Abstract:
A cylindrical array of tightly spaced optical discs are each positioned vertically on edge to form a horizontal stack. Lifting a subset of optical discs enables that subset of optical discs to be grasped by their perimeters with much more room for robotic grippers between adjacent optical discs. An optical disc storage container includes a molded tray for vertically aligning a plurality of optical discs into the cylindrical array. The molded tray includes a bottom surface and side surfaces to support the optical discs and one or more openings formed in the bottom surface. A lifting mechanism is positioned along the one or more openings and is configured to lift the subset of optical discs a short distance relative to the remaining optical discs in the array, thereby enabling robotic grippers to grab the portion of the lifted optical disc protruding from the non-lifted optical disc array.

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority under 35 U.S.C. §119(e) of the U.S. Provisional Patent Application Ser. No. 62/064,807, filed Oct. 16, 2014 and titled, “METHOD FOR SELECTING INDIVIDUAL DISCS FROM TIGHTLY SPACED ARRAY OF OPTICAL DISCS,” which is hereby incorporated by reference in its entirety for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the field of optical disc storage and access. More specifically, the present invention relates to the system and method of selecting individual optical discs from a tightly spaced array of optical discs. 
     BACKGROUND OF THE INVENTION 
     Optical discs provide a reliable long term storage medium available for digital information. In order to automate archived optical disc storage in a cost effective manner, optical discs are shelved for occasional automated retrieval. One method of storage is to place the optical discs in drawers where subgroups of optical discs can be accessed. However, an amount of empty space equal to or greater than the useable length of the drawer must be reserved for the drawer to slide open and the optical discs retrieved. In archival storage of optical discs it is desirable to minimize unused space in such storage configurations. 
     In addition to minimizing the amount of empty space needed for optical disc retrieval, it is also desired to minimize the amount of space that the optical discs themselves occupy so as to maximize optical disc storage density. As such, optical discs are stacked as closely together as possible. A problem with closely stacking optical discs is the subsequent process of accessing a specific optical disc within a tightly spaced optical disc stack. One technique of accessing a specific optical disc within an optical disc stack is to use a robotic gripper. The specific optical disc is accessed by moving the robotic gripper a determined distance within the optical disc stack based on an anticipated average thickness of each optical disc. However, variances in manufacturing tolerances for optical disc thicknesses results in inaccurate determination of a specific optical disc position within an optical disc stack. 
     SUMMARY OF THE INVENTION 
     A cylindrical array of tightly spaced optical discs are arranged such that all optical discs share the same access of symmetry. Lifting a subset of optical discs, for example every other optical disc in a stack of optical discs, every third optical disc in the stack, every fourth optical disc in the stack, etc., enables that subset of optical discs to be grasped by their perimeters with much more room for robotic grippers between adjacent optical discs. There are multiple configurations for lifting a subset of discs to protrude above the remaining optical discs with sufficient spacing between adjacent optical discs for robotic grippers. In some embodiments, an optical disc storage container comprises a molded tray for vertically aligning a plurality of optical discs into the cylindrical array. The molded tray includes a bottom surface and side surfaces to support the optical discs and one or more openings formed in the bottom surface along a horizontal axis of the tray. A lifting mechanism is positioned along the one or more openings and is configured to lift the subset of optical discs a short distance relative to the remaining optical discs in the array. A lifted optical disc is lifted a sufficient distance so as to enable robotic grippers to grab the portion of the lifted optical disc protruding from the non-lifted optical disc array. 
