodiment of
the present
disclosure, the coin discriminator sensor 334 is adapted to identify the
denomination of the
coins and discriminate between valid and invalid coins.
[00103] Some coin discrimination sensors suitable for use with the disc-type
coin
sorter shown in FIGS. 1A-3 are described in detail in U.S. Patent Nos.
7,743,902;
5,630,494; and 5,743,373. Another coin discrimination sensor suitable for use
with the
present disclosure is described in detail in U.S. Patent No. 6,892,871.
[00104] As discussed above according to one alternative embodiment of the
present
disclosure, the discrimination sensor 334 discriminates between valid and
invalid coins.
Downstream of the discrimination sensor 334 is a diverting pin 342 disposed
adjacent inner
alignment wall 332 that is movable to a diverting position (out of the page as
viewed in
FIG. 3) and a home position (into the page as viewed in FIG. 3). In the
diverting position,
the diverting pin 342 directs coins off of inner alignment wall 332 and into a
reject slot
349. The reject slot 349 includes a reject surface 343 and a reject wall 344
that rejected
coins abut against as they are off-sorted to the periphery of the sorting head
312. Off-
sorted coins are directed to a reject area (not shown). Coins that are not
rejected (i.e., valid
coins) eventually engage an outer wall 352 of a gauging channel or region 350
where coins
are aligned on a common outer radius for entry into the coin exit station or
exit slot area
360 as is described in greater detail below.
[00105] According to some embodiments of the present disclosure, the diverting
pin
342 is coupled to a voice coil 190 (not shown) for moving the diverting pin
342 between
the diverting position and the home position. More details on diverting pins
such as
diverting pins 242 and 342 and voice coils are discussed in U.S. Pat.
7,743,902. Other
3030P-CPS-CAD I 28
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types of actuation devices can be used in alternative embodiments of the
present disclosure
instead of voice coils. For example, a linear solenoid or a rotary solenoid
may be used to
move a pin such as diverting pin 342 between a diverting position and a home
position.
[00106] As the pad 118 continues to rotate, those coins not diverted into the
reject
slot 349 continue to the gauging region 350. The inner alignment wall 332
terminates just
upstream of the reject slot 349; thus, the coins no longer abut the inner
alignment wall 332
at this point. The radial position of the coins is maintained, because the
coins remain under
pad pressure, until the coins contact an outer wall 352 of the gauging region
350.
According to some embodiments, the sorting head 312 includes a gauging block
354 which
extends the outer wall 352 beyond the outer periphery 118a of the rotating pad
118.
1001071 The re-gauging wall 352 extends radially inward in the
counterclockwise
direction as viewed in FIG. 3 so as to align the coins along a common outer
radius 356
which is positioned outboard of the outer periphery 118a of the rotating pad
118 and the
outer periphery 312a of the sorting head 312 as the coins approach a series of
coin exit
slots 361-366 which discharge coins of different denominations. Accordingly,
as each coin
approaches the exit slots 361-366, a portion of each coin is positioned
outside the periphery
118a of the rotating pad 118 and the outer periphery 312a of the sorting head
312. The
first exit slot 361 is dedicated to the smallest diameter coin to be sorted
(e.g., the dime in
the U.S. coin set). Beyond the first exit slot 361, the sorting head 312 shown
in FIG. 3
forms five more exit slots 362-366 which discharge coins of different
denominations at
different circumferential locations around the periphery of the sorting head
312. Thus, the
exit slots 361-366 are spaced circumferentially around the outer periphery
312a of the
sorting head 312 with the innermost edges 361a-366a of successive channels
located
progressively closer to the center C3 of the sorting head 312 so that coins
are discharged
in the order of increasing diameter. The number of exit slots can vary
according to
alternative embodiments.
[00108] The innermost edges 361a-366a of the exit slots 361-366 are positioned
so
that the inner edge of a coin of only one particular denomination can enter
each channel
361-366. The coins of all other denominations reaching a given exit slot
extend inwardly
beyond the innermost edge of that particular exit slot so that those coins
cannot enter the
channel and, therefore, continue on to the next exit slot under the
circumferential
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movement imparted on them by the pad 118. To maintain a constant radial
position of the
coins, the pad 118 continues to exert pressure on the coins as they move
between successive
exit slots 361-366.
[00109] According to some embodiments of the sorting head 312, each of the
exit
slots 361-366 includes a coin counting sensor 371-376 for counting the coins
as coins pass
through and are discharged from the coin exit slots 361-366. In embodiments of
the coin
processing system utilizing a discrimination sensor 334 capable of determining
the
denomination of each of the coins, it is not necessary to use the coin
counting sensors 371-
376 because the discrimination sensor 334 provides a signal that allows the
controller 180
to determine the denomination of each of the coins. Through the use of the
system
controller 180 (FIG. 1B), a count is maintained of the number of coins
discharged by each
of the exit slots 361-366.
[00110] Now that the overall sorting heads 212 and 312 have been described,
particular areas of these sorting heads will be described in more detail.
Reject Areas
[00111] FIGS. 4A and 4B are bottom plan views of reject regions 240, 340 of
sorting
heads 212, 312, respectively, and FIGS. 5A and 5B are bottom plan views of
reject regions
or areas 240, 340 of sorting heads 212, 312, respectively, with
representations of coins in
the reject regions. FIGS. 6A and 6B are partial cross-sectional views of the
sorting heads
212, 312, respectively, and pad 118 in a location near the diverter pins 242,
342. FIGS.
7A and 7B are partial cross-sectional views of the sorting heads 212, 312,
respectively, and
pad 118 at two locations near the diverter pins 242, 342 illustrating the tilt
of exemplary
coins (US 100, 250, and 500 coins) in the reject regions 240, 340,
respectively.
[00112] Turning to FIGS. 4A and 5A, as described above, the reject region 240
of
sorting head 212 comprises a reject surface 243, a diverter pin 242, and a
reject wall 244.
A coin approaches diverter pin 242 having an inner edge aligned along inner
alignment
wall 232. The inner alignment wall 232 is positioned radially inward near the
diverter 242
to a relieved portion 232b of the inner alignment wall 232. The reject wall
244 has an
upstream portion 244a near the diverter pin 242. The coins are initially
maintained in a
relatively flat position as surface 239 extends from the inner alignment wall
232 to the edge
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212a of the sorting head 212. An outward portion of the surface of the sorting
head 212
then transitions upward via ramp 241 which leads up into an elevated surface
243 of the
reject slot 249. A ledge 239a keeps a passing coin approaching diverter 242
under positive
control by pinching the coin between ledge 239a and the rotating pad 118. If
the diverter
242 remains in its retracted upper position as the coin passes under it, the
coin remains
gripped between the ledge 239a and pad 118 and eventually the coin reaches a
downstream
portion 239b of the ledge whereat the coin has passed the reject slot 249.
[00113] Region 210a is at "0" depth, meaning at the lowermost surface of the
sorting
head. Surface 259 is beveled from a "0" depth adjacent to region 210a upward
as toward
a higher region 259a near the outer portion of sorting head 212. Ramp 248 is a
beveled
surface extending downward from downstream portion 239b of the ledge to area
210a. As
a non-rejected coin passes over downstream portion 239b, a portion of the coin
may be
dragged under the edge of reject wall 244 and down ramp 248 and into contact
with beveled
surface 259. The movement of a coin over this region can cause some coins to
flutter which
can cause wear of the sorting head on surfaces 248 and 259 and on the bottom
edge of wall
244.
[00114] If, however, the diverter pin 242 is in its extended lower position,
the coin
strikes the diverter pin 242, bounces away from inner alignment wall 232 and
out from
under ledge 239a and enters the reject slot 249, strikes reject wall 244 and
then travels out
from under the sorting head 212.
[00115] FIG. 6A is a partial cross-sectional view of the sorting head 212 and
pad
118 in a region near the diverter pin 242 when no coin is present. FIG. 7A
illustrates partial
cross-sectional views of the sorting head 212 and pad 118 at two locations
near diverter
pin 242 illustrating the tilt of exemplary coins (US 100, 250, and 500 coins).
In a first
location where coins are about to first abut diverter pin 242 shown by
exemplary (a) coin
C10-5A1 for a dime and the cross-section taken through the middle of the dime
along line
7A-10 shown in FIG. 5A, (b) coin C50-5A1 for a half dollar and the cross-
section taken
through the middle of the half dollar along line 7A-50 shown in FIG. 5A, and
(c) coin C25-
5A1 for a quarter through the middle of the quarter (the cross-section line
not being shown
in FIG. 5A). Coins in this first location are shown in dashed lines in FIG.
7A. The second
location is where coins are positioned to the radially outside surface or edge
of diverter pin
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242 as shown for a dime by position C10-5A2 in FIG. 5A. Coins in this second
location
are shown in solid lines in FIG. 7A. According to some embodiments, in FIG.
7A, the
radially outward upward tilt of the dime is about 2.5 at the first location
(dashed coin C10-
5A1) and about 4.40 at the second location (solid coin C10-5A2), the radially
outward
upward tilt of the quarter is about 2.7 at the first location (dashed coin)
and about 4.4 at
the second location (solid coin), and the radially outward upward tilt of the
half dollar is
about 3.2 at the first location (dashed coin) and about 3.9 at the second
location (solid
coin).
1001161 Turning to FIG. 6A, the portion 232b of the inner alignment wall 232
is
illustrated along with ledge 239a, the upstream portion 244a of reject wall
244, and reject
surface 243. The ledge 239a and portion 244a of the reject wall 244 meet at a
corner 244aa.
As coins approach this area, their inner edges are aligned with line 118b
which is at a radial
distance equivalent of inner alignment wall 232.
1001171 As seen in FIG. 7A, a coin pinched between resilient rotating pad 118
and
ledge 239a is tilted upward in a radially outward direction (the inner edge of
the coin is
lower than the outer edge). At the first location (coins shown in dashed
lines) just before
or as coins strike the diverter 242, they are pinched between the pad 118 and
the sorting
head 212 between roughly line 118b and the corner 244aa. At the second
location when
the coins to be rejected are adjacent the radial outside surface or edge of
the diverter pin
242, the coins are barely under any pad pressure as pad pressure is exerted
only over a
minimal distance between the inner edge of each coin and corner 244aa. As a
result, coins
striking diverter 242 are almost immediately released from pad pressure as
coins are ejected
out from under edge 244aa and control over the rejected coins is lost. The
resulting almost
immediate loss of control over a rejected coin can yield a less than
predictable trajectory
of rejected coins. FIG. 7C illustrates the range and hence the duration of
"pad controlled
drive" of a rejected dime from first pin contact C10-7C1 to end of pad-to-disc
grip C10-
7C2. That is, the position of dime C10-7C1 illustrates where a rejected dime
first strikes
the diverter pin 242 while the position of dime C10-7C2 illustrates the last
position where
a rejected dime is when any kind of pad control is present. As can be seen,
pad control
over a rejected dime is lost prior to the dime striking reject wall 244. As
seen in FIG. 7C,
reject wall 244 downstream of bend 244b is angled from a line tangent to a
circumference
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intersecting the downstream straight portion of reject wall 244 by an angle
a7C. According
to some embodiments, angle a7C is about 430
.
[00118] Turning back to FIG. 5A, exemplary paths of a rejected dime are shown.
For example, a dime striking pin 242 may move from position C10-5A2 and then
strike
reject wall 244 such as at position C10-5A3 and then either to position C10-
5A4 along
direction D5A-1 or position C10-5A5 along direction D5A-2. The lack of control
over the
manner and direction in which rejected coins leave the reject slot 249 can
cause problems
when the rejected coins come into contact with hardware such as a coin chute
or external
diverter designed to redirect the coins. Exemplary coin chutes and external
diverters are
described in more detail in U.S. Pat. Nos. 6,039,644 and 7,743,902. For
example, a rejected
coin could be ejected from reject slot 249 in a manner whereby it strikes the
back of a coin
chute and bounces back into the path of a subsequently rejected coin and the
collision of
the coins could result in a jam forming in the chute. Such a jam of coins in a
coin chute
can even lead to a backup of coins back into the reject slot 249.
[00119] According to some embodiments, coins approach the reject area 240
aligned
radially to a common inner edge of 5.010" radius on top of the rotating,
resilient disc pad
118 having a 5.500" radius outer edge. That is, the inner alignment wall 232
is positioned
at a radius of 5.010" from the center C of the pad (center C2 of the sorting
head 212). All
coins overhang the outer edge 118a of the coin pad 118. The sorting head 212
"ceiling" of
surface 239 extends radially beyond the outermost edge of the largest diameter
coin in the
coin set at a height of approximately 0.025" above the coin pad 118 surface.
