Banknote processing

Banknote processing equipment is disclosed, which comprises a chamber having an open end for insertion of a bag into the chamber and an extractor adapted to establish a lower ambient pressure between the chamber and the bag to that within the bag to cause the bag to expand into an open configuration during a banknote filling operation, whereby the banknote processing equipment can deposit banknotes in the bag.

This application is a U.S. national phase under 35 U.S.C. § 371 of International Patent Application No. PCT/GB2012/053142 filed on Dec. 14, 2012 and further claims priority to United Kingdom Patent Application No. 1200239.0 filed on Jan. 9, 2012. The disclosures of the foregoing International and United Kingdom patent applications are hereby incorporated by reference herein.

This invention relates to banknote processing equipment, which can cause a bag to expand into an open configuration so that the banknote processing equipment can deposit banknotes in the bag. It also relates to a corresponding method.

In banks and retails outlets, banknotes are often sorted using specialist machinery and deposited into plastic bags. When a desired quantity of banknotes has been deposited into a bag, the bag is then sealed (for example, by heat) and collected for onward transit from the bank or retail outlet. An example of a device suitable for receiving banknotes, allowing them to be deposited in a bag and then heat-sealing the bag is disclosed in our PCT application, published as WO2010/125372.

One problem with using bags in this way is that, with lightweight items such as banknotes, it is difficult to ensure that the banknotes fall straight to the bottom of the bag because the bag will not usually open completely without some manipulation. Typically, some special arrangement is required to allow banknotes to fall to the bottom of the bag. One such arrangement used with security documents such as banknotes is the use of a block-bottom and gusseted sides. However, these are relatively expensive to provide, and it is desirable to eliminate this expense as the bags used to transport banknotes are disposed of after each use. Furthermore, even where this arrangement is used it is normal for the bags to be supplied in a flattened configuration, requiring the user to expand the bag when installing it in the device used to deposit banknotes within it.

In accordance with a first aspect of the invention, there is provided banknote processing equipment comprising a chamber having an open end for insertion of a bag into the chamber and an extractor adapted to establish a lower ambient pressure between the chamber and the bag to that within the bag to cause the bag to expand into an open configuration during a banknote filling operation, whereby the banknote processing equipment can deposit banknotes in the bag.

By extracting air from within the chamber and reducing the pressure around the bag, the bag is caused to expand and open. This allows the easy deposition of banknotes into the bag. Furthermore, there is no requirement to manipulate the bag to open it initially or to hold it open whilst the filling operation is carried out and a cheap and simple bag (e.g. with no block-bottom or gusseted sides) can be used. The above-mentioned problems are therefore overcome.

By “filling”, we mean depositing a desired amount of banknotes in the bag. This does not necessarily mean that the entire volume of the bag is occupied with the banknotes.

In one embodiment, the open end of the chamber is adapted to support a free end of the bag in an open position. This allows the passage of banknotes into the bag through the free end. The adaptation of the open end of the chamber to support the free end of the bag could be by way of a set of pegs or a flange on the open end of the chamber over which the free end of the bag may be stretched.

Typically, the bag will have a base or closed end opposed to the free end. Thus, the banknotes will deposit on the base or closed end.

In another embodiment, the open end of the chamber is adapted to support a frame integral with the bag. Such a frame may provide a means for holding the bag and provide a closure for sealing the bag after the filling operation is complete. Such a bag and frame is explained in detail in our PCT application, published as WO2011/138594.

However, in a preferred embodiment, the banknote processing equipment further comprises a clamping arrangement operable to clamp at least part of the free end of the bag against the chamber during the banknote filling operation.

To achieve this, the clamping arrangement typically comprises a plurality of flaps, which are brought into engagement with inner surfaces of the bag on operation of the clamping arrangement. For example, the flaps may be rotatable or movable from a first position in which they are disengaged from the inner surfaces of the bag to a second position in which they are engaged with the inner surfaces of the bag.

