Cassette tape player having circuit for detecting reverse rotation of take-up reel

Abstract: A system for preventing improper tape feed in a cassette tape player uses pulse width measurements from the take-up reel (28) output signal to sense normal or aberrant tape feeding conditions. The pulse width of the output signal is compared with a predetermined range of pulse widths associated with normal tape operation. The tape player either stops or reverses the rotation of the take-up reel (28) if the pulse width of the output signal is outside of the predetermined range, denoting an aberrant tape feeding condition.

Description: The present invention relates to cassette tape players with a system for preventing improper tape feed and more particularly to a circuit and algorithm for detecting reverse rotation of the take-up reel of a cassette tape. Audio cassette tapes are commonly used for recording and playback of music and other audio recordings in vehicles and home entertainment systems. Cassette tape cartridges vary widely in quality of material and design. The best cassette tape cartridges are made from impact and heat resistant material which are durable and which provide thousands of hours of quality playback. However, inferior cassette tape cartridges are also widely used due to their low cost. "Bargain" cassettes may not comply with minimum standards for cassette design, testing and manufacturing. If a cassette is not manufactured to precise tolerances, it will not maintain uniform rolling friction of internal parts and may result in improper tape guidance. In severe cases, this may result in tape spilling into the transport mechanism and wrapping around the capstan. A condition commonly referred to as "tape eating" occurs when tape spills from the cassette and wraps onto the capstan, pinch roller or other parts of the cassette player. "Tape eating" occurs relatively frequently in home and vehicle cassette tape players. Three principal factors are associated with "tape eating": (i) the cassette take-up hub may not rotate freely; (ii) the tape may be loosely wound on the tape reels or separated from the tape pack; (iii) the cassette may have thin tape commonly used in long-playing C-120 cassettes. When take-up hub rotation is impaired, tape pulled by the capstan from the supply reel does not wind onto the take-up hub. Tape then spills into the tape transport mechanism and wraps onto the capstan or pinch roller. The equipment manufacturers, particularly during the warranty period. When a consumer returns a vehicle to the dealer for repair, it is frequently necessary to entirely remove and disassemble the tape player from the vehicle for service leading to consumer dissatisfaction. Several attempts have been made to prevent "tape eating" in the prior art. One example is disclosed in U.S. Patent 4,348,702 to Taraborrelli which discloses a device for preventing tape windup on the capstan of a tape deck. The Taraborrelli device incorporates a rotation-sensing switch and switch wiper mounted on the bottom of a take-up spindle. The rotation sensing switch only allows rotation when the take-up spindle rotates in a proper direction. If the take-up spindle changes direction due to tape windup on the capstan, a tab on a rotation-sensing switch engages a vertical edge at the bottom of the take-up spindle and stops the sensor switch from rotating. When the rotation-sensing switch stops, the rotation-sensing circuit disables the drive mechanism to prevent tape windup on the capstan. Another approach is disclosed U.S. Patent 4,597,547 to Tarpley, Jr. et al which discloses a logic circuit for detecting reverse rotation of a take-up reel in a tape transport mechanism wherein three motion sensing switches are added to a tape player adjacent the take-up reel to detect a sequence of switch actuation according to the sequence of A-B-C. Subsequent switch activation sequences are then monitored by a logic circuit which can sense and react to an improper switching sequence. The switches and logic circuit are additional elements which must be added to a cassette tape player, thereby increasing cost. In U.S. Patent No. 4,632,333 to Tarpley, Jr. another circuit sensing improper rotation of a take-up reel is disclosed wherein three switches are provided on the cassette player adjacent to the take-up reel. The sensing circuit outputs a pulse each time the sensor switches are actuated. Monostable multivibrators receive the pulses and provide output signals into a gate which responds by providing a control signal to a sensor switch. Improper cause of impaired take-up reel rotation is generally related to one of the following conditions and cassette cartridge defects: the hub may be dislodged out of position and jammed as a result of the cassette being dropped. the cassette shell may be made from low-grade plastic which warps upon exposure to high temperatures. improper sonic welding of a cassette may cause misalignment between the two shell halves which reduces internal dimensional tolerances. inadequate internal support between the two half shells of the cassette may result in shell deformation when placed in a tape player. Step formations in the tape pack may cause excessive friction, especially when repeated changes in play and fast forward or rewind modes occur in cassettes having poor internal tape guidance. "Tape eating" caused by loose tape is more frequently encountered with vehicle cassette tape players than in home tape players due to the extreme conditions in which the tapes are used and stored. When the cassette tapes are stored in the vehicle outside their protective case, vehicle vibrations can be transferred