The coins
rotated toward the reject area 240 are pressed into the coin pad 118 by a
distance equivalent
to their thickness, less 0.025". When the coins enter the reject area 240, the
sorting head
212 ceiling is raised beyond an edge of a radius of 5.220", that is, the
upstream portion
244a of reject wall 244 is positioned at a radius of 5.220" and the reject
slot 249 has an
elevated surface 243 located beyond that radius. The edge of the raised
ceiling (at wall
portion 244a) of the reject surface 243 is now significantly inboard of the
outer edge of all
coins in the coin set (e.g., U.S. coins) as well as inboard of the outer pad
edge 118a. With
the disc ceiling raised in reject slot 249, the upward pressure exerted by the
pad 118 lifts
the outer portion of the coin, resulting in a tilted condition of the coin as
discussed above
and shown in connection with FIG. 7A.
33
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[00120] As discussed above, coins to be rejected are rotated within the reject
area
240, in the above discussed pressed (i.e., under pad pressure) and tilted
condition, toward
an extended reject pin 242 which projects into the coin path by a distance of
approximately
0.025" to 0.030". As the coins to be rejected are driven into contact with the
reject pin 242,
they are driven outward beyond the outer edge of the pad and hurled toward a
reject chute
leading to a reject coin collection area.
[00121] Turning to FIG. 7E, an enlarged, cross-sectional view of a rejected
coin C-
7E abutting the outside, lower corner of diverter pin 242 is illustrated. The
diverter pin
242 is rounded near its lower end. The point below which the vertical sides of
diverter pin
242 begin to round is indicated by line 242t. The exposed vertical side of
diverter pin 242
between line 242t and surface 239 has a height indicated by 242e which
according some
embodiments is about 0.007 inches. While the reject pin 242 extends a specific
distance
downward into the coin stream, the tilted coin contacts only a portion of that
extended
length at or near the rounded corner 242a. The larger the tilt angle of a coin
to be rejected,
the less pin surface is contacted. Coins striking the pin 242 will, over time,
wear away the
outer surface of the pin near corner 242a. Once this wear reaches a certain
point, the
diverter pin 242 will no longer redirect a coin to be rejected sufficiently
outward so that it
enters the reject surface 243, instead allowing a reject coin to pass the
reject area 240 and
to move on toward exit slots 261-266 and then potentially into a container for
acceptable
coins. Additionally, when coins strike the diverter pin 242 below line 242t,
they can cause
the diverter pin 242 to move upward and allow a coin to be rejected to pass
underneath the
diverter pin and onto gauging area 250.
[00122] Additionally, turning back to FIG. 4A, as discussed above,
acceptable/non-
rejected coins are rotated through the reject area 240, past the retracted
reject pin 242, along
a narrow ledge 239a which narrows further beyond the diverter pin 242 as the
edge of reject
wall 244 moves inward to wall portion 244b which is positioned at a radius of
5.175"
according to some embodiments. The acceptable/non-rejected coins are then
dragged by
this slight grip of the pad 118 into a downward ramped surface 248 beyond the
reject wall
244 and onward toward the exit slots 261-266. The tilted condition of the
coins as they are
dragged past the reject wall causes a "slapping" of the coins onto the flat
disc surface 239b
and the ramp 248 leading from the recessed reject area 240. Overtime, this
slapping impact
34
3030P-CPS-CAD I
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of the coins pounds a curved dent into the ramp surface 248. The edge of this
dent acts to
stall coin travel.
[00123] A flow sensor 410a is positioned just beyond the reject wall 244 to
identify
any passing coin. The passing coin may be an accepted coin, or as previously
described a
reject coin which bypassed rejection. As the specific position of the coin on
the pad 118
and the timing of pad rotation are precisely monitored, the flow sensor
expects each
accepted coin to be detected within a certain time window. If the coin
experiences any
delay, due to slipping, dragging, or stalling, its motion may exceed the pre-
determined
sensing window timeframe and trigger an error condition.
[00124] As will be described below, the reject area 340 addresses all of these
conditions by providing a more positive and predictable control of coins
throughout the
new reject area 340, increasing stability, decreasing wear and tear on the
sorting disc 312,
reject pin 342, coin pad 118 and on the coins themselves. At the same time,
the projection
of the reject pin 342 and the level of pad pressure on the coins are
increased, helping to
ensure that coins are driven in a controlled manner, and in a specific
direction.
[00125] Turning to FIGS. 4B and 5B, as described above, the reject region 340
of
sorting head 312 comprises a reject surface 343, a diverter pin 342, and a
reject wall 344.
A coin approaches diverter pin 342 having an inner edge aligned along inner
alignment
wall 332. The reject wall 344 has an upstream wall portion 344a near the
diverter pin 342.
According to some embodiments, the upstream wall portion 344a is located just
radially
inward of the outside edge of the diverter pin 342. The coins are initially
maintained in a
relatively flat position as surface 339 extends from the inner alignment wall
332 to the edge
312a of the sorting head 312. The entire portion of the surface of the sorting
head 312
outward of inner alignment wall 332 then transitions downward via ramp 348
which leads
down to a lower surface 347. From a radius just inward of the outer edge 118a
of the
rotating resilient pad 118 and extending to the outer edge 312a of the sorting
head 312 the
surface 347 continues until reaching a ramp 341 which leads up into reject
surface 343.
An elevated portion or surface 346 of the sorting head has an outer wall 346b
positioned at
a radius just inward of the outer edge 118a of the resilient pad 118 and an
inward wall 346a
near a radius slightly inward of the radius of the inner alignment wall 332.
An upstream
ramp 345a leads up from surface 347 to elevated portion or recess 346. The
diverter pin
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342 is positioned within elevated portion 346 which is elevated from surface
347 by about
half as much as rejected channel 343. The surface 347 generally surrounds
elevated portion
346. On the downstream side of the diverter pin 342, elevated portion 346
transitions back
down to the level of surface 347 in the region of 347b via downward ramp 345b
positioned
near the radius of the inner alignment wall 332. According to some
embodiments, the
surface 347 including region 347b have the same depth as surface 310, namely,
a "0" depth,
meaning at the lowermost surface of the sorting head 312. Surface 347 has a
small area
347a extending from outer wall 346b of the elevated portion 346 to a radius
corresponding
to the outer edge 118a of the resilient pad 118.
[00126] FIG. 6B is a partial cross-sectional view of the sorting head 312 and
pad
118 in a region near the diverter pin 342 when no coin is present. FIG. 7B
illustrates partial
cross-sectional views of the sorting head 312 and pad 118 at two locations
near diverter
pin 342 illustrating the tilt of exemplary coins (US 100, 250, and 500 coins).
As above
with respect to FIG. 7A, in FIG. 7B the first location is the location where
coins are about
to first abut diverter pin 342 and the second location is where coins are
positioned adjacent
to the outside edge of diverter pin 342. In FIG. 5B, the first location is
shown by exemplary
(a) coin Cl 0-5B1 for a dime and the cross-section taken through the middle of
the dime
along line 7B-10 shown in FIG. 5B, (b) coin C50-5B1 for a half dollar and the
cross-section
taken through the middle of the half dollar along line 7B-50 shown in FIG. 5B,
and (c) coin
C25-5B1 for a quarter through the middle of the quarter (the cross-section
line not being
shown in FIG. 5B). The second location is shown for a dime by position C10-5B2
in FIG.
5B. In FIG. 7B coins in this first location are shown in dashed lines and
coins in this second
location are shown in solid lines. According to some embodiments, in FIG. 7B,
the radially
outward downward tilt of the dime is about 5.50 at the first location (dashed
coin C10-5B1)
and about 8.1 at the second location (solid coin C10-5B2), the radially
outward downward
tilt of the quarter is about 5.40 at the first location (dashed coin) and
about 8.10 at the second
location (solid coin), and the radially outward downward tilt of the half
dollar is about 5.5
at the first location (dashed coin) and about 8.3 at the second location
(solid coin).
According to some embodiments, the radial outward downward tilt of coins at
the first
location in the reject area 340 is greater than about 5 . According to some
embodiments,
the radial outward downward tilt of coins in the reject area 340 is greater
than about 4 or
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4.50. According to some embodiments, the radial outward downward tilt of coins
in the
reject area 340 is greater than about 2 . According to some embodiments, the
radial
outward downward tilt of coins in the reject area 340 is between about 2 and
7 .
According to some embodiments, the radial outward downward tilt of coins at
the second
location in the reject area 340 is greater than about 8 . According to some
embodiments,
the radial outward downward tilt of coins in the reject area 340 (such as at
the second
location) is greater than about 7 or 7 1/2 . According to some embodiments,
the radial
outward downward tilt of coins in the reject area 340 (such as at the second
location) is
between about 5 and 11 .
1001271 Turning to FIG. 6B, the elevated surface 346 and its inward wall 346a
and
outward wall 346b are illustrated along with surface 347, small area 347a, and
corner 347aa
where area 347a meets the bottom of wall 346b. As coins approach this area,
their inner
edges are aligned with line 118c which is at a radial distance equivalent of
inner alignment
wall 332. According to some embodiments, the elevated surface 346 is about
.035 - .045
inches above surface 347.
[00128] As a coin approaches the reject region 340, it is pressed against
surface 339,
down ramp 348, and then pressed against surface 347. Then the inner edge of
the coin
travels up ramp 345a and then along surface 346 and becomes tilted as
illustrated in FIG.
7B. As seen in FIG. 7B, a coin pinched between resilient rotating pad 118 and
corner
347aa is tilted downward in a radially outward direction (the inner edge of
the coin is higher
than the outer edge). At the first location (shown in dashed lines) just
before or as coins
strike the diverter 342, they are pinched between the pad 118 and the sorting
head 312
between roughly line 118c and the corner 347aa. At the second location when
the coins to
be rejected are adjacent the diverter pin 342, the coins are still maintained
under significant
pad pressure as pad pressure is exerted over the distance between the inner
edge of each
coin and corner 347aa. As a result, coins striking diverter 342 are not
immediately released
from pad pressure and control over the rejected coins is maintained. FIG. 7D
illustrates
the range and hence the duration of "pad controlled drive" of a rejected dime
with sorting
head 312 from first pin contact C10-7D1 to end of pad-to-disc grip C10-7D2.
That is, the
position of dime C10-7D1 illustrates where a rejected dime first strikes the
diverter pin 342
while the position of dime C10-7D2 illustrates the last position where any
kind of pad
37
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pressure control is present. As can be seen, pad pressure control over a
rejected dime is
maintained until after the dime strikes reject wall 344. The resulting
maintenance of control
over a rejected coin yields a predictable trajectory of rejected coins. As
seen in FIG. 7D,
reject wall 344 downstream of bend 344b is angled from a line tangent to a
circumference
intersecting straight portion 344c of reject wall 344 by an angle a7D.
According to some
embodiments, angle a7D is about 300. According to some embodiments, angle a7D
is
between about 25 and 35 .
[00129] A comparison of FIGS. 7A and FIG. 7B shows more pad/sort head contact
on coins before and after coins strikes diverter pin 342 for reject area 340
versus reject area
240. As discussed above, the design of reject area 340 keeps a coin under pad
pressure
even after the coin strikes pin 342. Rejected coins remain under pad pressure
as coin
continues to move along surface 347 and up ramp 341. Pad pressure remains on
the
outward side of a rejected coin until coin almost reaches top of ramp 341 and
enters reject
slot 349. Meanwhile, the inward side of a rejected coin remains under pad
pressure as the
inward side of the rejected coin travels up ramp 345a and moves through
elevated recess
region 346 and even after striking pin 342. Before a rejected coin is
completely released
from pad pressure it has already contacted reject wall 344 in an upstream area
344a of
reject wall and through bend 344b of reject wall 344. Thus, the release
trajectory of a
rejected coin is in the direction 340a (FIG. 4B) parallel to a straight
portion 344c of reject
wall 344 before the coin is completely released from being under pad pressure.
This leads
to a smooth and more predictable release of rejected coins.
[00130] Turning back to FIG. 5B, the path of a rejected dime is shown. A dime
striking pin 342 moves from position C10-5B2, is guided by upstream wall
portion 344a
and bend 344b of the reject wall 344 to position C10-5B3 while still under pad
control and
then follows along wall 344 to position C10-5B4 and then to position C10-5B5
along
direction D5B. According to some embodiments, coins first engage reject wall
344 at a
point past bend 344b. For example, in the case of a dime, according to some
embodiments,
dimes first contact reject wall 344 at a location downstream of bend 344b but
just upstream
of the position depicted by position C10-5B3. As can be seen in, for example,
FIGS. 4B
and 5B, the reject surface 343 of the reject slot 349 is defined by the shape
of reject wall
344 and the upper edge of ramp 341 and has a rounded peninsula extending
upstream of
3030P-CPS-CAD1 38
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the inner edge of ramp 341 toward recess 346. The upstream end 344a is
positioned at a
radial location just radially inward of the outside edge of the diverter pin
342. According
to some embodiments, rejected coins repositioned to the outside edge of reject
pin 342
proceed to engage wall portion 344a. According to some embodiments, the bend
344b of
the reject wall 344 is a gentle bend and assists with smoothly guiding
rejected coins into a
direction parallel to the outwardly extending straight portion 344c. According
to some
embodiments, the radius of bend 344b is a little larger than the radius of the
largest coin to
be sorted. According to some embodiments, the outwardly extending straight
portion 344c
is oriented at or nearly 600 from a radius of the rotating pad 118
intersecting the straight
portion 344c (or 30 from a circumference intersecting the straight portion
344c as seen by
angle a7D shown in FIG. 7D). According to some embodiments, this angle may be
between about 25 and 35 . The control over the manner and direction in which
rejected
coins leave the reject slot 349 alleviates problems discussed above in
connection with reject
region 240. An exemplary chute for receiving rejected coins from reject slot
349 is
described below in connection with FIGS. 16 and 17.