     In an aspect, an optical disc storage and retrieval system is disclosed. The system includes a tray and a lifting mechanism. The tray is configured to store an array of vertically aligned optical discs. The tray comprises a bottom surface and opposing side surfaces configured to support the optical discs, wherein the bottom surface comprises one or more openings. The lifting mechanism is positioned adjacent to the one or more openings, wherein the lifting mechanism is configured to selectively lift a subset of the optical discs in the array such that a portion of each optical disc in the subset protrudes from a non-lifted subset of the optical discs in the array. In some embodiments, the subset of the optical discs comprises one or more non-sequential optical discs in the array. In some embodiments, the subset of optical discs comprises every even numbered optical disc in the array or every odd numbered optical disc in the array. In some embodiments, the subset of optical discs comprises every Nth numbered optical disc in the array, where N is one of an integer greater than one. In some embodiments, the tray comprises one or more cylindrical recesses. In some embodiments, each cylindrical recess comprises a plurality of grooves, each groove structured to receive an optical disc. In some embodiments, the tray further comprises a plurality of lead-ins extending from the bottom surface and opposing side surfaces, wherein the plurality of grooves are formed by the plurality of lead-ins. In some embodiments, the lifting mechanism comprises a lifting probe configured to selectively lift a single optical disc. In some embodiments, the lifting mechanism comprises a comb-like structure having a plurality of rigid bristles, each bristle configured to align with one of the optical discs in the subset. In some embodiments, the lifting mechanism comprises two comb-like structures, a first comb-like structure having a first plurality of rigid bristles configured to align with every even numbered optical disc in the array and a second comb-like structure having a second plurality of rigid bristles configured to align with every odd numbered optical disc in the array, wherein the lifting mechanism selecting engages either the first comb-like structure or the second comb-like structure. In some embodiments, the lifting mechanism comprises a cam shaft having a plurality of cams, each cam configured to align with one of the optical discs in the subset. In some embodiments, the cam shaft comprises two sets of cams, a first set of cams wherein each cam in the first set is configured to align with every even numbered optical disc in the array and a second set of cams wherein each cam in the second set is configured to align with every odd numbered optical disc in the array, wherein the lifting mechanism selecting engages either the first set of cams or the second set of cams. In some embodiments, the system further comprising a robotic gripper configured to selectively grab one of the lifted subset of optical discs. 
     In another aspect, an optical disc storage device is disclosed. The optical disc storage device includes a tray and a plurality of lead ins. The tray is configured to store an array of vertically aligned optical discs, wherein the tray comprises a bottom surface and opposing side surfaces configured to support the optical discs. The plurality of lead ins extend from the bottom surface and opposing side surfaces, wherein the plurality of lead ins form a plurality of grooves, each groove configured to receive one optical disc. In some embodiments, the bottom surface and a portion of the side surfaces form a cylindrical interior surface. In some embodiments, a remaining portion of the side surfaces form a linear interior surface coupled to the cylindrical interior surface. In some embodiments, each lead in matches a contour of an interior surface of the side surfaces and the bottom surface such that the lead in has a cylindrical contour coincident with the cylindrical interior surface and has a linear contour coincident with the linear interior surface. 
     Other features and advantages of the present invention will become apparent after reviewing the detailed description of the embodiments set forth below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Several example embodiments are described with reference to the drawings, wherein like components are provided with like reference numerals. The example embodiments are intended to illustrate, but not to limit, the invention. The drawings include the following figures: 
         FIG. 1  illustrates a top down perspective view of an optical disc storage device, or tray, according to an embodiment. 
         FIG. 2  illustrates a partial side perspective view of the tray loaded with a plurality of optical discs. 
         FIG. 3  illustrates a top down perspective view of another optical disc storage device, or tray, according to an embodiment. 
         FIG. 4  illustrates a tray and a cam shaft having a plurality of cams according to an embodiment. 
         FIG. 5  illustrates the configuration shown in  FIG. 4  with the tray removed. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Embodiments of the present application are directed to a method and system for selecting individual optical discs from an optical disc array. Those of ordinary skill in the art will realize that the following detailed description of the method and system is illustrative only and is not intended to be in any way limiting. Other embodiments of the method and system will readily suggest themselves to such skilled persons having the benefit of this disclosure. 
     Reference will now be made in detail to implementations of the method and system as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts. In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer&#39;s specific goals, such as compliance with application and business related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure. 