to the cassette and the tape may become loose and may spill into the mechanism upon insertion into the tape player, at which time the tape can wrap onto the capstan. "Tape eating" caused by the use of thin tape, like C-120 and C-90 tapes, can results from an initial formation of a small loop in the tape caused by the tape following the curvature of the capstan upon initial insertion. If a cassette tape cartridge does not have ramps or tape strippers which are required by the industry standard, tape will be able to follow the capstan rotation, catch under the pinch roller, and subsequently wrap around the capstan. It is estimated that a significant percentage of all cassette system failures in vehicle warranty claims are in some way related to defective or improperly stored cassette cartridges. Cassette system failures are costly to rotation of the take-up reel interrupts this control signal, causing the sensor switch to respond by stopping or reversing the tape deck mechanism. The need for switches and monostable multivibrators in a special sensing circuit again increase the cost of the cassette tape deck equipped with such a system. DE-A-3829052 is concerned with a tape protection device for use with a magnetic recording/reproducing apparatus of the helical scanning type and including take-up and supply reel drive means, a rotatably mounted magnetic drum head, means for rotating said supply reel, said take-up reel, and said head, the device comprising detecting means for providing a rate-indicating signal indicative of the rate of rotation of one of said reels; comparison means responsive to said detecting means for producing a head-stopping signal upon receipt of a rate-indicating signal indicative of a rate of reel rotation beyond a given value; and head-stopping means responsive to said detecting means for stopping the rotation of said head upon receipt of said head-stopping signal. According to the present invention there is provided a tape player apparatus for playing a cassette tape cartridge having a magnetic tape which is wound between a take-up reel and a supply reel, the apparatus comprising: a drive motor; a take-up reel spindle driven by the drive motor, the take-up reel spindle having a rotational frequency; a supply reel spindle; detecting means for providing a signal indicative of the rate of rotation of one of said reels; comparison means responsive to said detecting means for establishing whether the rate of rotation of one of said reels is outside the normal operating range and if so initiating braking of one of said reels; characterised by means for sensing the rotational frequency of the take-up reel spindle, the sensing means producing an output signal having a pulse width inversely proportional to the rotational frequency; means for measuring the pulse width of the output signal; means for comparing the pulse width of the output signal with a predetermined range of pulse widths, the predetermined range being incrementally adjustable in response to changes in the rotational frequency; means for interrupting the operation of the take-up reel spindle in response to the pulse width falling outside of the predetermined range thereby denoting an aberrant tape condition. A circuit embodying the invention is incorporated in a tape player a for detecting aberrant operational conditions which can be implemented without incurring significant additional cost for additional hardware or circuitry. In a system embodying the invention an algorithm can be programmed into any microprocessor-controlled tape deck or microprocessor-based AM/FM radio utilizing inputs from already existing spindle rotation sensor inputs to detect proper operation and the aberrant operational conditions. Appartus embodying the invention has a further advantage that already existing hardware and microprocessor capacity is used to reduce the cost of implementing a "tape eating" or aberrant operational condition system with little or no additional cost except for the cost of programming existing microprocessor capacity with the algorithm disclosed. In an apparatus embodying the invention an actuator attached to the bottom of the take-up reel spindle in the cassette tape player rotates as the spindle rotates. A sensor mounted on the cassette tape player is actuated by the rotating actuator as the take-up reel spindle is rotated to produce a periodic output signal. As the diameter of the take-up reel increases with tape accumulation thereon, the period, and therefore the pulse width, of the signal also increases. A microprocessor control receives the output signal and compares the pulse width of the output signal to the pulse width of a prior signal. Time constants are both added to and subtracted from the pulse width of the prior signal and compared to the pulse width of the output signal to determine a range in which the pulse width should fall during normal operation. A control signal is generated when the pulse width of the output signal is outside the normal operating range, thereby indicating reverse rotation of the take-up reel caused by the tape winding around the capstan of the cassette tape player. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a plan view of a reel-to-reel tape deck under normal operating conditions. Figure 2 is a plan view of a conventional reel-to-reel cassette tape deck developing a slack tape loop adjacent to capstan. Figure 3 is a plan view of a portion of a conventional cassette tape deck showing a slack loop wrapping around the capstan and being caught between the incoming tape and the capstan. Figure 4 is a cross-sectional view of the take-up reel spindle. Figure 5 is a diagrammatic view illustrating the effect of increasing the diameter of tape wound on the take-up reel spindle. Figure 6A is a diagrammatic view of the output of the circuit of the present invention when operating at radius A of Figure 5. Figure 6B is a diagrammatic view showing the output of the circuit of the present invention when operating at the radius B of Figure 5. Figure 7 is a flow chart illustrating the steps of the present invention. Figure 8 is a diagrammatic view illustrating the variables utilized by the algorithm of the present invention. Figure 9 is a diagrammatic view illustrating the constant adjustment of pulse width value utilized in the algorithm of the present invention. Figure 10 is a diagrammatic view showing the output of the circuit when an aberrant tape condition is signalled by the system. A tape deck generally indicated by reference numeral 20 is shown. The tape deck 20 includes a supply reel 22 secured to a supply reel spindle 24. A magnetic tape 26 is transferred between supply reel 22 and a take-up reel 28 which is secured to a take-up reel spindle 30. The tape 26 is guided by feed alignment roller 32 past the playback head 34. A capstan 36 and pinch roller 38 move the tape at a constant speed past the playback head 34. A take-up alignment roller 40 guides the tape 26 as it is fed from between the capstan 36 and pinch roller 38 to the take-up reel 28. Referring now to Figure 2, a common condition is illustrated wherein a loop 42 forms between the capstan roller 36 and the take-up alignment roller 40. This occurs upon initial start-up of the tape deck 20 or if the take-up reel 28 stops rotating. The loop 42 forms as tape follows the curvature of the capstan roller 36. Normally the loop 42 is automatically eliminated as the take-up reel 28 takes up the excess tape 26. Referring now to Figure 3, an aberrant tape feed condition is illustrated wherein the loop 42 becomes caught around the capstan roller 36 and forms a roll 44 of tape which rapidly accumulates on the capstan roller 36. If the loop becomes caught between the capstan roller 36 and the pinch roller 38, the rotation direction of the take-up reel 28 is reversed and tape feeds in the reverse direction from the take-up reel 28 as it winds about the capstan roller 36. Referring now to Figure 4, the structure of a take-up reel spindle 30 is shown in cross-section. A spindle drive 50 frictionally engages a rubber ring 52 which is secured to the take-up reel spindle 30 to drive the spindle. A drive pulley 54 forms part of the spindle drive 50 and is rotated by means of a drive belt 56. A multi-pole magnetized disc 46 is secured to the take-up reel spindle 30 as shown in Figure 4. A slip clutch 58 is provided to prevent excess tension from occurring on the tape. A sensor such as a reed switch 48 responds to changes in the magnetic field caused by the rotation of the multi-pole magnetized disc 46. The multi-pole magnetized disc 46 and reed switch 48 are currently included in conventional tape decks for sensing end-of-tape and other spindle rotation conditions. Referring to Figures 5 through 10, utilization of input from existing hardware such as the multi-pole magnetized disc 46 and reed switch 48 to detect aberrant tape conditions and reverse the rotation of the take-up reel utilizing an algorithm in conjunction with preexisting microprocessor control elements is explained. Referring now to Figure 5, variables utilized in the algorithm are diagrammatically illustrated. The radius of the tape pack, designated r, increases as tape winds onto the cassette cartridge reel. As the radius increases, the rotational frequency of the take-up spindle decreases. The take-up reel rotates in a counterclockwise direction. The radius increases from a minimum radius of A for an empty take-up reel to a maximum radius of B for a full take-up reel. Frequency = V 2πr V = velocity r = radius A = minimum radius B = maximum radius For example, for a C-60 cassette the radius changes approximately 34 micrometers per revolution and consequently the rotational frequency changes approximately 0.002 revolutions per second. Referring now to Figures 6a and 6b, the output of the take-up spindle sensor is illustrated. In 6a the take-up spindle sensor output is illustrated for an empty take-up reel. Figure 6b illustrates the take-up spindle sensor output for a full take-up reel. The pulse width of the output signal is proportional to the rotational frequency of the take-up reel. The rotational frequency is related by the radius of the tape pack as stated above, and consequently the pulse width of the output signal increases as the radius of the tape pack increases and the rotational frequency decreases. Similarly, the pulse width of the output signal decreases as the rotational frequency of the take-up reel increases. Referring to Figure 7, the flow chart illustrating the steps of the reverse rotation detection algorithm will be described beginning with "START". The first step is an initialization routine wherein initial X and Y values are determined. This initial step is conducted because the diameter of the tape pack at the time the player is started could be any size, from full to empty and X and Y values previously stored for one tape may not be the correct values for another tape. For example, if one tape is ejected and another tape is replaced, the diameter of the tape on the take-up reel will almost always be different requiring adjustment of the X and Y values. Determination of the initial X and Y value is accomplished by measuring the first valid pulse width t 1 . The microprocessor accomplishes this by determining whether the take-up spindle output