1001311 Turning to FIG. 4C, a bottom plan view of the reject area 340 of
sorting
head 312 is provided illustrating the passage of a non-rejected coin. In FIG.
4C, the non-
rejected coin is a dime C10-4C, the smallest diameter coin in the U.S. coin
set. The non-
rejected coin C10-4C passes under retracted diverter pin 342 and its inner
side slides down
ramp 345b to surface 347b while its outer side is maintained pressed against
surface 347
which is at the same height as surface 347b whereby the coin is returned to a
flat position.
The movement of a non-rejected coin in this manner through reject area 340 for
sorting
head 312 eliminates or significantly reduces the flutter which can occur with
non-rejected
coins in the reject area 240 of the sorting head 212 downstream of diverter
pin 242.
Accordingly, FIG. 4C illustrates that even for the small diameter dime C10-4C,
the dime
transitions over the reject slot 349 and has a leading edge past the reject
wall 344 while the
trailing edge of the coin is still near the upstream edge of ramp 341. This
illustrates that
even for the small dime, two opposing edges of the dime (one past or
downstream of the
reject wall 344 and a second edge upstream of reject surface 343 and reject
wall 344) are
pressed flat by the pad 118 at surfaces that are at or near the same height.
Accordingly, the
amount of up and down movement of a non-rejected coin as a non-rejected coin
passes
39
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reject surface 343 and reject wall 344 is reduced, significantly reducing or
eliminating coin
flutter otherwise associated with the transitioning of a coin past reject slot
249.
[00132] Similar to the reject area 240 described above, according to some
embodiments, coins approach the reject area 340 aligned radially to a common
inner edge
of 5.010" radius on top of the rotating, resilient disc pad 118 having a
5.500" radius outer
edge. That is, the inner alignment wall 332 is positioned at a radius of
5.010" radius from
the center C of the pad (center C3 of the sorting head 312). All coins
overhang the outer
edge 118a of the coin pad 118. However, unlike the reject area 240, the
"ceiling" of surface
347 is not recessed and the coins are fully pressed into the coin pad 118 by a
distance
equivalent to their thickness, less 0.005" (the adjusted gap between the
sorting disc 312 at
surface 347 and the surface of the coin pad 118). As coins enter the reject
area 340, the
outer portion of the disc surface 347 remains at "0" depth while the inner
portion is recessed
approx. 0.040" upward into recess 346 of the disc 312. With the coins fully
pressed into
the pad 118 along the outer edge 118a, the inner portion of the coin lifts
upward fully into
the recessed area 346 (see FIG. 7B). All coins lift upward to the same tilt
angle.
[00133] With reference to Table lA and FIG. 7G, the gip area for non-rejected
coins
(e.g., coins which pass through the reject regions 240, 340 and do not engage
diverter pin
242,342) will now be discussed. According to some embodiments, for non-
rejected coins
the width of the effective ceiling (the gripping distance from the edge of a
coin to a chord
beyond which the pad no longer grips a coin) in the reject area 340 is 0.490"
(the distance
between line 118c and outer pad edge 118a shown in FIG. 6B), as compared to
the design
of sorting head 212 for non-rejected coins where the effective ceiling
(gripping distance)
is initially 0.210" (the distance between line 118b and wall portion 244a, see
FIGS. 4A and
6A) and then 0.165" (the distance between line 118b and wall portion 244b, see
FIGS. 4A
and 6A). This increase in effective width dramatically increases the gip area
on the non-
rejected coins by about 300% as indicated in Table 1A.
3030P-CPS-CAD I 40
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1001341
Table 1A
Reject Area - Coin Pad Grip Comparison
Row Denomination 10c lc 5c 25c $1 50c
Coin Radius
1 0.3525 0.3750 0.4175 0.4775 0.5215 0.6025
(in.)
Coin Area A
2 0.3904 0.4418 0.5476 0.7163 0.8544 1.1404
(sq. in.)
Reject Region
240 Hold Area
3 0.0975
0.1013 0.1080 0.1168 0.1228 0.1332
A2 @ 0.210"
(sq. in.)
Reject Region
240 Hold Area
4 0.0695 0.0721 0.0766 0.0827 0.0868 0.0940
Al @ 0.165"
(sq. in.)
Reject Region
340 Hold Area
0.2896 0.3058 0.3340 0.3701 0.3944 0.4354
A3 @ 0.490"
(sq. in.)
Hold Area
6 297% 302% 309% 317% 321% 327%
Increase
7 Al% of A 17.8% 16.3% 14.0% 11.5% 10.2% 8.2%
8 A2% of A 25.0% 22.9% 19.7% 16.3% 14.4% 11.7%
9 A3% of A 74.2% 69.2%
61.0% 51.7% 46.2% 38.2%
[00135] In Table 1A, the area of a coin is nr2. For example, the radius of a
U.S.
dime is 0.3525 inches, its area (A=m-r2) is 0.3904 square inches as indicated
in Row 2. FIG.
3030P-CPS-CAD I 41
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7G illustrates the hold areas for a non-rejected dime in the reject region 240
and reject
region 340. For reject region 240, the hold area Al of dime downstream of
diverter 242
pin is shaded in coin C10-7G1 and is the area between inner alignment wall 232
(line 118b)
and wall portion 244b (shown in FIG. 4A) (indicated numerically in Row 4). For
reject
region 240, the hold area A2 of dime upstream of diverter 242 pin is shaded in
coin C10-
7G2 and is the area between inner alignment wall 232 (line 118b) and wall
portion 244a
(shown in FIG. 4A) (indicated numerically in Row 3). For reject region 340,
the hold area
A3 of dime (upstream and downstream of diverter 342 pin) is shaded in coin C10-
7G3 and
is the area between inner alignment wall 332 (line 118c) and outer pad edge
118a (shown
in FIG. 6B) (indicated numerically in Row 5). The average of the increase
between the
values in Row 5 vs Row 3 and Row 5 vs Row 4 is provided in Row 6. Row 7
provides the
percentage of the area of a non-rejected coin being gripped or held by pad 118
for coins
downstream of diverter 242 pin. For example, for a non-rejected dime
downstream of
diverter 242 pin in the reject region 240 of the sorting head 212, 17.8% of
the area of the
dime is gripped or held by the pad 118. Row 8 provides the percentage of the
area of a
non-rejected coin being gripped or held by pad 118 for coins below or upstream
of diverter
242 pin. For example, for a non-rejected nickel below or upstream of diverter
242 pin in
the reject region 240 of the sorting head 212, 19.7% of the area of the nickel
is gripped or
held by the pad 118. Row 9 provides the percentage of the area of a non-
rejected coin
being gripped or held by pad 118 in the reject region 340 of sorting head 312.
For example,
for a non-rejected dime in the reject region 340 of the sorting head 312,
74.2% of the area
of the dime is gripped or held by the pad 118. As can be seen in FIG. 7G and
detailed in
Table 1A, the reject region 340 provides a dramatically increased hold area
over coins
passing through the reject region 340 as compared to reject region 240.
[00136] An additional benefit of reject area 340 and reject pin 342 will be
discussed
in conjunction with FIGS. 7E and 7F. Turning to FIG. 7F, an enlarged, cross-
sectional
view of a rejected coin C-7F abutting the outside, lower corner of diverter
pin 342 is
illustrated. The diverter pin 342 is rounded near its lower end. The point
below which the
vertical sides of diverter pin 342 begin to round is indicated by line 342t.
The exposed
vertical side of diverter pin 342 between line 342t and surface 346 has a
height indicated
by 342e which according some embodiments is about 0.027 inches. While the
reject pin
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342 extends a specific distance downward into the coin stream, the tilted coin
contacts a
portion of that extended length at or near the rounded corner 342a. With
reference to FIGS.
7E and 7F, by increasing the recess depth (raising the ceiling) from the
0.020" depth (for
surface 239) to the 0.040" depth (for surface 346) above the "0" depth, the
effective height
of the reject pin 342 is increased by over 300% (0.027/0.007 is greater than
about 380%).
Referring to FIG. 7E, as the top inside edges of coins abut diverter pin 242
they contact the
pin 242 near area 242k. Over time, area 242k is worn down and a channel is
formed in pin
242 near area 242k. The top inside edges of subsequent coins engage the pin
242 in the
= growing channel 242k. Referring to FIG. 7F, as the inside edges of coins
abut diverter pin
342 they contact the pin 342 near area 342k. Over time, area 342k is worn
down.
[00137] Comparing FIGs. 7E and 7F, it can be seen that by reversing the coin
tilt
direction, reject pin 342 wear from rejected coins will occur from the "tip
up" in an angular
orientation, rather than from the "middle down" for pin 242 and reject area
240. The wear
pattern evident from FIG. 7F allows significantly more wear to occur before an
error
condition will occur as a result of a coin to be rejected not properly
striking reject pin 342
and failing to enter reject surface 343. Additionally, the radially outward
downward tilt of
the coins when coins strike the diverter pin 342 (together with the greater
exposes vertical
side 342e) reduces the likelihood they will cause the diverter pin 342 to move
upward and
allow a coin to be rejected to pass underneath the diverter pin and onto
gauging area 350
as compared to the arrangement of reject region 240.
[00138] Another benefit of reject area 340 discussed above is the maintenance
of
pad control of a rejected coin for a longer period of time and greater
distance after a reject
coin contacts the reject pin 342. As described above, rejected coins which
contact the reject
pin 342 are no longer immediately removed from pad contact and disc control.
Instead, the
coins are transitioned from a first radius of rotation (aligned with wall 322)
to a second
radius of rotation (aligned with the outer edge of reject pin 342 and the
upstream end 344a
of reject wall 344. This second radius is sufficiently larger to allow the
reject coins to enter
the reject slot 349 and engage reject wall 344 and be directed along a reject
path DB5
parallel to a downstream straight portion 344c of reject wall 344.
Accordingly, the rejected
coins, while still fully pressed into the pad 118, are guided into contact and
directional
control of the outwardly extending straight portion 344c of the reject wall
344. The rejected
43
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coins are driven along the straight portion 344c of the reject wall 344 by the
maintained
pressure and rotation of the pad. This driven action causes the exiting
rejected coins to
achieve a generally predictable path of travel approximately parallel to the
straight portion
344c of the reject wall 344.
[00139] In Table 1B, the area that a rejected coin is gripped or held by pad
118 is
provided in Row 3 and the percentage of the surface area of a rejected coin is
gripped or
held by pad 118 is provided in Row 4. The distance of 0.350 inches referred to
in the below
Table 1B is the distance from the outside edge of diverter pin 342 to pad edge
118a such
as the distance from the inner edge of coin C10-5B1 in FIG. 5B to the edge
118a of pad
118. As compared to reject region 240 in which a rejected coin which contacts
the reject
pin 242 is almost immediately removed from pad contact and disc control, after
a rejected
coin strikes diverter pin 342 in reject region 340, a substantial portion of
the area of the
surface of rejected coins is still under pad pressure or pad grip ¨ from over
20% of the
surface area (for 500 coins) to almost 50% (for dimes).
[00140]
Table 1B
Reject Area 340 - Coin Pad Grip of Rejected Coins
Row Denomination 10c 1c 5c 25c $1 50c
Coin Radius
1 0.3525 0.3750 0.4175 0.4775 0.5215 0.6025
(in.)
Coin Area A
2 0.3904 0.4418 0.5476 0.7163 0.8544 1.1404
(sq. in.)
Reject Region
340 Hold Area
3 0.1934 0.2022 0.2177 0.2379 0.2516 0.2751
A4 @ 0.350"
(sq. in.)
4 A4% of A 49.5% 45.8% 39.8% 33.2% 29.4% 24.1%
[00141] An additional benefit of reject area 340 relates to the manner in
which non-
rejected coins pass through the reject area 340. As described above, non-
rejected
44
3030P-CPS-CAD I
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(accepted) coins enter the reject area 340 is the same orientation (alignment,
radius, and
tilt) as coins to be rejected, however, they pass under the retracted reject
pin 342 and engage
an inner ramp 345b that drives the inner portion of the coin downward into the
pad. This
re-orients the coins into a flat, horizontal, fully pressed condition and
allows the rotating
pad to guide the coins away from the reject area 340 and onward toward the
exit slots 361-
366. This "flattened" orientation eliminates or reduces coins dragging across
the reject
wall 344, eliminates or reduces the "slapping" condition described above in
connection
with reject area 240, and increases the longevity of the disc surface
surrounding the reject
area 340, resulting in a nearly unrestricted passage of non-rejected coins and
maintaining
the coin travel well within the time window of flow sensor 410b which operates
in the same
manner as flow sensor 410a described above.
