Abstract:
A stream of coins of mixed denominations is passed through a first station in which the mixed coins are counted and the stream of mixed coins is then sorted to segregate coins of a selected denomination from those of other denominations. The coins of the other denominations are deposited into a first vault chamber, and the coins of the selected denomination are deposited into a second vault chamber. A report of the value of the counted coins of all denomination is generated. At a processing station to which the vault chambers are transported, the coins of the selected denomination in the second vault chamber from repeated sorting operations by many users can be weighed to determine the total value thereof. Thus, only the coins of other denominations need to be counted and separated into denominations, thereby reducing the processing time, the wear on high speed counting and sorting apparatus, and the costs of coin processing.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to methods for processing mixed coins to determine the value thereof and, more particularly, to such methods in which mixed coins are segregated. 
     In recent years there have been developed machines which allow users to insert a large volume of mixed coinage and which process to coins to determine the total value thereof while counterfeits, mutilated coins and foreign coins are rejected and returned to the user. The user receives a printout indicating the total value of the coins which have been accepted, and this slip can be presented to a cashier in the supermarket or other facility where the processing machine is located for redemption in U.S. currency. 
     The coins which are received in the processing unit are generally stored in mixed condition in a vault within the processing unit. Periodically, the vault is removed and taken to another site for further processing such as an armored car carrier&#39;s facility or a bank vault. At that facility, the large volume of coins which have now been collected is sorted and valued in high speed counting and sorting equipment. 
     It is known that the pennies comprise by far the largest volume of the coins which are passed through such coin processing facilities. It is further known that the processing of mixed coins in high speed counting and sorting equipment produces substantial wear and tear on the equipment, and this is a factor in the service charge which the initial user incurs in his or hers processing of the mixed coinage. 
     It is an object of the present invention to provide a novel method for processing mixed coinage in which the coins of the denomination constituting the largest volume can be segregated, separately stored and ultimately separately processed at the final processing location. 
     It is also an object to provide such a coin processing method in which the sorting and counting of the coins at the final processing facility can be performed expeditiously to reduce the cost and time required for processing such coins. 
     Another object is to provide a novel coin processing apparatus which segregates the coin denomination of largest volume to facilitate further processing. 
     A further object is to provide such coin processing apparatus which may be simply and economically fabricated and in which the coins are stored in a removable vault which may be readily transported. 
     A still further object is to provide such coin processing apparatus in which the vault in which the coins are stored enables ready removal of the mixed coins and determination of the segregated denomination is effected by weighing of the vault with that denomination of coins remaining therein. 
     SUMMARY OF THE INVENTION 
     It has now been found that the foregoing and related objects may be readily attained in a method for counting coins of mixed denominations and segregating coins of a single denomination from those of other denominations, in which a stream of coins of mixed denominations is passed through a first station in which all coins are counted to determine the total value thereof. The stream of mixed coins is sorted to segregate coins of a selected denomination from coins of other denominations, and the coins of other denominations are deposited into a first vault chamber. The segregated coins of the selected denomination are deposited into a second vault chamber and a valuation of the counted coins is provided. 
     Usually, the method involves a further step of weighing the segregated coins of the selected denomination in the second vault chamber after multiple customer transactions to determine the total value thereof. Usually, the coins are United States coinage and the selected denomination is a penny, and the sorting step removes the coins in the mixed stream by denomination with any dimes in the stream being channeled to the stream of mixed coins which are of denomination larger than pennies. 
     Generally, the coin sorting step offsorts the segregated coins of the selected denomination from the stream of coins exiting the counting step into the second vault chamber, while the stream of the remaining coins is directed into the first vault chamber. The counting step also removes from the stream of mixed coins foreign, mutilated and counterfeit coins, and the removed coins are separately discharged. 
     The vault chambers may be separable, and the method will include the step of weighing the second vault chamber with the selected coins therein to determine its weight and thereby the total value of the coins of the selected denomination. 
     This will usually take place at a processing station and the method includes the steps of periodically transporting the vault chambers with the coins therein to a processing center and weighing the segregated coins in the second chamber to determine the value thereof. Preferably, the vault chambers are formed in a single vault and the method includes the step of removing the mixed coins from the first chamber and weighing the vault thereafter. At the processing center, the mixed coins are removed from the first chamber and the mixed coins are counted and sorted. 
     A coin processor for counting coins of mixed denominations and segregating coins of a selected denomination from those of other denominations comprises a housing having an upper portion and a lower portion providing a vault receiving chamber. A vault is removably seated in the vault receiving chamber and provides a first coin receiving chamber and a second coin receiving chamber. In the upper portion of the housing is a coin counter for receiving coins of mixed denominations and counting all coins. A coin sorter is also provided in the upper portion for segregating a stream of mixed coins exiting the counter into a stream of coins of a selected denomination and a stream of coins of other mixed denominations. A first conduit for the stream of coins of other mixed denominations extends to the first chamber in the vault, and a second conduit for the stream of coins of the selected denomination extends to the second chamber in the vault. The processor also includes indicia providing means for displaying the total value of the counted coins. 