       FIG. 1  illustrates a top down perspective view of an optical disc storage device, or tray,  100  according to an embodiment. In some embodiments, the tray  100  includes a front wall  108 , side walls  102  and  104 , a back wall  106  and a bottom wall  120 . In some embodiments, a middle wall  118  is included to provide additional structural support. In some embodiments, the tray  100  is plastic molded. In some embodiments, the side walls  102  and  104  and the bottom wall  120  generally have a cylindrical shape within an interior of the tray  100  that substantially matches a circular shape of an optical disc. However, a top most portion, such as at  122 , of the side walls  102 ,  104  is not cylindrical in the interior of the tray  100 , and instead is substantially linear. The cylindrical interior portion of tray  100  has a depth substantially equal to one-half of the diameter of the optical disc to be stored. In other words, the cylindrical interior surface has a 180 degree inner circumference. This enables a bottom half of the optical disc to rest along the cylindrical interior surface of the side walls  102 ,  104  and the bottom wall  120 . The liner portion of the interior surface of the side walls  102 ,  104  extends vertically from point where the cylindrical interior surface ends. Lead-ins  114  extend inward from the interior surface of the side walls  102 ,  104  and the bottom wall  120  to form grooves  116  into which optical discs are positioned, one optical disc per groove  116 . The lead ins  114  match a contour of the interior surface of the side walls  102 ,  104  and the bottom surface  120  such that the lead ins  114  have a cylindrical contour where the interior surface of the side walls  102 ,  104  and the bottom wall  120  is cylindrical and have a linear contour where the interior of the side walls  102 ,  104  are linear. The linear portions of the lead ins  114 , such as at area  122 , guides the optical disc into its appropriate groove  116  and insures the optical disc rests in the groove  116  such that the center of mass of the optical disc is below the top of the groove. The linear portions of the lead ins  114  also provide stability to the optical disc when it is raised in preparation for being grabbed by a robotic gripper, as described in greater detail below. 
     The tray  100  also includes a pair of rails  110  and  112  formed on the outside of side walls  102  and  104 , respectively. The pair of rails  110 ,  112  are configured to slide into complimentary slots (not shown) in a storage drawer (not shown), which constrain the tray  100  to move in a single Cartesian direction allowed by the pair of slots. At the front of each tray  100 , the rails  110  and  112  protrude beyond the front wall  108  of the tray  100 . A hook feature  124  is molded into the protruding portion of the rail  110  and a hook feature  126  is molded into the protruding portion of the rail  112 . A finger feature  128  complimentary to a hook feature is molded into a rear portion of each rail  110 ,  112 . The two sets of hook and finger features are designed such that hook and finger features of two separate trays can be meshed together by vertical movement of one tray relative to another. Thus two trays  100  can be interlocked such that their rails form a single continuous assembled rail. Once the interlocking hook and finger features slide into the slots, the two trays cannot be disassembled since the slots do not allow vertical movement. The interlocking structure allows any two trays in any number to be joined or assembled forming a pair of interlocking assembled rails, such that each of the trays can be pulled from the interlocking mechanism to provide access to the tray behind it. Examples of such interlocking trays are further described in the co pending U.S. patent application Ser. No. 14/885,903, entitled “SEPARABLE DRAWER FOR HIGH DENSITY OPTICAL DISC ARCHIVAL STORAGE”, which is hereby incorporated in its entirety by reference. 
       FIG. 2  illustrates a partial side perspective view of the tray  100  loaded with a plurality of optical discs  150 .  FIG. 2  further illustrates a magnified portion of the tray  100  and the plurality of optical discs  150 . Each optical disc  150  is positioned in a corresponding groove  116 . In this manner, each optical disc  150  is stored vertically, on edge within the groove  116 , and the plurality of optical disc  150  form a horizontal stack of vertically aligned optical discs. The portion of each optical disc  150  within the tray  100  rests on edge against the cylindrical interior portion of the tray. Vertical storage of each optical disc  150  minimizes the amount of support needed for each optical disc, in this case the area of the cylindrical interior portion in contact with the optical disc edge. If the optical discs were instead stored horizontally using a similar method of lead ins to separate each adjacent optical disc, then each optical disc would require support along its entire circular area. Without such support each optical disc would sag over time due to gravity. In the vertical storage configuration, gravity does not force a bending moment on the optical disc. 
     Each lead in  114  has a thickness T that forms an empty space  152  between each adjacent optical disc  150 . Each lead in  114  also has a linear length L that extends from the side wall  102  and a curved portion  130 . The lead ins  114  are separated by a distance D. The distance D is large enough to allow the optical disc to be loaded into and unloaded out of the groove  116 , but small enough to prevent the loaded optical disc  150  from leaning away from a substantially vertical position. In some embodiments, the distance D is substantially equal to a maximum thickness of the optical disc  150  as allowed by manufacturing tolerances. The linear length L of the lead in  116  does not extend into a writeable area of the optical disc  150  so that contact between the optical disc  150  and the sides of the lead ins  114  does not damage a readable area of the optical disc  150 . A function of the lead ins  114  is to provide a minimum separation between adjacent optical discs for retrieval by a robotic gripper. Another function of the lead ins  114  is to provide predictable reference points for each optical disc. Still another function of the lead ins  114  is to stabilize the optical discs  150  when loaded in the tray  100 . 