Preferably, each flap has a leading edge with chamfered corners or that is curved. The leading edge is shaped in this way to prevent it catching on the bag as the flaps are brought into engagement with the inner surface of the bag.

Preferably, the banknote processing equipment further comprises a sealing mechanism movable into engagement with the bag for sealing the bag in a sealing operation occurring after the filling operation.

The sealing mechanism may be coupled to the clamping arrangement such that the clamping arrangement releases the free end of the bag as the sealing mechanism is moved into engagement with the bag to allow the bag to be sealed.

The chamber may have one or more side walls for containing expansion of the bag, in use.

When in the open configuration the bag could be in contact with the one or more side walls of the chamber. Indeed, it could conform to an interior shape of the chamber, for example defined by the side walls.

In the open configuration, the bag may occupy an interior volume of the chamber. Alternatively, it may partially occupy an interior volume of the chamber.

In a preferred embodiment, the device further comprises one or more side rails running along the length of the chamber from the open end and protruding from the side walls inwardly into the chamber. The side rails prevent the bag from conforming precisely to the interior shape of the side walls and allow the passage of air between the bag and the side walls. This prevents the extractor from being overloaded and overheating.

The banknote processing equipment preferably further comprises a support for holding a base of the bag, in use, during the filling operation. The support could be a mesh or one or more bars passing through chamber to support the contents of the bag during the filling operation and to prevent the bag from being drawn into the extractor.

Typically, the extractor is a fan.

The banknote processing equipment preferably further comprises a speed controller adapted to control the speed of operation of the extractor in response to a speed control signal. This allows the extractor to be slowed down or even stopped during the filling operation and after expansion of the bag (i.e. when the bag has expanded into the open configuration). Despite the slower speed of operation it has been found that the bag remains in the open configuration. This feature enables the saving of energy and lower-noise operation. The speed controller could vary the speed of operation continuously or it could vary the speed of operation to one of a plurality of discrete speed settings.

The speed controller may be adapted to control the speed of operation of the extractor to a cooling speed for cooling a welded region of the bag during and/or after the sealing operation.

In accordance with a second aspect of the invention, there is provided a method for holding a bag in an open configuration for deposition of banknotes in the bag by banknote processing equipment during a banknote filling operation, the method comprising inserting a bag into a chamber forming part of banknote processing equipment and establishing a lower ambient pressure between the chamber and the bag to that within the bag to cause the bag to expand into the open configuration, whereby the banknote processing equipment can deposit banknotes in the bag.

Typically, the lower ambient pressure between the chamber and the bag is established by extracting at least some of the atmosphere from the chamber after insertion of the bag into the chamber. The atmosphere is usually air.

The method normally further comprises clamping at least part of a free end of the bag against the chamber during the banknote filling operation.

The method preferably further comprises maintaining a passage for fluid flow between the chamber and bag after the bag has expanded into the open configuration. The passage of fluid flow may be maintained by preventing the bag from conforming to the interior shape of the chamber such that a gap exists between the bag and a side wall of the chamber.

In a preferred embodiment, the method further comprises sealing the bag in a sealing operation occurring after the filling operation. The sealing operation is typically a heat-sealing operation, although it may employ other means such as using a closure device, preferably integral with the bag.

The free end of the bag is typically releases from the chamber after the filling operation and prior to the sealing operation.

The method may further comprise controlling the speed of operation of an extractor for establishing the lower ambient pressure between the chamber and the bag to a suitable speed for cooling a welded region of the bag during and/or after the sealing operation. This speeds up the overall cycle time since the welded region of the bag cools and solidifies more rapidly. It has been found that a six-second period of fan operation at full speed after the sealing operation is adequate to cool the welded region.

The method preferably further comprises reducing the speed of an extractor for establishing the lower ambient pressure between the chamber and the bag after the bag has expanded into the open configuration. This allows a lower speed to be maintained during the filling operation, thereby reducing energy consumption and the noise level. The speed may be reduced such that the extractor is stopped. The lower speed may be maintained until a new bag is loaded.