signal is high or low when the tape player is started and then waiting for the first low-to-high or high-to-low transition in the output signal before proceeding with the pulse width measurement. The system measures both low and high pulses which are both compared by the algorithm for better resolution. The microprocessor then references the stored values for X and Y in a look-up table which correspond to selected pulse width values to be assigned. Once the initial X and Y values are assigned, they are periodically updated. The X and Y values are updated at predetermined pulse width switch point values. Each time a predetermined pulse width switch point value is encountered, X and Y values are updated. Referring now to Figures 8 and 9, under normal operating conditions, a cassette cartridge is inserted into the cassette tape player and the drive motor is turned on, causing the take-up spindle to rotate and actuate the take-up reel sensor. When the microprocessor conducts the initialization process as described above, the first measured value t 1 of the take-up reel sensor causes the initial X and Y values to be assigned. In the next step, the pulse width values t 1 and t 2 are measured and stored in memory as reference values for later comparison. The pulse width value of t 3 is measured and compared to the value of t 1 + X and the value of t 1 - Y. During normal operation, the value of t 3 meets the t 1 - Y < t 3 < t 1 + X condition and the pulse width value t 4 is then measured. The value of t 4 is then compared to the value of t 2 + X and the value of t 2 - Y. If the value of t 4 meets the t 2 - Y < t 4 < t 2 + X condition for normal operation, the algorithm updates the t 1 and t 2 reference values with the t 3 and t 4 values respectively. The values of X and Y are also adjusted to maintain a constant proportional relationship between the measured pulse width value and the X and Y values as the diameter of the tape pack increases. The pulse width value t 5 is then measured and compared to the value of t 3 + X and the value of t 3 + Y. If the value of t 5 meets the t 3 - Y < t 5 < t 3 + X condition for normal operation the pulse width value t 6 is measured. The t 6 value is compared to the value of t 4 + X and the value of t 4 - Y. If the value of t 6 meets the t 4 - Y < t 6 < t 4 + X condition for normal operation, the microprocessor updates the t 3 and t 4 reference values, with the t 5 and t 6 values respectively. The values of X and Y are also adjusted to maintain a constant proportional relationship between of the measured pulse width value and the X and Y values as the diameter of the tape pack increases. This process is continued as long as normal operation criteria continues to be met. Referring now to Figure 10, a graphical representation of the take-up spindle output signal during normal operation and three cases of output signals during aberrant tape feed conditions are juxtaposed. In the top illustration, normal conditions exist and the time t 3 falls within the range t 1 - Y < t 3 < t 1 + X permitting normal operation to continue. In case 1, t 3 is > t 1 + X which falls outside the acceptable t 1 - Y < t 3 < t 1 + X range. This occurs when the take-up spindle reverses direction after the 50% pulse width value of t 1 + X. When this condition occurs, the algorithm controlling the microprocessor sends a control signal to the cassette mechanism to either stop or reverse the mechanism. In case 2, t 3 < t 1 - Y. This occurs when the take-up spindle reverses direction before the 50% pulse width value of t 1 - Y. When this occurs, the algorithm controlling again sends a control signal to the cassette mechanism to either stop or reverse the mechanism, depending upon the application. Finally, in case 3 the take-up reel reverses direction after the pulse width value of t 1 - Y and before the pulse width value of t 1 + X. When this condition is detected, the algorithm does not distinguish the "tape eating" condition from normal operation. The algorithm is ineffective to detect "tape eating" when it occurs within this narrow time frame (K h ). The present invention may be practiced using an Intel 8085 microprocessor based SDK-85 development system and the Tanashin Denki model TN-555 auto-reverse cassette mechanism. The interface between the microprocessor and the cassette mechanism included a PNP transistor biased as a saturated switch and a 7407 TTL high voltage hex inverter. The transistor was used to interface the take-up spindle output signal of the Hall effect sensors in the cassette mechanism to the 8355 I/O/ROM input port of the Intel 8085 microprocessor. The 7407 hex inverter interfaced the 8355 I/O/ROM output port to the program direction change input of the cassette mechanism. Appendix A details a preferred software program which is written in Intel 8085 Assembly Language. A brief description of the major software routines is as follows: MAIN PROGRAM: Executes initialization process, calls the sub-routines, and updates measured pulse width values. DCHK SAMPLE SUB-ROUTINE: Takes samples of sensor output. COMPARE SUB-ROUTINE: Calculates range of pulse widths for normal operation and compares the sensor output with the calculated range. STOP/REVERSE CASSETTE SUB-ROUTINE: Sends control signal to the cassette mechanism to either stop or reverse the mechanism. The above description describes only a preferred embodiment and is to be interpreted in an illustrative sense and not in a restrictive sense. There are alternate embodiments which have not been specifically mentioned but which are obvious and intended to be included within the scope of the invention as defined by the following claims.