RE-GAUGING AREAS
[00142] FIGS. 8A and 8B are bottom plan views of re-gauging areas 250, 350 of
sorting heads 212, 312, respectively. FIGS. 9A and 9B are bottom plan views of
re-gauging
areas 250, 350 of sorting heads 212, 312, respectively, with representations
of coins in the
re-gauging areas 250, 350. FIGS. 10A and 10B are partial cross-sectional views
of the
sorting heads 212, 312, respectively, and pad 118 in a regions of re-gauging
areas 250, 350,
respectively. FIGS. 11A and 11B are bottom plan views of re-gauging areas 250,
350 of
sorting heads 212, 312, respectively, illustrating radial displacement of
exemplary coins
(US 100, 50, 10, $1, 250, and 500 coins) as the coins pass through the re-
gauging areas
250, 350.
[00143] Coins approaching the re-gauging area 250 are aligned to a common
inner
radius, with the inner portion pressed into the coin pad 118. For the coins to
be sorted by
diameter, they need to be reoriented (re-gauged) to a common outer edge so
that each coin
has a distinct and relatively unique inner edge radius. This aligns the coins
to coin exit
slots or channels 261-266 located downstream at the perimeter of the sorting
disc 212.
[00144] Turning to FIG. 8A, as described above, the re-gauging area 250
comprises
a gauging block 254 which has an outer wall 252. The outer wall 252 begins
from an
upstream location from a radial position beyond the outer edge 118a of the
rotating pad
118 and then curves inward until reaching a bend 252b in wall 252 at which
point the outer
3030P-CPS-CAD1
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wall 252 maintains a fixed radial position 256 as it proceeds downstream. The
re-gauging
wall 252 comprises two sections ¨ an upstream section 252v and a downstream
section
252d. The bottom of the upstream section 252v extends below the "0" level of
the sorting
head 312 by the thickness of the gauging block (see FIG. 10A). The bottom of
the
downstream section 252d is at level "0"¨ the level of surface 210 (see FIG.
10A).
[001451 Coins received from the reject area 240 strike different points along
outer
wall 252 depending upon their diameter. The points along outer wall 252 where
US 100,
250, and 500 coins initially contact outer wall 252 are shown by the locations
of coins C10-
9A, C25-9A, and C50-9A, respectively, in FIG. 9A. The points (from left to
right) along
outer wall 252 where US 100, 50, 10, $1, 250, and 500 coins, respectively,
initially contact
outer wall 252 are shown in FIG. 11A (only the locations of the 100, 250, and
500 coins
are labeled - coins C10-11A, C25-11A, and C50-11A, respectively).
[00146] Coins engage outer wall 252 and are moved radially inward as they are
driven along the outer wall 252 under pad pressure in the counterclockwise
direction as
viewed in FIGS. 8A and 11A so as to align the coins along a common outer
radius 256
which is positioned inboard of the outer periphery 118a of the rotating pad
118 and the
outer periphery 212a of the sorting head 212 as the coins approach a series of
coin exit
slots 261-266 which discharge coins of different denominations. The wall 252
can be
wholly integral to the sorting disc 212 or partially integral with an attached
precision
profiled gauging block 254 providing a portion of the wall surface.
[00147] With re-gauging area 250, as seen in FIG. 11A coins are re-gauged by a
significant amount. The larger a coin's diameter, the further it must be re-
gauged. For
example, the U.S. coin set is re-gauged by a radial distance ranging from
0.615" (Dime) to
1.115" (Half Dollar). For example, see line T10 tracing the center of a dime
and the radial
shift from the beginning of line T10 at T10a (inboard of edge 118a of the
rotating pad 118)
to a final radial position of a dime at TlOb (downstream of bend 252b).
Likewise, line T50
illustrates the radial inward movement of the center of a 500 coin from its
initial radial
position near T50a (outboard of edge 118a of the rotating pad 118) to a final
radial position
of a half dollar at T50b (downstream of bend 252b).
[00148] The re-gauging area 250 also comprises a flat, horizontal surface 257
and a
downward angled or beveled surface 258 which meet at a wall 257a. With
reference to
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FIG. 8A, surface 210 is a flat, horizontal surface at level "0" and surface
257 is a flat,
horizontal recessed area positioned above level "0". Moving radially outward
from surface
210, surface 258 transitions upward to meet recessed surface 257. See also,
the cross-
sectional views of a 100 coin and a 250 coin illustrated in FIG. 10A. With
reference to
FIG. 10A, once coins are rotated into the re-gauging area, they achieve a
tilted orientation
within a tapered recess. Cross-sectional views along lines 10A-10 (dime), 10A-
25
(quarter), and 10A-50 (half dollar) in FIG. 9A are shown in FIG. 10A.
According to some
embodiments, this recess is approximately 0.045" deep at the outer area 257,
extending
downward toward a "0" depth at the furthest inner area meeting surface 210.
The 0.045"
depth must be held precisely, as it forms the height of the downstream section
252d of the
re-gauging wall 252 and at the same time provides the depth required to gip
the thinnest
coin in the coin set. If this area is too shallow, coins may not be
sufficiently restrained and
drive past the downstream section 252d of the re-gauging wall 252. And if this
area is
too deep, it may not provide sufficient pressure on the thinner coins,
allowing them to
bounce off the wall, inwardly beyond the re-gauging radius 256.
[00149] As the coins contact the re-gauging wall 252, they are pushed inward
along
the tapered surface 258, deeper into the coin pad 118, increasing the amount
of pressure
and resistance, as the edges of the coins scrape along the top surface of the
pad 118. The
significant re-gauging distance, increasing pad pressure and resistance, wall
impact angle,
and pad surface scraping produces a great amount of wear and tear on the disc
212, wall
252v of gauging block 254, pad 118, and the coins themselves.
[00150] Re-gauging area 350 of sorting disc 312 will now be discussed in
connection with FIGS. 8B, 9B, 10B, and 11B. According to some embodiments, the
re-
gauging area 350 of sorting disc 312 addresses these issues by minimizing the
re-gauging
distance, shortening the re-gauging path, using a simple gauging block to
achieve the
movement, and reversing the coin tilt direction. By minimizing the re-gauging
distance,
the outer edges of coins remain outside the edge 118a of the coin pad 118,
reducing the
amount of pressed area and surface friction. The shortened re-gauging path
reduces the
area required for the re-gauging process. And the reversed tilt eases the
resistance and
scraping of the pad surface, lightening the impact loads.
47
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[00151] As with re-gauging area 250, coins approaching the re-gauging area 350
are
aligned to a common inner radius, with the inner portion pressed into the coin
pad 118.
For the coins to be sorted by diameter, they need to be reoriented (re-gauged)
to a common
outer edge so that each coin has a distinct and relatively unique inner edge
radius. This
aligns the coins to coin exit slots or channels 361-366 located downstream at
the perimeter
of the sorting disc 312.
[00152] Turning to FIG. 8B, as described above, the re-gauging area 350
comprises
a gauging block 354 which has an outer re-gauging wall 352. The outer wall 352
begins
from an upstream location from a radial position beyond the outer edge 118a of
the rotating
pad 118 and also ends downstream at a point or corner which is also positioned
radially
beyond the outer edge 118a of the rotating pad. According to some embodiments,
the outer
wall 352 is linear and the re-gauging block has a rectangular plan shape and a
three-
dimensional shape of a cuboid.
[00153] Coins received from the reject area 340 strike different points along
outer
wall 352 depending upon their diameter. The points along outer wall 352 where
US 100,
250, and 500 coins initially contact outer wall 352 are shown by the locations
of coins C10-
9B, C25-9B, and C50-9B, respectively, in FIG. 9B. The points (from left to
right) along
outer wall 352 where US 100, 50, 10, $1, 250, and 500 coins, respectively,
initially contact
outer wall 352 are shown in FIG. 11B (only the locations of the 100, 250, and
500 coins
are labeled - coins C10-11B, C25-11B, and C50-11B, respectively).
[00154] Coins engage outer wall 352 and are moved radially inward as they are
driven along the outer wall 352 under pad pressure in the counterclockwise
direction as
viewed in FIGS. 8B and 11B so as to align the coins along a common outer
radius 356
which is positioned outboard of the outer periphery 118a of the rotating pad
118 and the
outer periphery 312a of the sorting head 312 as the coins approach a series of
coin exit
slots 361-366 which discharge coins of different denominations. According to
some
embodiments, the wall 352 and gauging block 354 are completely separate from
the sorting
disc 312 with the side 352 of the gauging block providing a removeably
attachable
precision profiled wall surface.
[00155] The re-gauging area 350 also comprises a flat, horizontal recessed or
elevated surface 358 surrounded by zero ("0") depth surface 310. An entrance
ramp 357
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leads up into recessed area 358 and a trailing exit ramp 359 leads downward
back to surface
310. An outward wall 358a of the recessed area 358 is maintained at a fixed
radial position
just inward of the outer edge 118a of the rotating pad 118. See also, the
cross-sectional
views of a 100 coin, a 250 coin, and a 500 coin illustrated in FIG. 10B. Cross-
sectional
views along lines 10B-10 (dime), 10B-25 (quarter), and 10B-50 (half dollar) in
FIG. 9B
are shown in FIG. 10B. In the illustrated embodiment, the recessed area 358
has a generally
triangular shape having a generally straight inward edge positioned at
approximately 900
degrees from a generally straight downstream edge near ramp 359 and the
outward wall
358a is a circular arc and forms the third side of the generally triangular
shaped recess 358.
[00156] With reference to FIG. 10B, once coins are rotated into the re-gauging
area,
they achieve a tilted orientation with inward edges being positioned within
the recess 358.
The re-gauging area 350 is configured to cause coins to tilt in the opposite
direction of the
design of re-gauging area 250. The outer portion 310 is maintained at a "0"
depth, keeping
full pad pressure on all coins at the outermost pad perimeter as they rotate
through the area
350. According to some embodiments, the inner recessed area 358 is flat and
recessed at
an elevated level of 0.045" above level "0", although inner recessed area 358
could also be
tapered inwardly deeper to further ease the resistance to coin movement and
further reduce
pad surface scraping (such as discussed below in connection with FIGS. 10D and
10E).
According to some embodiments, all coins enter the recess 358 at the same tilt
angle, e.g.,
approximately 5 degrees when the radially inward edge of the coins leave the
top of
entrance ramp 357, and the angle of their tilt is reduced as they are pushed
inward as they
are driven along re-gauging wall 352. The "0" depth press at the perimeter
keeps the coins
from bouncing off the wall 352 at their impact. For example, according to some
embodiments, in FIG. 10B, the radially outward downward tilt of the dime is
about 5.2 ,
the radially outward downward tilt of the quarter is about 5.00, and the
radially outward
downward tilt of the half dollar is about 5.2 when the radially inward edge
of the coins
leave the top of entrance ramp 357. According to some embodiments, the radial
outward
downward tilt of coins in the re-gauging area 350 is greater than about 5 .
According to
some embodiments, the radial outward downward tilt of coins in the re-gauging
area 350
is greater than about 40 or 4 V2 . According to some embodiments, the radial
outward
downward tilt of coins in the re-gauging area 350 is between about 2 and 7 .
Conversely,
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according to some embodiments, in FIG. 10A, the radially outward upward tilt
of the dime
is about 1.70, the radially outward upward tilt of the quarter is about 2.00,
and the radially
outward upward tilt of the half dollar is about 2.10
.
1001571 When the coins reach the top of exit ramp 359, the angle of tilt has
been
reduced. For example, the radially outward downward tilt of the half dollar is
about 2.4
when the radially inward edge of the coins reaches the top of exit ramp 359.
When the
coins reach the bottom of exit ramp 359, the tilt of the coins is reduced to 0
.
[00158] With re-gauging area 350, as seen in FIG. 11B coins are re-gauged by a
lesser amount as compared to re-gauging area 250. The larger the coin's
diameter, the
further it must be re-gauged. For example, the U.S. coin set is re-gauged by a
distance
ranging from 0.030" (Dime) to 0.530" (Half Dollar). For example, see line V10
tracing
the center of a dime and the radial shift from the beginning, upstream end of
line V10 to a
final radial position of a dime at the downstream end of line V10. Likewise,
line T50
illustrates the radial inward movement of the center of a 500 coin from an
initial, upstream
radial position to a final downstream radial position.