In accordance with a third aspect of the invention, there is provided method for filling a bag with banknotes, the method comprising holding a bag in an open configuration for deposition of banknotes in the bag by banknote processing equipment during a banknote filling operation according to the method of the second aspect of the invention, and depositing banknotes in the bag using the banknote processing equipment during the banknote filling operation.

In the device shown inFIGS. 1 to 3, a chamber1is made from two sheet metal U-shaped parts2a,2bjoined together along their longitudinal edges. The top edges of the chamber1are folded over to form flanges3a-3d.

Six side rails4a-4fare mounted to the chamber1. The six side rails4a-4fare affixed to the chamber1by way of tabs on the side rails4a-4fthat are passed through corresponding apertures in the chamber1and twisted to prevent them passing back through the apertures. The tabs on each of side rails4c,4fpass through apertures in both of the U-shaped parts2a,2band thereby hold the two U-shaped parts2a,2btogether.

Towards a lower end of the chamber three support rods5a-5cpass through the chamber1. An extractor fan6is mounted to the underside of the chamber1.

To use the device, a bag7(seeFIG. 3) is inserted through the open end of the chamber1, that is the end of the chamber1adjacent the flanges3a-3d. The free end (i.e. not the closed end) of the bag7is stretched over the flanges3a-3dto hold it in place and the closed end of the bag7is allowed to rest on the support rods5a-5c.

The extractor fan6is then started, drawing air through the chamber1from the open end adjacent the flanges3a-3dto the opposed, base end where the extractor fan6is mounted and out through the fan6in the direction of the arrows shown inFIG. 3. This reduces the air pressure within the chamber1around the bag7.

As a result of the reduction in pressure within the chamber1the bag7expands outwardly (as indicated by the arrows shown inFIG. 3) towards the side walls of the chamber1. Thus, the bag7adopts an open configuration in which banknotes can be deposited simply by releasing them above the free end of the bag7such that they fall under gravity to rest on the closed end of the bag7. The support rods5a-5cprovide support to prevent the bag7being drawn into the extractor fan6and for the banknotes deposited in the bag7.

Once the bag is in the open configuration, the speed of extractor fan6may be reduced. This is achieved by a speed controller (not shown) which controls the speed of extractor fan6in response to a speed control signal. The speed control signal may be issued by a master controller in an item of banknote processing equipment (for example, banknote sorting or counting equipment) to which the device shown inFIGS. 1 to 3is fitted. The speed of the extractor fan6may be reduced to a dead stop. This speed-reduction feature reduces the noise of operation and power consumption of the device.

The side rails4a-4fprevent the bag7from conforming entirely to the shape of the interior of the chamber1when it expands into the open configuration. Instead, the bag expands against the side rails4a-4fand the side walls of the chamber1between the side rails4a-4f. This results in air channels of approximately triangular cross-section being formed between the bag7, the side walls of the chamber1and the side rails4a-f. Thus, the passage of air through the chamber1and extractor fan6is maintained even when the bag7is in the open configuration, which prevents the extractor fan6being overworked and potentially overheating.

The device forms part of an item of banknote processing equipment, such as a banknote deposit safe, a cash dispenser, a banknote sorter or banknote counter. In some cases, more than one device may be fitted to the same piece of equipment. It is then possible to use a single fan coupled to each device to reduce the pressure in each chamber simultaneously or, with a suitable system of baffles, selectively in each chamber.

FIGS. 4 and 5show plan and side cross-sectional views of a second embodiment of the invention. Generally, the structure of the second embodiment is the same as that of the first embodiment described above with reference toFIGS. 1 to 3. However, there are some important additions as will become apparent.