     In one embodiment, the first chamber is removable from the vault and the vault has a door to access the first chamber and which may be locked for security. In another embodiment, the vault has separate discharge ports for each of the chambers through which the coins therein may be separately discharged. 
     Preferably, the coin sorter includes a channel for a stream of coins and means along the channel for segregating the coins of the selected denomination. When the coins to be sorted are those of the United States and the selected denomination being a penny, the sorter includes means for combining dimes with the stream of larger diameter coins. 
     Desirably, the counter includes means for removing foreign, counterfeit and mutilated coins and a discharge chute for the removed coins. Conveniently, the indicia providing means is a printer. The housing has an opening therein, an access door closing the opening through which the vault may be removed, and means for locking the access door. The vault desirably includes wheels on which the vault may be moved and an engageable element which can be engaged to remove it from the housing. The vault may also have recesses in its bottom end for seating the forks of a fork lift to move the vault at the processing center. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front perspective view of a coin processing unit embodying the present invention; 
     FIG. 2 is a front perspective view of the coin processing unit with the front panel opened; 
     FIG. 3 is a perspective view of the coin processing unit with the processing mechanism support slid outwardly; 
     FIG. 4 is a perspective view of the coin processing unit with the vault moved outwardly thereof by a dolly; 
     FIG. 5 is a perspective view of the vault and dolly with the vault cover in place; 
     FIG. 6 is a perspective view of the vault with the cover pivoted open and with coins disposed therein; 
     FIG. 7 is a perspective view of the vault with the cover open and showing the mixed coin insert with its handles pivoted upwardly for removal from the vault; 
     FIG. 8 is a perspective view of the coin insert being lifted by a fork lift; 
     FIG. 9 is a perspective view of the vault being transported on a fork lift truck; 
     FIG. 10 is an enlarged fragmentary perspective bottom view of the bottom of the vault on the fork lift; 
     FIG. 11 is a perspective view of the vault supported above a receptacle into which the pennies are being transferred; 
     FIG. 12 is a perspective view of the mixed coins being drained from the vault insert into a receptacle; 
     FIG. 13 is a diagrammatic front view of the coin vault; 
     FIG. 14 is a diagrammatic top view of the vault of FIG. 13; 
     FIG. 15 is a diagrammatic top view of a preferred vault construction with the cover removed; 
     FIG. 16 is a diagrammatic front view of the vault of FIG. 15; 
     FIG. 17 is a diagrammatic view of the coin processing apparatus; 
     FIG. 18 is a perspective view of the coin processing apparatus; 
     FIGS. 19 a  and  19   b  together comprise a diagrammatic flow chart of the operations at the coin processing facility; and 
     FIG. 20 is a diagrammatic view of the coin processing apparatus using a now preferred pick off sequence for the coins. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Turning first to FIG. 1, therein illustrated is a coin processing unit embodying the present invention. The housing generally designated by the numeral  10  has an access door  12  with a key lock  14 . The top wall  16  has a hopper  18  into which mixed coins are introduced for processing. On the rear panel  20  is a display screen  24  and a slot  22  through which a printed record is discharged. Also on the panel  20  are start and printer buttons  19  and  21 . When the key lock  23  is released, the panel  20  may be pivoted downwardly to enable servicing of the printer (not seen) and other components on or behind the panel  20 . In the access door  12  is a reject chute  26  into which foreign, mutilated and counterfeit coins are discharged. 
     Turning next to FIGS. 2 and 3, opening of the door  12  allows access to the vault generally designated by the numeral  36 . Mounted on the slide base  38  are the coin counter generally designated by the numeral  28  and the coin sorting rail  30  which receives the coins from the counter  28 . Coins from the hopper  18  are conveyed by a conveyor belt (not shown) to the counter  28 . 
     As the coins exiting the counter  28  pass along the rail  30 , coins other than pennies are diverted into the chute  34  and the pennies are diverted into the penny chute  32 . Coins rejected by the counter  28  are diverted into the reject chute  26 . 
     As seen in FIG. 3, the slide base  38  can be pulled outwardly of the housing  10  for servicing the counter  28 , rail  30  and other components. 
     Turning next to FIGS. 4 and 5, the vault  36  can be seen to have wheels  56  on its inner end, and it can be engaged and moved outwardly of the housing  10  by a dolly generally designated by the numeral  44  which has a projecting arm  48  which will slide between channel members  46  on the bottom of the vault  36 . Adjacent the end of the arm  48  is an upstanding pin (not shown) which will seat in an aperture in the bottom wall of the vault  36 . As seen in FIG. 4, depending from the slide base  38  are a penny discharge  40  and a mixed coin discharge  42  which are aligned with the penny feed port  72  and mixed coin feed port  70  in the cover  68  of the vault  36 . 