1001591 The significantly reduced re-gauging distances for U.S. coin are
described
in the Table 2A below. In Table 2A, "Index R." is the radius of the outer edge
of coins
when their inner edge is aligned with alignment wall 232, 332 (the radius of
outer edge of
coins when they enter re-gauging areas 250/350) and the "Gauging R." is the
radius of the
outer edge of coins as they leave re-gauging area 250/350. The last row of
Table 2A
provides the percentage of the re-gauging radial displacement for re-gauging
area 350 vs.
re-gauging area 250. For example, a dime is radially displaced by 0.030 inches
in re-
gauging area 350 divided by 0.615 inches in re-gauging area 250 equals about
5%.
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[00160]
Table 2A
Re-Gauging Area - Coin Displacement Comparison
Denomination 10c lc 5c 25c $1 50c
Displacement Distance - Index R. vs. Gauging R.
Re-gauging area 250
0.615 0.660 0.745 0.865 0.953 1.115
Index @ 5.100" R.
Re-gauging area 350
Index 0.030 0.075 0.160 0.280 0.368 0.530
@ 5.685" R.
Percentage
of Re-gauging area 5% 11% 21% 32% 39% 48%
250
[00161] According to some embodiments, the inward push of the re-gauging
operation is achieved using a simple rectangular block or rectangular cubiod
354. The
block is designed symmetrical in both X and Y axes, and is configured to be
"flip-able"
and "reversible", providing at least four re-gauging coin contact surfaces,
e.g., an upper (or
first) and a lower (or second) surface or portion of re-gauging wall 352 and
an upper (or
first) and a lower (or second) surface or portion of the opposing wall 353 of
the re-gauging
block 354 (see FIG. 8B and 10B). As one surface wears, dents, or otherwise may
negatively
affect coin flow due to long term use, the gauging block 354 may be removed
and re-
attached in a new orientation providing a fresh re-gauging surface. This
extends the useful
life of an already lower cost part with the repositioning able to be done by
personnel with
little or no service training. For example, with reference to FIG. 8B, the re-
gauging block
354 may be attached to the sorting head 312 via at least one screw 354a
screwed into a
corresponding hole in the sorting head 312 via openings 354b in the re-gauging
block.
According to some embodiments, the openings 354b are positioned in the re-
gauging block
so as to be located in the same position relative to the sorting head 312 no
matter which
end is positioned upstream and no matter which surface is facing downward such
as (with
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reference to FIG. 8B) by placing the holes 354b along a line half way along
the width (x-
axis) and at common distances from the ends along the length (y-axis), e.g.,
one hole Y1
inches from each end and one hole Y2 inches from each end. According to some
embodiments, the sorting head 312 has a dowel pin set (raised bumps or
projections from
the surface of sorting head 312) that aid in the precision locating of the
gauging block 354
relative to the sorting head 312. For example, precision placement pins may be
located
below the location of the first and last openings 354b or the first and third
openings 354b
(from left to right in FIG. 8B).
[00162] Compared with re-gauging area 250 and recess 257, the precision of the
depth of recess 358 is no longer an issue. Coin stability throughout the re-
gauging area 350
is increased dramatically, maintaining a stable, distinct, and defined pathway
as the coins
leave the area on a common outer edge radius 356 with their outer portions off
the coin pad
118 beyond the edge 118a.
[00163] Referring to FIG. 10A, it can be seen that coins in re-gauging area
250 of
sorting head 212 have radially inward lower edges that deform the top of pad
118. As
coins travel through the re-gauging area 250 they are driven radially inward
by gauging
block 254. However, because the radially inward lower edges of the coins are
pressed into
the pad 118, they tend to generate a "plowing" effect on the upper pad
surface, including
an underlying foam core as the coins are moved radially inward by the gauging
block 254.
This "plowing" effect, in some cases, can lead to surface wear, to surface
weakening, and
ultimately, to tearing of the upper pad surface.
[00164] Additionally, the "plowing" effect can lead to a "rebounding" or
"slingshot"
effect as the pressure on the top of the pad generating the "plowing" effect
is relieved such
as when the coins move downstream of the re-gauging wall 252 and/or the re-
gauging
block 254 whereby the top of the pad 118 which has been pushed radially inward
by a coin
moving along re-gauging wall 252 moves or rebounds radially outward as a coin
moves
past the downstream end of the gauging block 254 and/or along the re-gauging
wall 252
and/or the downstream end of the re-gauging wall 252. The rebounding of the
top of the
pad 118, in turn, may cause the corresponding coin to move radially outward
rather than
having its radially outward edge being positioned at the desired common outer
radius 256.
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[00165] FIG. 10C is a partial cross-sectional view the re-gauging area 350 of
FIG.
9B illustrating the tilt of an exemplary coin (US 500 coin) in the re-gauging
area and FIG.
10D is a partial cross-sectional view an alternative re-gauging area 350' from
that of FIGS.
9B and 10C illustrating the tilt of an exemplary coin (US 500 coin) in the
alternative re-
gauging area 350'. FIG. 10E is a bottom plan view of the alternative re-
gauging area 350'
of FIG. 10D.
[00166] Referring to FIG. 10C, as described above in connection with FIG. 10B,
the
re-gauging area 350 comprises a flat, horizontal recessed or elevated surface
358
surrounded by zero ("0") depth surface 310. The outward wall 358a of the
recessed area
358 is maintained at a fixed radial position just inward of the outer edge
118a of the rotating
pad 118. The gauging block 354 and the outer re-gauging wall 352 of the
gauging block
354 are also illustrated.
[00167] Referring to the enlarged portion shown in FIG. 10C, the zero ("0")
depth
surface 310 is spaced slightly above the unbiased level of the top 118t of the
pad 118.
According to some embodiments, the zero ("0") depth surface 310 is spaced
above the
unbiased level 118t of the top of the pad 118 by a distance of at or between
about 0.005"
and 0.010". In some embodiments, the pad 118 may comprise a lower foam layer
118f
and an upper skin layer 118s coupled to the lower foam layer 118f such as with
adhesive.
A coin (a US 500 coin C50 in the illustrated example) is shown being held
between the top
of the pad 118 and the lower surface of recessed area 358 and the outward wall
or edge
358a of the recessed area 358 in a radially outward downward tilted manner by
an angle
C50-10Cang of about 2.4 such as at about 2.4 when the radially inward edge
of the coins
reaches the top of exit ramp 359.
[00168] According to some embodiments, the elevated surface 358 is raised
relative
to the zero-depth surface 310 by a distance 358h. According to some
embodiments, the
distance 358h is about 0.040 ¨ 0.050 inches. According to some embodiments,
the distance
358h is selected based on the thickness of the thinnest coin which the sorting
head 312 is
designed to sort. As illustrated in FIG. 10C, a radially inward lower edge or
"plowing"
edge C-PE of the coin deforms the top of the pad 118 pushing or biasing the
top 118t of
the pad 118 downward by a distance C50-10Cd. According to some embodiments,
factoring the thickness of the coin, the distance 358h of the elevated surface
358, and the
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spacing between the zero-depth surface 310 and the unbiased level 118t of the
top of the
pad 118, the distance C50-10Cd_in is about 0.04 inches such as about 0.041
inches for a 500
coin. For a US coin set, the distance of deformation may range between about
0.005" and
0.045" inches.
[00169] While the radially inward lower edge or "plowing" edge C-PE of a coin
moving through re-gauging area 350 deforms the top 118t of the pad 118 less
than a
corresponding coin moving through re-gauging area 250, coins moving through re-
gauging
area 350 may still generate a "plowing" effect and corresponding "slingshot"
effect
described above. As a pressed, tilted coin is driven to transition radially
inward from one
radial position to another, the "plowing" coin may be "slingshot" in the
opposite direction
causing the corresponding coin to move radially outward rather than having its
radially
outward edge being positioned at the desired common outer radius 356. For
example,
during the re-gauging process, a stream of coins enter the re-gauging area 350
aligned to
the common inner radius associated with inner alignment wall 332. The outer
edges of the
coins contact the gauging block 354 and are pushed inwardly to a common outer
radius
356 used for sorting coins by diameter according to the location the radial
inward edges of
the coins. During the radial transition, the inner, lower edge C-PE of a
corresponding coin
"plows" the upper pad surface radially inward, generating a reactive pad force
in the
radially outward direction. As a coin moves past the downstream end of the
gauging block
354, the reactive pad force may cause a coin to "slingshot" outward leaving
the coin at a
radial location outward of the desired common outer radius 356. The undesired
outward
movement of the coin may allow the coin to exit from an improper earlier exit
slot 361-
366 than the exit slot associated with its denomination, resulting in a mis-
sort.
[00170] FIG. 10D is a partial cross-sectional view an alternative re-gauging
area
from that of FIGS. 9B and 10C illustrating the tilt of an exemplary coin (US
500 coin) in
the alternative re-gauging area 350'. FIG. 10E is a bottom plan view of the
alternative re-
gauging area 350' of FIG. 10D.
[00171] Referring to FIGS. 10D and 10E, the re-gauging area 350' comprises a
flat,
horizontal recessed or elevated surface 358' surrounded by zero ("0") depth
surface 310'
which can be same as zero-depth surface 310. Relative to the elevated surface
358 of FIG.
10C, the flat, horizontal surface 358' is shorter in the radial direction. An
entrance ramp
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357' leads up into recessed area 358' and a trailing exit ramp 359' leads
downward back
to surface 310. An outward edge or wall 358a' of the recessed area 358' is
maintained at
a fixed radial position at or near of the outer edge 118a of the rotating pad
118 such as
being just inward or outward of the outer edge 118a of the pad 118. Between
the outward
edge 358a' and the elevated surface 358' is a radially outward downward tilted
surface
358t'.
[00172] The gauging block 354' and the outer re-gauging wall 352' of the
gauging
block 354' correspond to gauging block 354 and the outer re-gauging wall 352
of the
gauging block 354 and may be identical thereto.
[00173] Referring to the enlarged portion shown in FIG. 10D, the zero ("0")
depth
surface 310' is spaced slightly above the unbiased level of the top 118t of
the pad 118.
According to some embodiments, the zero ("0") depth surface 310' is spaced
above the
unbiased level 118t of the top of the pad 118 by a distance of at or between
about 0.005"
and 0.010". As described above in connection with FIG. 10C, in some
embodiments, the
pad 118 may comprise a lower foam layer 118f and an upper skin layer 118s
coupled to
the lower foam layer 118f such as with adhesive. According to some
embodiments, U.S.
coins are tilted in a radially outward downward tilted manner by an angle of
about 9.0
when the radially inward edge of the coins leave the top of entrance ramp
357'. As the
coins move along the gauging block 354'/re-gauging wall 352' they are
maintained in a
radially outward downward tilted manner at roughly the same angle as when they
leave the
top of entrance ramp 357' until they reach the top of exit ramp 359', except
for US 500
coins, according to some embodiments, which are tilted in a radially outward
downward
tilted manner by an angle of about 8.5 when they reach the top of exit ramp
359'. As
shown in FIG. 10D, a coin (a US 500 coin C50 in the illustrated example) is
shown being
held between the top 118t of the pad 118 and the lower surface of recessed
area 358', the
outward edge 358a', and the tilted surface 358t' in a radially outward
downward tilted
manner by an angle C50-10Dang of about 8.5 when the radially inward edge of
the coins
are near the upstream side (top) of exit ramp ramp 359'. . When the coins
reach the bottom
of exit ramp 359', the tilt of the coins is reduced to 0 .
[00174] According to some embodiments, the elevated surface 358' is raised
relative
to the zero-depth surface 310 by a distance 358h'. According to some
embodiments, the
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distance 358h' is about 0.15 inches such as about 0.150 inches. According to
some
embodiments, the distance 358h' is selected based on the thickness of the
thickest coin
which the sorting head 312 is designed to sort to ensure that the lower, inner
edge of each
coin is above the top 118f or the pad 118. As illustrated in FIG. 10D, a
radially inward
lower edge or "plowing" edge C-PE of the coin is positioned above the top of
the pad 118
and thus does not deform the top of the pad 118. According to some
embodiments,
factoring the thickness of the coin, the distance 358h' of the elevated
surface 358', and the
spacing between the zero-depth surface 310 and the unbiased level 118t of the
top of the
pad 118, the distance C50-10Dd_in is about 0.07 inches such as about 0.070
inches for a 500
coin. For a US coin set, the distance of clearance may range between about
0.030" and
0.075" inches.
[00175] By raising the radially inward, lower edge or "plowing" edge C-PE of
the
coin above the top of the pad 118, the re-gauging area 350' significantly
reduces or
eliminates the "plowing" effect and "slingshot" effect associated with re-
gauging area 250
and associated mis-sorting of coins as well further reducing or eliminating
the "plowing"
effect and "slingshot" effect associated with re-gauging area 350 and
associated mis-
sorting of coins.