A chamber10has an open end for receiving bags and an extractor fan11mounted on the underside of the chamber10. The extractor fan11is able to draw air through the open end, through the chamber10and out through the base end (opposite to the open end) as shown by the arrows. Three support rods12a-12cpass through the chamber10near its base end. The arrangement so far is identical to that of the first embodiment, the extractor fan11and support rods12a-12cperforming the same functions as the equivalent extractor fan6and support rods5a-5cof the first embodiment. These functions have already been described above. However, the second embodiment also comprises a sealing mechanism and a clamping arrangement.

The clamping arrangement comprises a pair of flaps13a,13b, each disposed on a long edge of the open end of the chamber10. The flaps13a,13bare rotatable around respective hinges14a,14brunning along the long edges of the chamber10. They are able to move between the positions indicated as A and C (in dashed lines), and can be held at the interim position indicated as B (also in dashed lines) by detents.

When the flaps13a,13bare in position C, an operator is able to load a bag15into chamber10. In position A, the flaps13a,13bclamp the bag15to the chamber10by engaging the inner surfaces of bag15and applying a clamping force to the bag15pushing it against the side walls of the chamber. This not only holds the bag15in the correct configuration to allow deposition of banknotes in the bag15, it also provides a well-defined opening into the bag15so that banknotes do not collide with the open end of the bag15as they are deposited.

As best seen inFIG. 4, the flaps13a,13bhave chamfered corners16a-16don their leading edges. This prevents the corners catching on the bag15as the flaps13a,13bare moved into position A to engage the bag15. An alternative design for the flaps13a,13bcould have curved leading edges.

The flaps13a,13boccupy effectively the full width of the chamber to force the bag15open as much as possible along its entire width, thereby providing as wide an opening as possible. They are designed to have a width that is slightly less than the width of the bag15when open. Typically, the width of the flaps13a,13bwill be around 3 mm to 5 mm less than the width of the bag15when open.

The sealing mechanism comprises a pair of sealing arms17a,17bmounted to the chamber10on pivots18a,18b. Each sealing arm17a,17bis provided with a stub axle19a,19bto enable a force to be applied to the sealing arms17a,17bto draw them together and pull them apart. At the top of each sealing arm17a,17bis a sealing element20a,20b. The sealing elements20a,20bapply heat to the bag15when the sealing arms17a,17bare drawn together so that the sealing elements20a,20bengage the bag15. This welds the sides of the bag15together, thereby closing the open free end.

The operation of this embodiment is similar to the first embodiment. The flaps13a,13bare moved manually to position C by an operator. The bag15is then inserted through the open end of the chamber10. The extractor fan11is then started, drawing air through the chamber10from the open end to the base end where the extractor fan11is mounted and out through the fan11in the direction of the arrows shown inFIG. 5. This reduces the air pressure within the chamber10around the bag15.

As a result of the reduction in pressure within the chamber10, the bag15expands rapidly outwardly towards the side walls of the chamber10. The bag15conforms approximately to the internal volume of the chamber10, the side walls of which constrain further expansion of the bag15. Thus, the bag15adopts the open configuration shown inFIG. 5. Even with a normal non-gusseted bag, the chamber10can cause it to open into a well-formed shape with a rectangular cross-section and a flat bottom suitable for receiving banknotes.

The flaps are then manually rotated to position C to clamp the free end of the bag15to the chamber10and to present a neatly-formed opening of the appropriate size to receive banknotes.

Banknotes can then be deposited simply by releasing them above the clamped free end of the bag15such that they fall under gravity to rest on the closed end of the bag15. The support rods12a-12cprovide support to prevent the bag15being drawn into the extractor fan11and for the banknotes deposited in the bag15.

Once the bag is in the open configuration, the speed of extractor fan11may be reduced. This is achieved by a speed controller (not shown) which controls the speed of extractor fan11in response to a speed control signal. The speed control signal may be issued by a master controller in an item of banknote processing equipment (for example, banknote sorting or counting equipment) to which the chamber10is fitted. The speed of the extractor fan11may be reduced to a dead stop. This speed-reduction feature reduces the noise of operation and power consumption.