Claims: A tape player apparatus for playing a cassette tape cartridge having a magnetic tape (26) which is wound between a take-up reel (28) and a supply reel (22), the apparatus comprising: a drive motor; a take-up reel spindle (30) driven by the drive motor, the take-up reel spindle having a rotational frequency; a supply reel spindle (24); detecting means for providing a signal indicative of the rate of rotation of one of said reels; comparison means responsive to said detecting means for establishing whether the rate of rotation of one of said reels is outside the normal operating range and if so initiating braking of one of said reels; characterised by means (46,48) for sensing the rotational frequency of the take-up reel spindle (30), the sensing means (46,48) producing an output signal having a pulse width inversely proportional to the rotational frequency; means for measuring the pulse width of the output signal; means for comparing the pulse width of the output signal with a predetermined range of pulse widths, the predetermined range being incrementally adjustable in response to changes in the rotational frequency; means for interrupting the operation of the take-up reel spindle (30) in response to the pulse width falling outside of the predetermined range thereby denoting an aberrant tape condition. An apparatus as claimed in Claim 1, wherein the measuring means comprises a microprocessor control. An apparatus as claimed in Claim 1, wherein the comparing means comprises a microprocessor control using a comparison function defined by: t i - Y < t i+2 < t i + X for a normal operating condition and (t i+2 < t i - Y) or (t i+2 > t i + X) for an aberrant operating condition where t i is a first pulse width value, t i+2 is a second pulse width value occurring one period after the first pulse width value, X is a first constant which is related to the first pulse width value, Y is a second constant which is related to the first pulse width value. An apparatus as claimed in Claim 1, wherein the sensing means comprises: an actuator associated with the take-up reel spindle which rotates with the take-up reel spindle; and a sensor mounted on the apparatus, the sensor actuated by the actuator to produce an output signal. An apparatus as claimed in Claim 4, wherein the sensor comprises a reed switch. An apparatus as claimed in Claim 4, wherein the sensor comprises a Hall Effect sensing device. An apparatus as claimed in Claim 4, wherein the actuator is a disc having alternating magnetized segments. An apparatus as claimed in Claim 1, wherein the range of pulse widths is defined by: t i - Y < t i+2 < t i + X for a normal operating condition and (t i+2 < t i - Y) or (t i+2 > t i + X) for an aberrant operating condition where t i is a first pulse width value, t i+2 is a second pulse width value occurring one period after the first pulse width value, X is a first constant which is related to the first pulse width value, Y is a second constant which is related to the first pulse width value. A tape player for cassette tapes as claimed in any one of Claims 1 to 8 further comprising: a magnetized element associated with a take-up reel spindle of the cassette tape player which rotates with the take-up reel spindle; a sensor mounted on the cassette tape player, the sensor actuated by the magnetized element as the take-up reel spindle is rotated to produce a periodic output signal having a variable pulse width as tape is wound at a substantially constant rate onto the take-up reel, the pulse width being proportional to the diameter of the take-up reel, the take-up reel having a diameter which increases as tape accumulates thereon thereby gradually increasing the pulse width of the periodic output signal; a microprocessor control which receives the periodic output signal, compares the pulse width of the periodic output signal to the pulse width of a prior output signal plus a first time constant and compares the pulse width of the periodic output signal to the pulse width of the prior output signal minus a second time constant to determine whether the pulse width of the periodic output signal is within an acceptable range indicating normal operation, and generates a control signal when the duration of the period is greater than or less than the acceptable range indicating reverse rotation of the take-up reel.

Inventors: TARPLEY GERALD W JR, TARPLEY, GERALD W., JR.
Applicants: FORD MOTOR CO, FORD MOTOR COMPANY
Application year: 1993
Main classification: G11B15
IPC codes: G11B15