[00176] The distances (in inches) by which the plowing edge C-PE for U.S.
coins
pressed into or residing above the unbiased level of the top 118t of the pad
118 are
described in the Table 2B below in connection with re-gauging areas 250, 350,
and 350'
which compares fully re-gauged coins with disc-to-pad gap set at 0.005". The
disc-to-pad
gap is measured from the unbiased top 118t of the pad 118 to the zero ("0")
depth surface
210, 310, 310'. Fully re-gauged coins refers to the points along outer wall
252 where
coins initially contact outer re-gauging wall 252, 352, 352' as shown in, for
example, FIGS.
9A, 9B, 11A, and 11B.
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[00177]
Table 2B
Re-Gauging Area ¨ Plowing Edge vs. Unbiased Top of Pad Comparison
Denomination 10c lc 5c 25c $1 50c
Coin Thickness 0.053 0.062 0.078 0.067 0.079 0.086
d-in for Re-gauging
area 250 Index @ -0.028 -0.039 -0.059 -0.055 -0.071
-0.081
5.100" R. (FIG. 10A)
d-in for Re-gauging
area 350 Index
-0.008 -0.017 -0.033 -0.022 -0.034 -0.041
@ 5.685" R. (FIGS.
10B-10C)
Difference in d-in
between re-gauging -0.02 -0.022 -0.026 -0.033 -0.037
-0.04
areas 250 and 350
% reduction in
amount C-PE extends
into top 118f of pad
71% 56% 44% 60% 52% 49%
118 between re-
gauging areas 250
and 350
d-in for Re-gauging
area 350' Index
+0.033 +0.031 +0.028 +0.058 +0.060 +0.070
@ 5.685" R. (FIG.
10D)
[00178] As can be seen in Table 2B, according to some embodiments, the re-
gauging
area 350' is dimensioned so that the inner, lower edge ("plowing edge") of
each coin in a
coin set which the sorting head 312 is designed to handle is above the
unbiased top 118f of
the pad 118 during the radially inward re-gauging process. According to some
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embodiments, the inner, lower edge ("plowing edge") of each coin in a coin set
which the
re-gauging area 350 of the sorting head 312 is designed to handle extends
below the
unbiased top 118f of the pad 118 during the radially inward re-gauging process
by an
amount which is substantially less than the amount by which a coin of a
corresponding
denomination extends below the unbiased top 118f of the pad 118 in re-gauging
area 250.
EXIT SLOT AREA CONFIGURATIONS
[00179] Turning to exit slot areas 260, 360 of sorting heads 212 and 312,
FIGS. 12A
and 12B are partial bottom plan views of the exit slot areas illustrating at
least the first two
exit slots 261-262 and 361-362 of sorting heads 212, 312, respectively. FIGS.
13A and
13B are partial cross-sectional views of the sorting heads 212, 312,
respectively, and pad
118 in regions of the first exit slots 261, 361, respectively, along lines 13A-
13A and 13B-
13B indicated in FIGS. 12A and 12B, respectively. FIG. 12C is an upward
perspective
view of a first exit slot 361 of sorting head 312.
[00180] Turning to exit slot area 260 of sorting head 212 and FIG. 12A, coins
approaching the exit slots 261-266 are aligned to a common outer radius 256
which is
entirely inboard of the pad edge 118a, and fully pressed into the pad surface
by surface 210
at level "0".
[00181] The exit slots 261-266 are positioned around the perimeter of the
sorting
disc 212 and spaced apart to provide sufficient area for coins to enter the
appropriate exit
slots, in which they driven are outwardly along the slot length, out of the
slot and off the
edge 118a of the pad 118.
[00182] Exit slot 261 will be described in more detail with the understanding
that
the remaining exit slots 262-266 have the same configuration. Exit slot 261
has a straight
or nearly straight downstream exit wall 261c and a parallel upstream exit edge
261b. These
exit wall 261c and edge 261b are at an angle relative to the edge 212a of the
sorting disc
212 and an intersecting radius of rotating pad 118. The upstream ends of exits
edge/wall
261b, 261c are joined by a curved wall 261d. The curved wall 261d is curved to
match the
size and shape of the corresponding coins to be exited via the associated exit
slot 261. For
example, the smallest diameter US coin is a dime and the second smallest
diameter US
coin is a penny. For a sorting head 212 designed to sort US coins, the first
exit slot 261 is
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sized to permit dimes to enter the exit slot 261 and the second exit slot 262
is sized to
permit pennies to enter the exit slot 262. Hence, the curve of curved entry
wall 261d
matches and is slightly larger than the curve of the edges of a dime and the
curve of curved
entry wall 262d matches and is slightly larger than the curve of the edges of
a penny, and
so on for exit slots 263-266. Within the exit slot 261 are three recessed
surfaces 1211,
1221, and 1231 the configurations of which are best seen in FIG. 13A. In FIG.
13A, a
partial cross-sectional view of the sorting head 212 and pad 118 in a region
of the first exit
slot 261 along lines 13A-13A indicated in FIG. 12A is shown. A dime C10 is
shown in
the exit slot 261 engaging the downstream exit wall 261c. The top of the
recess is
horizontal surface 1211. Surface 1221 is angled from surface 1211 down to
shallower
surface 1231 which is angled down to level "0" of surface 210.
[00183] The innermost edge 261a, 262a, of the exit slots 261-262 are spaced
inboard
slightly more than the innermost edge of the associated coin. This provides
clearance for a
coin of the associated diameter to enter a corresponding exit slot, and
provides support for
larger coins (coins of larger diameters) to pass the exit slots associated
with coins of smaller
diameters.
[00184] The exit slot is oriented outwardly toward the disc perimeter and has
a
tapered cross-section which extends from a "0" depth outboard to an inboard
depth slightly
less than the thickness of the associated coin. This orientation causes the
inner portion of
the coin to lift up into the slot, engaging the outwardly directing downstream
exit wall
261c, 262c, while the trailing edge remains under greater pad pressure for
driving the coin
out of the disc and off of the pad.
1001851 At the outboard, upstream side 261b, 262b, of each exit slot 261-262,
beyond the common path of the coins, a sensor 271-272 is placed to count coins
passing
beneath it. These sensors 271-272 count only those coins exiting the
associated exit slot
261-262. The exit slot sensors 271-276 are used to verify that a coin has
entered and exited
a respective exit slot 261-266 and/or for validation of a coin about to exit
an exit slot 261-
266.
[00186] Coins driven against the downstream walls 261c, 262c of the exit slots
261-
262 will slip backward on the pad surface as the pad rotates to drive the
coins out of the
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exit slot 261-262 and off the pad surface. This slippage distance will vary
with the evolving
conditions of the coins, disc 212, and pad 118.
[00187] The size of each exit slot 261-266 (width and length) determines the
amount
of space required on the disc to encompass all of the exit slots necessary for
the largest of
coin sets. There are some coin sets with so many coins that the space required
for their exit
slots cannot be accommodated within the sorting disc 212. In this case, some
coins would
need to be excluded. In other cases, additional coins or tokens could not be
added.
[00188] Turning to sorting head 312 and FIG. 12B, the exit slot area 360
addresses
these issues by significantly reducing the size of the exit slots, shortening
the length of the
exit path, and decreasing the pad slip distance. The configuration of the exit
slots 361-366
also decreases the wear and tear on the coins, disc 312, and pad 118.
[00189] Similar to the design of sorting disc 212, coins approach the
exit slots 361-
366 aligned to a common outer radius 356, but unlike the design of sorting
disc 212, the
outer portion of the coins lies beyond the outer edge 118a of the coin pad 118
for sorting
disc 312. As such, these coins are already "partially exited", require far
less exit slot width
to affect the coins, and a much shorter length to fully exit the coins from
the disc 312 and
be completely off the pad surface.
[00190] The reduced length of the exit slots 361-366 (only 361-362 shown in
FIG.
12B) allows just enough space for the corresponding coins to enter, quickly
engage the
downstream exit walls 361c-362c, and be driven out of the disc 312 and off the
pad 118.
[00191] Each exit slot 361-362 has an outer, upstream rail edge (e.g., edge
1241a
shown in FIGS. 12C and 13B) of narrow ledge or peninsula 1241, 1242 near the
perimeter
of the disc 312, just inboard of the outer edge 118a of the pad 118, which
acts to tightly
grip the coin along the pad perimeter. This rail and grip, with no outer
constraint on the
coin's outer overhanging portion, causes the inner portion of the coin to
immediately and
firmly lift up into the exit recess 1251, 1252.
[00192] Each exit recess 1251, 1252 is defined by straight or nearly
straight
downstream exit walls 361c-362c, innermost edges 361a, 362a, the transition
wall 361b,
and curved inboard entrance ramps 1261, 1262 which are curved to match the
size and
shape of the corresponding coins to be exited via the associated exit slots
361-362. For
example, the smallest diameter US coin is a dime and the second smallest
diameter US
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coin is a penny. For a sorting head 312 designed to sort US coins, the first
exit slot 361 is
sized to permit dimes to enter the exit slot 361 and the second exit slot 362
is sized to
permit pennies to enter the exit slot 362. Hence, the curve of curved inboard
entrance ramp
1261 matches and is slightly larger than the curve of the edges of a dime and
the curve of
curved inboard entrance ramp 1262 matches and is slightly larger than the
curve of the
edges of a penny, and so on for exit slots 363-366.
[00193] Each exit recess 1251, 1252 is further defined by a straight or nearly
straight
outboard beveled surface 1281, 1282 that extend downstream from cornered
beveled
transitions 1271, 1272, respectively. The cornered beveled transitions 1271,
1272
transition between inboard entrance ramp 1261 and beveled surface 1281 and
between
inboard entrance ramp 1262 and beveled surface 1282, respectively. Short
upstream exit
ramps 1291, 1292 extend from the downstream end of peninsula 1241, 1242 up to
surface
1251, 1252 between the downstream ends of outboard beveled surfaces 1281,
1282,
respectively, and the outer periphery 312a of the sorting disc 312. A narrow
ledge or
peninsula 1241, 1242 is formed between each of the outboard beveled surfaces
1281, 1282
and the outer periphery 312a of the sorting disc 312 and ends at the short
upstream exit
ramps 1291, 1292.
[00194] In FIG. 13B, a partial cross-sectional view of the sorting heads 312
and pad
118 in a region of the first exit slot 361 along lines 13B-13B indicated in
FIG. 12B is
shown. A dime C10 is shown in the exit slot 361 engaging the downstream exit
wall 361c.
The recess surface 1251 is generally horizontal and positioned above
surrounding "0" level
surfaces 310 downstream beyond downstream exit wall 361c and upstream on
peninsula
1241. Surface 1281 is angled downward from surface 1251 to the peninsula 1241
and
meets the peninsula at the "0" level at edge 1241a. The coin C10 can be seen
extending
beyond the outer periphery 312a of the sorting disc 312 and the outer
periphery 118a of the
pad 118. According to some embodiments, in FIG. 13B, the radially outward
downward
tilt of the dime is about 7.6 . According to some embodiments, the radially
outward
downward tilt of the quarter in its corresponding exit slot is about 4.9 , and
the radially
outward downward tilt of the half dollar in its corresponding exit slot is
about 3.6 .
According to some embodiments, the radial outward downward tilt of coins in
their
corresponding exit slots 361-366 is greater than about 7 . According to some
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embodiments, the radial outward downward tilt of coins in their corresponding
exit slots
361-366 is greater than about 6 or 6.5 . According to some embodiments, the
radial
outward downward tilt of coins in their corresponding exit slots 361-366 is
between about
and 100. According to some embodiments, the radial outward downward tilt of
coins in
their corresponding exit slots 361-366 is greater than about 2 . According to
some
embodiments, the radial outward downward tilt of coins in their corresponding
exit slots
361-366 is greater than about 3 or 3.5 . According to some embodiments, the
radial
outward downward tilt of coins in their corresponding exit slots 361-366 is
between about
3.6 and 9.4 . According to some embodiments, the radial outward downward tilt
of coins
in their corresponding exit slots 361-366 is between about 2 and 10 .
[001951 According to some embodiments, in FIG. 13A, the radially outward
downward tilt of the dime in exit slot 261 is about 4.0 .
[00196] Once a coin is engaged by the exit recess 1251, 1252, the pad 118
drives
the coin against the short exit wall 361c, 362c. After a brief rotation of the
pad 118 the
coin exits. This brief rotation produces minimal slippage of the coin relative
the pad 118,
maintaining a reasonably predictable position of the coin on the pad 118
throughout the
exiting process.
[00197] Each narrow peninsula 1241, 1242 also acts as a support for the outer
portions of passing coins to ensure a flat transition across the length of
exit slots 361-362.
By the time the trailing edge of a passing coin leaves the narrow peninsula
1241, 1242, the
lead edge of the coin is fully supported by surface 310 (downstream of the
downstream
exit walls 361c-362c) sufficient to maintain the coin in a flat orientation.