     The dolly  44  has a frame  50  on which wheels  54  are mounted and a handle  52  by which the dolly  44  and vault  36  may be tilted to lift the outer end of the vault for movement on the wheels  54  and  56 . 
     As seen in FIG. 5, the cover  68  has an opening therein through which a latch ear  69  extends. A lock (not shown) is secured in the latch ear  69  to lock the cover  68  closed both when in the coin processor and for transport. 
     As seen in FIG. 6, the cover  68  of the vault  36  may be pivoted into an open position for access to the interior which includes the penny vault chamber  60  and the mixed coin insert  62 . The cover  68  has an aperture  76  for the mixed coins which registers with the mixed diverter  70  which diverts the mixed coins into the mixed coin insert  62 . The cover  68  also has the penny feed port  72 . In FIG. 6, mixed coins  66  are shown in the insert  62  and pennies  64  are shown in the vault chamber  60 . 
     In this embodiment of vault  36 , after pivoting the cover  68  into the open position at the processing facility, a pair of handles  74  on the mixed coin insert  62  may be pivoted upwardly to allow the insert to be lifted upwardly from the vault  36 , as seen in FIG.  7 . As seen in FIG. 8, these handles  74  are dimensioned to seat on a fork  80  of a fork lift generally designated by the numeral  78 , thus facilitating movement of the insert  62  at the processing facility. 
     As seen in FIG. 9, the entire vault  36  can be moved easily by supporting it on the forks  80  of the fork lift  78 . The forks  80  seat between the channel members  46  on the bottom wall. 
     Turning next to FIGS. 10 and 11, the pennies can be discharged from the chamber  60  through a pivotally mounted drain door  84  on the bottom wall  82  which is held normally closed by the slide bolt  86 . This drain door  84  and bolt  86  are protected with a channel member  87 . When the vault  36  is elevated by the fork lift  78 , the drain door  84  can be opened to discharge the pennies into a container  90 . 
     As seen in FIG. 12, the mixed coin insert  62  can be emptied at the processing facility by sliding the drain door  94  upwardly to unblock the drain opening  92 . The coins flow therethrough and are collected in the container  98 . Also clearly seen in this view is the diverter chute  70  which laterally offsets the flow of mixed coins passing through the aperture  76  in the cover  68 . When the insert  62  is in the vault  36 , the drain door  94  is held in position by the cover  68 . 
     The construction of the vault  36  is diagrammatically illustrated in FIGS. 13 and 14. As illustrated in broken line the bottom of the vault chamber  60  has walls which slope towards the drain door  84  to provide a funnel  102 . The aperture  100  in the bottom wall for engagement of the pin on the dolly  44  is in an area near the front wall of the vault and below the funnel  102 . 
     FIGS. 15 and 16 diagrammatically illustrate another vault  36   a  which has a penny vault chamber  60   a  and a fixed mixed coin chamber  104   a  which has a drain door  94   a  in the side wall of the vault  36   a.  In this embodiment, the penny feed port  72   a  and mixed coin diverter  70   a  are adjacent the center of the vault  36   a,  and the chutes (not shown) from the rail  30  are reoriented to feed thereinto. 
     FIG. 17 diagrammatically illustrates the counter and rail assembly and FIG. 18 illustrates the actual structure. Mixed coins in the receptacle  106  are picked up on the side surface of the rotating disc  108  which delivers them one at a time to the rail  30 . As the coins roll down the rail  30 , they pass by the alloy sensor  110  which determines their denomination and sends a signal to the counter mechanism (not shown). As the coins proceed further down the rail  30 , dimes are diverted at the dime window  112 , and coins other than pennies are picked off at the large coin pick off  114  and dropped into the mixed coin chute  34  along with the dimes. The pennies continue to the penny pick off  116  where they are dropped into the penny chute  32 . Coins rejected by the alloy sensor  110  are diverted to the reject chute  26 . 
     In the method using the coin processor of the present invention, the user pours the coins of mixed denomination into the hopper  18  and presses the “start” button  19 . The coins are picked up by the rotating disk  108  from the receptacle  106  and it feeds them one at a time onto the inclined rail  30 . As they pass the alloy sensor  110 , the denomination of the coins is noted and appropriate signals are registered in the counting unit (not shown); mutilated, foreign and counterfeit coins are directed into the reject chute  26  from which they can be recovered. 
     As the coins proceed down the rail  30 , dimes (which are smaller in diameter than pennies) fall through the dime window  112  and into the other coin chute  34 . At the large coin pickoff  114 , nickels, quarters, half dollars and dollars are directed into the other coin shute  34 . Finally, at the bottom of rail  30 , the pennies are directed into the penny chute  32  and flow into the penny vault chamber  60 . The other coins flow into the mixed coin insert  62  (or mixed coin vault chamber  104 ). 