Although not shown in this embodiment, the chamber could be fitted with side rails similar to the side rails4a-4falready described above with reference to the first embodiment. These side rails have the same effect as already described, namely providing air channels of approximately triangular cross-section being formed between the bag15, the side walls of the chamber10and the side rails. Thus, the passage of air through the chamber10and extractor fan11is maintained even when the bag15is in the open configuration, which prevents the extractor fan11being overworked and potentially overheating.

When the desired quantity of banknotes has been deposited in bag15by the banknote processing equipment to which chamber10is fitted, the flaps13a,13bare moved to position B and the sealing arms17a,17bare moved so that the sealing elements20a,20bengage the bag15. The sealing elements20a,20bare then energised to weld the open free end of the bag15.

The movement of the flaps13a,13bto position B occurs automatically as the sealing arms17a,17bare moved so that the sealing elements20a,20bengage the bag15. This is carried out by a mechanism shown inFIG. 6. Movement of the sealing arms17a,17bis caused by operation of a motor21, coupled via a pulley22and belt23to a main cam24. The main cam24has a “racetrack” groove in which the stub axles19a,19bof the sealing arms17a,17bare located. Thus, as the motor21rotates the main cam24through ninety degrees from the position shown inFIG. 6, the sealing arms17a,17bare brought together by the groove25acting on the stub axles19a,19b. A further ninety degree rotation of the main cam24causes the sealing arms17a,17bto be pulled apart, again by the groove25acting on the stub axles19a,19b.

A pair of secondary cams26a,26bis provided on the periphery of main cam24. A roller27bears on the peripheral surface of main cam24and follows its profile. When the secondary cams26a,26bare underneath it (as shown inFIG. 6), the roller27lifts the T-shaped member28against springs29a,29b. The T-shaped member is coupled to bellcranks30a,30b, and in this position these are moved out of the way so that the flap-operating levers31a,31bcan occupy the position indicated as A inFIG. 6(in which the flaps13a,13bare also in their position A).

However, when a sealing command is issued by a controller, the motor21is caused to rotate the main cam24through ninety degrees from the position it is shown to occupy inFIG. 6. This brings the sealing arms17a,17btogether for the sealing operation as already described. It also allows the springs29a,29bto urge the T-shaped member28downwardly as the secondary cam26amoves out of the way of roller27. The T-shaped member thus pulls the bellcranks30a,30binwardly so that rollers32a,32b(rotatably mounted on bellcranks30a,30b) push the flap-operating levers31a,31b(and hence flaps13a,13b) to position B. A pair of springs33a,33band balls34a,34bform detents together with notches35a,35bin the flap-operating levers31a,31b. The balls34a,34bare urged into the notches35a.35bby springs33a,33bas the flap-operating levers31a,31barrive at position B and hold them in that position.

After the sealing operation, the motor21is caused to rotate the main cam24through another ninety degrees, which returns the sealing arms17a,17b, T-shaped member28and bellcranks30a,30bto their original positions as shown inFIG. 5. The flaps13a,13bwill stay in position B due to the action of the above-mentioned detents on flap-operating levers31a,31b. This enables the operator to recover the bag straightforwardly, which is done by manually moving the flaps13a,13bto position C. The bag is then recovered and the system is ready to receive the next bag.

Optionally, the extractor fan11may be run for a period of a few seconds, typically six seconds, during and/or after the sealing elements20a,20bare energised. This helps to cool the welded region of the bag and speed up the cycle time.

The chamber10is mounted to or forms an integral part of banknote processing equipment, such as a banknote deposit safe, a cash dispenser, a banknote sorter or banknote counter. In some cases, more than one device may be fitted to the same piece of equipment. It is then possible to use a single fan coupled to each device to reduce the pressure in each chamber simultaneously or, with a suitable system of baffles, selectively in each chamber.