1001981 The reduced size of the exit slots 361-366, including the shortened
exit walls
361c, 362c, results in coin exit slots 361-366 that occupies significantly
less space on the
sorting head 312 than the exit slots 261-266 of sorting head 212 and requires
far less area
around the disc perimeter. This allows a greater number of coin exit slots to
be provided
around the disc 312 to accommodate those previously described excluded coin
and token
exit slots.
[00199] According to some embodiments, the exit slots 361-366 comprises exit
slots
sensors as described above in connection with exit slot sensors 271-276, 371-
376.
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1002001 According to some embodiments employing re-gauging area 350 and exit
slots 361-366, exit slot sensors 371-376 may be omitted. A resulting benefit
of such
embodiments is the elimination of the exit sensor implementation costs
including a
reduction in parts, related components, dedicated disc space, machining,
assembly, service,
etc.
1002011 With the shortened exit slots 361-366 contributing to minimal (near
zero)
pad slippage, a coin's location on the pad may be accurately tracked from a
sync sensor
1230 or trigger sensor 336 through the exit from the disc 312 and off of the
pad 118 surface.
According to some embodiments, the sync sensor 1230 is used to re-sync the
exact timing
when a coin passes sync sensor 1230 to compensate for any delay, due to
slipping,
dragging, or stalling of the coin passing through the re-gauging area 350
and/or reject
region 340. A signal or data from sync sensor 1230 (as in the case for other
sync and/or
trigger sensors 410a, 410b, 236, 336) is coupled to the controller 180 so the
controller can
precisely track the position of coins as they move under the sorting head.
Each accepted
coin that has been re-gauged by re-gauging wall 352 will be a known coin (as
determined
by the discrimination sensor 334) within the current coin set the sorting head
312 is
configured to sort and at a known location on the coin pad (based on the sync
sensor 1230
and an encoder 184). Accordingly, in some embodiments, all coins can be
tracked
throughout their travel along their exit path. This tracking is used to ensure
the delivery of
an exact quantity of coins to respective coin containers or receptacles. Once
a limit coin
has been exited, and as long as no additional limit denomination coins are
imminent, a
current batch may be processed to its end. A limit coin is a coin of a
particular
denomination that is or will be the last coin of the corresponding
denomination that is to
be delivered to a particular coin receptacle. For example, where 1000 dimes
constitute a
full bag of dimes, the limit dime coin is the 1000' dime detected to be
delivered to a
particular coin bag that is receiving dimes. If limit of another denomination
coin is
identified within the batch, it too may be exited and the batch processed to
its end. Once a
limit coin for a particular denomination has exited the sorting head 312 from
the
appropriate exit slot 361-366, the controller 180 can set a corresponding full
coin receptacle
flag or "Container Limit" flag in memory 188. Before or after the processing
of the batch
has ended, any "Container Limit" flags can cause the controller 180 to
generate one or
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more message signals to be sent to the operator interface 182 to cause the
display or
indication of an appropriate message or error condition (e.g., "250 container
full") so an
operator will know that one or more containers have reached their limit and
the operator
may exchange any full container with an empty replacement container.
[00202] FIG. 14 is a flowchart illustrating a Container Limit Stop Routine
1400
according to some embodiments. After a limit coin (n) for a given denomination
has been
detected, the Container Limit Stop Routine 1400 is started at step 1410. The
controller 180
then monitors for the detection of another coin (n+1) of the same denomination
at step
1420. If, after reaching a container limit (n), an additional limit
denomination coin of the
same denomination (n+1) is detected prior to the end of the current batch, the
speed of the
rotatable disc 114 carrying pad 118 is slowed, in some embodiments being
reduced to 50
rpm at step 1430. At step 1440 the rotatable disc 114 is continued to be
rotated until the
n+1 coin has been driven to a pre-determined position between sorting head 312
and pad
118 and then rotation of the rotatable disc 114 is stopped at step 1450. At
step 1460, a
"Container Limit" notification is communicated to the operator of the system
100 such as
via operator interface 182. At step 1470, the controller 180 monitors whether
the container
associated with the same denomination as the n+1 coin has been emptied. When
that
container has been emptied and/or replaced with an empty container, the
rotation of the
rotatable disc 114 is restarted at step 1480 and the routine ends at step
1490. During the
slow speed limit stop process, all coins continue to be tracked and their
relative positions
on the pad 118 identified for subsequent motion upon restart. According to
some
embodiments, at step 1480, the rotatable disc 114 is restarted at full speed
unless another
n+1 coin has been detected in which case the disc 114 is restarted at reduced
speed and the
process continues from step 1430.
1002031 FIG. 15A is a bottom plan view of a variation of sorting head 312
overlaying
exit slots 261-266 of sorting head 212 on the exits slots 361-366 of sorting
head 312 to
graphically illustrate the differences in the amount of space consumed on a
sorting head
for each type of exit slot. In the illustrated embodiment, sorting head 312"
is configured
to sort US coins. Exit slot 261, 361 is sized to accommodate and discharge
dimes which
have a diameter of 0.705 inches, exit slot 262, 362 is sized to accommodate
and discharge
pennies which have a diameter of 0.75 inches, exit slot 263, 363 is sized to
accommodate
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and discharge nickels which have a diameter of 0.835 inches, exit slot 264,
364 is sized to
accommodate and discharge quarters which have a diameter of 0.955 inches, exit
slot 265,
365 is sized to accommodate and discharge dollar coins which have a diameter
of 1.043
inches, and exit slot 266, 366 is sized to accommodate and discharge half
dollar coins
which have a diameter of 1.205 inches.
1002041 As discussed above, coins approach the exit slots 261-266 being
aligned to
a common outer radius 256 which is entirely inboard of the pad edge and the
outer
periphery 312a of the sorting head 312" in the area of exit slots 261-266. The
inner edges
of the exit slots 261-266 are located at an inner radius displaced from the
common outer
radius 256 by just more than the diameter of the coin denomination to be
exited via a given
exit slot. For example, according to some embodiments, the sorting head 312"
has an outer
periphery 312a which is circular at least in the area of the exit slots 261-
266 which is
centered about axis C2. A rotatable circular resilient pad is positioned below
the sorting
head 312" which is centered about axis C (which is the same axis as C2) and
has an outer
periphery aligned with the outer periphery 312a of the sorting head 312".
According to
some embodiments, the pad has a radius of 5.5 inches, the outer periphery 312a
of the
sorting head 312" is also at a radius of 5.5 inches in the area of exit slots
261-266 and the
common radius 256 is at a radius of 5.1 inches. As a result, the inner edge of
the dime exit
slot 261 is located at an inner radius displaced from the common outer radius
256 by just
more than the diameter of a dime, that is, inner radius 261i, is located at a
radius just inside
of 4.395 inches and is displaced from the outer periphery 312a of the sorting
head 312" by
a distance 261x by just more than 1.105 inches. As another example, the inner
edge of the
half dollar exit slot 266 is located at an inner radius displaced from the
common outer
radius 256 by just more than the diameter of a half dollar, that is, inner
radius 266i, is
located at a radius just inside of 3.895 inches and is displaced from the
outer periphery
312a of the sorting head 312" by a distance 266x by just more than 1.605
inches. Table
3A provides the corresponding information for each denomination of US coins
for exit
slots 261-266.
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[00205]
Table 3A
Distance from
Pad/Sorting Exit Slot Outer
Head Outer Common Inner Periphery to
Periphery Outside Radius Inner Radius
US Diameter Radius 118a, Radius (261,,
262,, (261x, 262x,
Coins (in.) 312a (in.) 256 (in.) etc.) (in.) etc.)
(in.)
100 0.705 5.500 5.100 4.395 1.105
0.750 5.500 5.100 4.350 1.150
50 0.835 5.500 5.100 4.265 1.235
250 0.955 5.500 5.100 4.145 1.355
$1 1.043 5.500 5.100 4.057 1.443
500 1.205 5.500 5.100 3.895 1.605
[00206] As discussed above, coins approach the exit slots 361-366 being
aligned to
a common outer radius 356 which is entirely outboard of the pad edge and the
outer
periphery 312a of the sorting head 312" in the area of exit slots 361-366. The
inner edges
of the exit slots 361-366 are located at an inner radius displaced from the
common outer
radius 356 by just more than the diameter of the coin denomination to be
exited via a given
exit slot. For example, according to some embodiments, the sorting head 312"
has an outer
periphery 312a which is circular at least in the area of the exit slots 361-
366 which is
centered about axis C3. A rotatable circular resilient pad is positioned below
the sorting
head 312" which is centered about axis C (which is the same axis as C3) and
has an outer
periphery aligned with the outer periphery 312a of the sorting head 312".
According to
some embodiments, the pad has a radius of 5.5 inches, the outer periphery 312a
of the
sorting head 312" is also at a radius of 5.5 inches in the area of exit slots
361-366 and the
common radius 356 is at a radius of 5.685 inches (0.185 inches radially
outward of the
outer periphery of the pad and sorting head 312" in the vicinity of the exit
slots). As a
result, the inner edge of the dime exit slots 361 is located at an inner
radius displaced from
the common outer radius 356 by just more than the diameter of a dime, that is,
inner radius
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361i, is located at a radius just inside of 4.98 inches and is displaced from
the outer
periphery 312a of the sorting head 312" by a distance 361x by just more than
0.52 inches.
As another example, the inner edge of the half dollar exit slots 366 is
located at an inner
radius displaced from the common outer radius 356 by just more than the
diameter of a
half dollar, that is, inner radius 366i, is located at a radius just inside of
4.48 inches and is
displaced from the outer periphery 312a of the sorting head 312" by a distance
366x by
just more than 1.02 inches. Table 3B provides the corresponding information
for each
denomination of US coins for exit slots 361-366.
[00207]
Table 3B
Distance from
Pad/Sorting Exit Slot Outer
Head Outer Common Inner Periphery to
Periphery Outside Radius Inner Radius
US Diameter Radius 118a, Radius (361ir, 362fr,
(361x, 362x,
Coins (in.) 312a (in.) 356 (in.) etc) (in.) etc.)
(in.)
100 0.705 5.500 5.685 4.980 0.520
0.750 5.500 5.685 4.935 0.565
50 0.835 5.500 5.685 4.850 0.650
250 0.955 5.500 5.685 4.730 0.770
$1 1.043 5.500 5.685 4.642 0.858
500 1.205 5.500 5.685 4.480 1.020
[00208] As can be seen from FIG. 15A and indicated by the values in Tables 3A
and
3B, the exit slots 361-366 consume much less space on the sorting head 312"
than the exit
slots 261-266.
[00209] According to some embodiments and as mentioned above, the common
outer radius 356 at which coins approaching the exit slots 361-366 are aligned
is entirely
outboard of the outer periphery of the resilient pad and the outer periphery
312a of the
sorting head 312" in the area of exit slots 361-366. According to some
embodiments, the
common outer radius 356 is positioned at least 0.03 inches beyond the outer
periphery of
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the resilient pad and/or the outer periphery 312a of the sorting head 312" in
the area of exit
slots 361-366. According to some embodiments, the common outer radius 356 is
positioned at least 0.18 inches (e.g., 0.185 inches) beyond the outer
periphery of the
resilient pad and/or the outer periphery 312a of the sorting head 312" in the
area of exit
slots 361-366. According to some embodiments, the common outer radius 356 is
positioned at least 0.3 inches (e.g., 0.326 inches) beyond the outer periphery
of the resilient
pad and/or the outer periphery 312a of the sorting head 312" in the area of
exit slots 361-
366.
[00210] According to some embodiments, the common outer radius 356 is
positioned at a radius of at least 5.53 inches and the outer periphery of the
resilient pad
and/or the outer periphery 312a of the sorting head 312" in the area of exit
slots 361-366
is positioned at a radius of 5.5 inches. According to some embodiments, the
common outer
radius 356 is positioned at a radius of at least 5.68 inches and the outer
periphery of the
resilient pad and/or the outer periphery 312a of the sorting head 312" in the
area of exit
slots 361-366 is positioned at a radius of 5.5 inches. According to some
embodiments, the
common outer radius 356 is positioned at a radius of at least 5.82 inches and
the outer
periphery of the resilient pad and/or the outer periphery 312a of the sorting
head 312" in
the area of exit slots 361-366 is positioned at a radius of 5.5 inches.
[00211] FIG. 15B is a bottom plan view of a variation 312' of sorting head 312
useful in explaining some additional benefits of some of the features of
sorting head 312.
The reduced size of the exit slots 361-366, and their positioning outward
toward the
perimeter of the disc, leaves more space radially inboard of the area near
exit slots 361-
366. This additional space allows the central opening 302 and the outer wall
306 of the
entry area 304 to expand outward accordingly. For example, the central opening
302 may
be increased from having a radius of R1 to a radius of R2 and the outer wall
306 of the
entry area 304 may be increased from having a radius of R3 to a radius of R4.