     In some applications, even with the spacing between adjacent optical discs provided by the lead ins it is difficult for some robotic grippers to grab an individual optical disc from within the stack of optical discs loaded in the tray. In some embodiments, the bottom wall of the tray is configured with one or more openings, such as slits, that expose a portion of the loaded optical discs to a lifting mechanism for selectively raising one or more of the optical discs into a raised position above a loaded position within the tray. In the raised position, a raised optical disc is more easily accessible by a robotic gripper, such as for gripping the raised optical disc from the front and back (as referenced in the Y direction). 
       FIG. 3  illustrates a top down perspective view of another optical disc storage device, or tray, according to an embodiment. The tray  200  is similar to the tray  100  in  FIGS. 1 and 2  with the addition of an opening  202  extending through a bottom wall of the tray  200 . In the exemplary configuration shown in  FIG. 3 , the opening  202  is along a single axis. In alternative configurations, openings can be positioned off center, which are offset from each other. Offset openings provide increased structural integrity compared to the single axis openings in  FIG. 3 . 
     The opening in the bottom of the tray expose a bottom portion of each optical disc edge. A lifting mechanism is positioned under or alongside the tray. The lifting mechanism is configured to selectively raise one or more of the optical discs loaded in the tray by pushing on the exposed optical disc edge. In some embodiments, the lifting mechanism comprises a cam shaft having a plurality of cams.  FIG. 4  illustrates a tray and a cam shaft having a plurality of cams according to an embodiment. The exemplary configuration shown in  FIG. 4  includes the tray  200  from  FIG. 3 . A camshaft  210  is aligned with the opening  202  ( FIG. 3 ) in the tray  200 .  FIG. 5  illustrates the configuration shown in  FIG. 4  with the tray  200  removed. The camshaft  210  is supported by a mount  220 , which can be removably coupled to a robotic mechanism (not shown). The cam shaft  210  includes a plurality of cams. In the exemplary configuration shown in  FIG. 5 , there are two subsets of cams within the plurality of cams. The first subset of cams  212  is configured and aligned to simultaneously raise all even numbered optical discs (not shown) loaded in the tray  200 , and the second subset of cams  214  is configured and aligned to simultaneously raise all odd numbered optical discs (not shown) loaded in the tray  200 . Specifically, the cam shaft  210  is positioned under the tray  200  such that each of the first subset of cams  212  is aligned with a corresponding one of the even numbered optical discs and each of the second subset of cams  214  is aligned with a corresponding one of the odd numbered optical discs. If one of the even numbered of optical discs is to be removed from the tray  200 , the cam shaft  210  is rotated in a first direction, such as clockwise, thereby engaging the edges of the even numbered optical discs with the first set of cams  212 , including the specific optical disc to be removed, through the opening  202  in the tray  200  and raising the even numbered optical discs a predetermined distance. In this manner, the raised even numbered optical discs protrude from the odd numbered optical discs loaded in the tray  200 , thereby enabling the robotic gripper to grip the protruding portion of the raised specific optical disc to be removed. Once the raised specific optical disc is removed from the tray  200  by the robotic gripper, the cam shaft  210  is rotated in a second direction, such as counter-clockwise, to its original position thereby lowering the even numbered optical discs back into the tray  200 . If one of the odd numbered of optical discs is to be removed from the tray  200 , the cam shaft  210  is rotated in the second direction, such as counter-clockwise, thereby engaging the edges of the odd numbered optical discs with the second set of cams  214 , including the specific optical disc to be removed, through the opening  202  in the tray  200  and raising the odd numbered optical discs the predetermined distance. For example, if the first and second sets of cams are positioned 180 degrees from each other on the cam shaft, then a 90 degree rotation clockwise can rotate the first set of cams to lift the even numbered optical discs while a 90 degree rotation counter-clockwise can rotate the second set of cams to lift the odd number optical discs. 
     Although the exemplary embodiment shown in  FIGS. 4-5  shows a single cam shaft having two subsets of cams, it is understood that more than one cam shaft can be used. Each cam shaft can have a single set of cam or two subsets of cams. Each cam shaft is aligned with its own corresponding opening in the tray bottom. Each set or subset of cams can be numbered and aligned with every Nth numbered optical disc in the optical disc stack. For example, a configuration having sets or subsets of cams can be used where a set or subset of cams is configured to raise every third optical disc starting with the first optical disc in the optical disc stack, a second set or subset of cams is configured to raise every third optical disc starting with the second optical disc and a third set or subset of cams is configured to raise every third optical disc starting with the third optical disc. It is understood that the number of openings in the tray bottom, the number of cam shafts and the number of subsets of cams on each cam shaft can be configured to selectively raise any subset of optical discs from the remaining optical discs in the optical disc stack. 
     In some embodiments, the lifting mechanism comprises a finger, or probe, coupled to a linear stage that moves laterally back and forth in the Y direction to be selectively positioned under a specific optical disc. Once positioned under the specific optical disc, the probe is raised from its original Z position in the Z direction, thereby engaging the specific optical disc edge through the opening in the tray and raising the specific optical disc a predetermined distance, such as 0.1 inches. The linear portions of the lead ins, such as at area  122  in  FIG. 1 , enable the raised specific optical disc to remain stable and aligned in the tray while in the raised position. In this manner, the raised specific optical disc protrudes from the remaining optical discs loaded in the tray, thereby enabling the robotic gripper to grip the protruding portion of the raised specific optical disc. Once the raised specific optical disc is removed from the tray by the robotic gripper, the probe is lowered in the Z direction to its original Z position. 
     In some embodiments, the lifting mechanism comprises a plurality of comb-like structures. Each comb-like structure includes a plurality of rigid bristles. In an exemplary, there are two comb-like structures. The first comb-like structure is configured and aligned to simultaneously raise all even numbered optical discs loaded in the tray, and the second comb-like structure is configured and aligned to simultaneously raise all odd numbered optical discs loaded in the tray. Specifically, the first comb-like structure is positioned under the tray such that each of a first plurality of rigid bristles is aligned with a corresponding one of the even numbered optical discs. The second comb-like structure is positioned under the tray such that each of a second plurality of rigid bristles is aligned with a corresponding one of the odd numbered optical discs. If one of the even numbered of optical discs is to be removed from the tray, the first comb-like structure is raised in the Z direction, thereby engaging the edges of the even numbered optical discs, including the specific optical disc to be removed, through the opening in the tray and raising the even numbered optical discs a predetermined distance. In this manner, the raised even numbered optical discs protrude from the odd numbered optical discs loaded in the tray, thereby enabling the robotic gripper to grip the protruding portion of the raised specific optical disc to be removed. Once the raised specific optical disc is removed from the tray by the robotic gripper, the first comb-like structure is lowered in the Z direction to its original Z position. The second comb-like structure can be similarly operated as the first comb-like structure to raise the odd-numbered optical discs in the tray. 
     Although the exemplary embodiment described above includes two comb-like structures, it is understood that more than two comb-like structures can be used. Each comb-like structure can be configured to include a plurality of rigid bristles numbered and aligned with every Nth numbered optical disc in the optical disc stack. For example, a configuration having three comb-like structures can be used where a first comb-like structure includes a first plurality of rigid bristles configured to raise every third optical disc starting with the first optical disc in the optical disc stack, a second comb-like structure includes a second plurality of rigid bristles configured to raise every third optical disc starting with the second optical disc and a third comb-like structure includes a third plurality of rigid bristles configured to raise every third optical disc starting with the third optical disc. It is understood that the number of openings in the tray bottom, the number of comb-like structures and the number of rigid bristles on each comb-like structure can be configured to selectively raise any subset of optical discs from the remaining optical discs in the optical disc stack. 
     The present application has been described in terms of specific embodiments incorporating details to facilitate the understanding of the principles of construction and operation of the method and system. Many of the components shown and described in the various figures can be interchanged to achieve the results necessary, and this description should be read to encompass such interchange as well. As such, references herein to specific embodiments and details thereof are not intended to limit the scope of the claims appended hereto. It will be apparent to those skilled in the art that modifications can be made to the embodiments chosen for illustration without departing from the spirit and scope of the application.