According
to some embodiments, the central opening 302 may be increased from having a
radius of
about 2.69 inches (R1) to a radius of about 3.08 inches (R2) and the outer
wall 306 of the
entry area 304 may be increased from having a radius of about 3.68 inches (R3)
to a radius
of about 4.38 inches (R4). The increase to the radii of the central opening
302 and the
outer wall 306 of the entry area 304 result in dramatic increases to coin
volume and
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centrifugal forces on the coins for a given turntable or rotatable disc 114
rpm (revolutions
per minute). The increased coin volume (a greater number of coins per
revolution) allows
the turntable rpm to be reduced while still achieving greater throughput
(coins per minute).
These changes can be balanced, or manipulated in either direction, to affect
sorting disc
performance as desired. The decreased size and complexity of the sorting
head's 312
geometry results in reduced machining time, less complex machining paths, and
fewer
critical tolerances to be maintained and verified, all of which come at a
lower cost.
[00212] The reduction in the coin-driven lengths of the exit slots will be
discussed
with reference to FIGS. 18 and 19. FIG. 18 is a bottom plan view of the first
sorting head
212 of FIG. 2 with indications of the coin-driven length of exit slots 261-
266. FIG. 19 is
a bottom plan view of the second sorting head 312 of FIG. 3 with indications
of the coin-
driven length of exit slots 361-366.
[00213] In FIG. 18, the length along which coins are driven out of exit slots
261-266
along downstream exit walls 261c-266c is illustrated as length 261-L for exit
slot 261,
length 262-L for exit slot 262, length 263-L for exit slot 263, length 264-L
for exit slot 264,
length 265-L for exit slot 265, and length 266-L for exit slot 266. The coin-
driven length
of each exit slot is measured from the first point of coin contact with the
inner, downstream
exit wall, e.g., downstream exit wall 261c for exit slot 261 to the point
where the
downstream exit wall ends at the outer periphery 212a of the sorting head 212.
[00214] In FIG. 19, the length along which coins are driven out of exit slots
361-366
along downstream exit walls 361c-366c is illustrated as length 261-L for exit
slot 361,
length 362-L for exit slot 362, length 363-L for exit slot 363, length 364-L
for exit slot 364,
length 365-L for exit slot 365, and length 366-L for exit slot 366. The coin-
driven length
of each exit slot is measured from the first point of coin contact with the
inner, downstream
exit wall, e.g., downstream exit wall 361c for exit slot 361 to the point
where the
downstream exit wall ends at the outer periphery 312a of the sorting head 312.
With
respect to FIG. 12C and exit slot 361, this is the distance between locations
361c-1 and
361c-2.
[00215] Table 4 provides the coin-driven length of the exit slots of the first
sorting
head 212 and the second sorting head 312 and the corresponding reduction in
length
according to some embodiments.
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[00216]
Table 4
10c 1c 5c 25c $1 50c
Driven- Driven- Driven- Driven- Driven- Driven-
Coin Coin Coin Coin Coin Coin
Length Length Length Length Length Length
261-L, 262-L, 263-L, 264-L, 265-L, 266-L,
361-L 362-L 363-L 364-L 365-L 366-L
Denomination (in.) (in.) (in.) (in.) (in.) (in.)
Sorting Head
1.914 1.970 2.064 2.243 2.293 2.455
212
Sorting Head
0.868 0.932 1.050 1.210 1.321 1.445
312
Reduction in
Driven-Coin 1.046 1.038 1.014 1.033 0.972 1.01
Length
Percentage
Reduction in
55% 53% 49% 46% 42% 41%
Driven-Coin
Length
Driven Length
in Head 312
45% 47% 51% 54% 58% 59%
as Percentage
of Head 212
[00217] The shorter coin-driven length of the exit slots of the second sorting
head
312 provide advantages according to some embodiments. An advantage of shorter
coin-
driven length of the exit slots is that they reduce the time that a coin is in
the exit slot which
helps with sorting accuracy. When coins enter an exit slot, they slow relative
to the
turntable speed due to their change in direction from concentric travel. Coins
traveling
concentrically behind an exiting coin tend to catch up with an exiting coin.
When a
collision between a non-exiting downstream coin and an exiting coin occurs,
disruption of
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the direction of travel of one or more of the colliding coins can happen,
sending one or
more of the colliding coins into another direction and ultimately into the
wrong container.
The shorter coin-driven length of the exit slots of the second sorting head
312 reduce the
possibility of collisions as coins in sorting head 312 exit the sorting head
312 more quickly.
REJECT CHUTE
[00218] With sorting head 212, rejected coins must be directed from the reject
area
240 downward into a pathway leading to a container for collecting rejected or
non-accepted
coins. Some of these expelled coins may also be valid coins or tokens, having
value, that
have no dedicated exit position or cannot be physically separated mechanically
by their
diameter. As described above, the coins driven out of the reject area 240 may
travel in
random paths (or less than predictable paths) and in random orientations as
they exit. With
no guidance after contacting the reject pin 242, the flight pattern of coins
lacks directional
control. According to some embodiments, the method of redirecting coin flow is
a curved
reject chute which intercepts the random, substantially horizontal paths of
the coins and
reorients them to a substantially vertical, downward direction. See, for
example, external
diverter described in U.S. Pat. No. 7,743,902 and coin chutes described in
U.S. Pat. No.
6,039,644. While such a method may be sufficient for coin streams of a stable,
predictable
flow, the stream resulting from reject area 240 is neither. The various
orientations of the
coins and the various speeds at which they travel while exiting allows
preceding coins to
affect the forward motion of coins which follow. This can cause coins to
impact one another
within the constrained area of the reject chute and can quickly cause a jam
condition as
coins pile up inside the chute area. This jamming condition may affect coins
passing into
the reject surface 243, or worse yet, may back up into the high-speed stream
of non-rejected
or accepted coins as they attempt to pass through and out of reject area 240.
[00219] The configuration of reject area 340 producing a more stable,
controlled
stream of coins exiting the sorting head 312 can eliminate or reduce the above
described
jamming problems when used with existing external diverters and/or coin chutes
discussed
above such as those described in U.S. Pat. Nos. 7,743,902 and 6,039,644.
[00220] FIG. 16 is a top plan view and FIG. 17 is a downward perspective view
of
a reject chute 1610. The reject chute 1610, in conjunction with either the
reject area 240
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or reject area 340, can eliminate or reduce the stalling and jamming
conditions of prior
reject chutes.
[00221] The reject chute 1610 has an upper wall 1620 and a lower tapered
surface
1640 and a bottom collection area 1630. The lower tapered surface 1640 extends
from the
bottom of the upper wall 1620 to the top edges 1630a of the bottom collection
area 1630.
The tapered surface 1640 has a generally funnel shape in that the upper wall
1620 is
positioned outside of the top edges 1630a of the bottom collection area 1630
and hence the
tapered surface narrows from the top of the tapered surface 1640a to the
bottom of the
tapered surface 1640b. According to some embodiments, the upper wall 1620 is
vertically
or near vertically oriented. According to some embodiments, the upper wall
1620 has a
lead portion 1620a that is linear and when operatively positioned adjacent to
reject area
340, the lead portion 1620a is parallel or generally parallel with the
straight portion 344c
of reject wall 344. According to some embodiments, the linear lead portion
1620a is in
line with straight portion 344c of reject wall 344. According to some
embodiments, the
linear lead portion 1620a is lined just behind the straight portion 344c of
reject wall 344 so
that should the linear lead portion 1620a bend slightly inward, the lead
portion 1620a will
not stick into the path of coins exiting from the reject slot 349 so that
coins being fed along
straight portion 344c of reject wall do not impact the lead portion 1620a. The
upper wall
1620 has a curved portion 1620b. As will be described more below, the curved
portion
1620b redirects coins engaging upper wall 1620 generally horizontally in a
direction
differing from the generally horizontal direction coins emerge from reject
area 340.
[00222] The configuration of the new reject chute 1610 intercepts expelled
coins in
the substantially horizontal orientation of their stream, whether stable (from
the reject area
340) or less than stable (from the reject area 240). But rather than
immediately redirecting
the coins to a vertical orientation, the design of reject chute 1610 redirects
the flow
sideways, along a curved portion 1620b of upper wall 1620, and away from the
direction
that coins are fed into reject chute 1610.
[00223] This redirection, and the natural deceleration of the coins due to
friction and
gravity, allows the coin stream to slow down and drop along the tapered
surfaces 1640
leading to a bottom exit opening 1630 through which coins may fall into a
reject collection
area.
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[00224] As used in connection with reject area 340, FIG. 16 illustrates an
exemplary
redirection of reject coins. As described above, a reject coin (in the
illustrated example a
dime C10) is redirected by diverter pin 342 and in a controlled manner engages
reject wall
344. From a location C10-16a adjacent the diverter pin 342, the coin moves
directly or
indirectly to location C10-16b. The coin then moves parallel to reject wall
344 in direction
D16A from location C10-16b to location C10-16c and then to location C10-16d.
At
location C10-16e, the coin engages curved portion 1620b of upper wall 1620 of
reject chute
1610 at which point it follows along curved wall 1620 to location C10-16f. As
the coin
loses velocity it begins to move away from the curved upper wall 1620 and
downward such
as at location C10-16g. The coin continues to move downward and may engage
tapered
surface 1640 as it moves from location C10-16h to location C10-16i and through
the
bottom exit opening 1630 such as at location C10-16j. As can been seen in FIG.
16, after
engaging upper curved wall 1620, the flow of the coin does not intersect the
flow of coins
emerging from reject area along direction D16A. Furthermore, after engaging
upper
curved wall 1620, the coins are laterally redirected away from direction D16A
and the
space there below. For example, and with reference to FIG. 16, coins emerging
from reject
slot along direction D16A, a left vertical plane may be defined by the left
edges of emerging
coins (viewed direction D16A) such as a plane intersecting downstream straight
portion
344c of reject wall 344. Similarly, a right vertical plane or planes may be
defined by the
right edges of emerging coins (viewed direction D16A). A rightmost plane may
be defined
by the right edges of the largest coins being rejected out of reject slot 349
in a given batch.
The curved wall 1620b is at an angle from direction D16A at a point where
coins traveling
in direction D16A initially contact the curved wall 1620b and serves to
redirect coins from
out of the space between the left and right planes. According to some
embodiments, the
angle of curved wall 1620b at the point of initial contact is between about
125 and 145
from direction D16A and/or the downstream straight portion 344c of the reject
wall 344.
Accordingly, rather than being initially redirected downward below the path
coins emerge
from a reject slot, the coins are initially redirected in a lateral direction
relative to the the
path coins emerge from a reject slot.
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[00225] According to some embodiments, a metal strip such as a stainless-steel
strip
is coupled to upper wall 1620 or at least curved portion 1620b of upper wall
1620 to serve
as a wear liner.
[00226] According to some embodiments, a horizontally linear surface such as a
vertical wall may be used to move the coins laterally out of the flow of coins
emerging
from reject area along direction Dl 6A. According to such embodiments, the
linear surface
is disposed at an angle other than 90 from the direction Dl 6A from which
coins are
emerging from the reject slot 249, 349. For example, according to some
embodiments, a
laterally displacing linear surface or wall is oriented about 1350 from the
direction Dl 6A
from which coins are emerging from the reject slot 349 and/or the downstream
portion
344c of the reject wall 344. According to some embodiments, this angle is
between 125
and 145 .
[00227] With this new orientation path provided by reject chute 1610, coin
flow of
various volumes and feed rates may travel unobstructed to the bottom exit
opening 1630.
This is especially beneficial if the "reject area" is being used for mass coin
elimination
when many coins in a row will be directed into the reject chute 1610. For
example, to
remove an old version coin upon introduction of a new version, as will be the
case with the
upcoming new UK 1 Coin, the reject area 240,340 can be used to separate the
old version
coins en masse by routing them to the reject chute 1610.
[00228] Comparing sorting head 312 to sorting head 212, the sorting head 312
takes
much less time to mill and manufacture, resulting in lower production costs.
For example,
according to some embodiments, it takes at least about 83% less time to
machine exit slots
361-366 as compared to exit slots 261-266. Likewise, according to some
embodiments, it
takes at least about 69% less time to machine re-gauging area 350 as compared
to re-
gauging area 250. While according to some embodiments, it takes more time to
machine
reject area 340 as compared to reject area 240, overall it takes at least
about 76% less time
to machine exit slots 361-366, re-gauging area 350, and reject area 340 as
compared to exit
slots 261-266, re-gauging area 250, and reject area 240. According to some
embodiments,
over 50 minutes of machining time are saved in machining exit slots 361-366,
re-gauging
area 350, and reject area 340 as compared to exit slots 261-266, re-gauging
area 250, and
reject area 240.
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1002291 While the disclosure is susceptible to various modifications and
alternative
forms, specific embodiments have been shown by way of example in the drawings
and
described in detail herein. It should be understood, however, that the
disclosure is not
intended to be limited to the particular forms disclosed. Rather, the
disclosure is to cover
all modifications, equivalents and alternatives falling within the spirit and
scope of the
inventions as defined by the appended claims.
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