     After all of the coins in the hopper  18  have been processed, the printer button  21  lights and is enabled. The user presses the printer button  21  and receives a printout from the printer output slot  22  and a visual image on the display  26 . The user can take the printout to the cashier to receive paper currency (and coins). 
     As is customary, there is a service charge for use of the processor and the computer program calculates the charge and deducts it from the value of the coins processed. The printout includes the several values. 
     After several days (the period may be based upon past experience, or upon a customers call, or as a result of a call from the store where the processor is located), the driver of an armored car service or coin processor operation company opens the access door  12  and inserts the projecting arm  48  of the dolly  44  into the vault  36  and withdraws it from the housing  10 . A lock (not shown) is inserted through the latch ear  69  on the top of the vault  36 , and the vault  36  is then rolled to the rear lift gate of a vehicle (not shown), elevated on the gate, and rolled into the vehicle interior. 
     At the processing facility (usually an armored car facility or bank vault), the vault  36  is removed from the vehicle and moved to a first processing point, usually by a fork lift  78 . The mixed coins are removed either by removing the insert  62  or by draining them through the drain opening  92 . The vault  36  is transported to a second processing point where it is weighed. The difference between this weight and the tare weight of the vault is utilized to determine the total value of the pennies. 
     The coins of other denominations are introduced into a high speed coin counter/sorter which both determines the total value thereof and segregates the coins into their individual denomination. 
     FIG. 19 is a flow chart showing various steps at the processing facility. 
     Because of some intermittent jamming problems which have been encountered in using the dime window to off sort the dimes at an initial station, it is presently considered preferable to off sort the dimes at the last station since the dime is the smallest coin. FIG. 20 diagrammatically illustrates a modification of a conventional off sorting rail  30   b  which initially off sorts the dollar, half dollar, quarter and nickels at a single pick off point  118 , the pennies at the next pick off point  120 , and the dimes at the last pick off point  122 . The existing nickel chute  124  is used for all of the larger coins from the pick off point  118 , the penny chute  126  is still used for the pennies, and a diverter chute  128  carries the dimes to the former nickel chute  124 . Except as modified above, the operations are the same. 
     Although the foregoing description and drawings are directed to United States coinage, the apparatus and method can be adapted to the coinage of other countries by modification of the sorting section of the counter mechanism. 
     Readily available coin counting and sorting machines may be quickly adapted to the present invention, usually by modifying the sorter rail and chutes. Among such counter/sorters are those of CT Coin A/S of Odense, Denmark; Scan/Coin, Malnio, Sweden; and F. Zimmermann of Berlin, Germany. 
     Thus, the penny separator feature allows only the penny be separated while all other denominations are captured mixed. Since the penny is the predominant coin denomination in such processing, isolating it from the other coins allows for the implementation of alternative, and more efficient, processing methods in balancing the contents of the self-service coin machine itself. 
     Operation of the heretofore available coin processing devices either sorts the coins by diameter into separate containers for each coin, or the coins are counted and output as mixed coin into a single container for subsequent processing. Since the penny is in between the size of the United States dime and nickel in terms of its diameter, separating it without separating the other coins requires a unique approach to the sorting process itself. 
     The second consideration in separating the penny from the other denominations is in the container design itself, the coin receiving vault. The coin vault actually receives the coin that has been processed and counted by the self-service coin machine. Traditionally, these units contain only one section for receiving coin as all denominations are mixed together. In this processing method, the coins are actually sorted by denomination later when the vault contents are balanced, normally by an armored carrier or bank vault. Some self-service coin machines actually sort and count all denominations within the self-service unit itself. In such cases, the coins are received into bags, not a coin vault. The novel approach of the present invention to sorting the penny from the other denominations requires a coin vault with separate receiving sections for the penny and the rest of the coins as hereinbefore described. 
     Separating the penny from the other denominations in self-service coin processing gives us an outstanding advantage in coin vault balancing as the pennies, which normally constitute up to 75 percent of the coins received, can be processed in bulk rather than counted by the piece and sorted along with the other coins. This saves the processor, or the party bearing the expense of processing, significant time and expense over piece counting and sorting the entire contents of the coin vault. Costs reductions and processing charges can be reduced by up to 60 percent with the penny separator feature. 
     These savings are based on labor savings in the central processing site such as: 
     Less time to transport the vaults within the central site facility because they are fork lift compatible. 
     Less time to sort the coins on the high-speed sorter because only the nickel, dime, quarter, half dollar and dollar coins are sorted. This reduces piece volume by 60 to 75 percent, and has a direct relationship to labor savings. 
     There are also other financial savings including: 
     There is also reduction in wear and tear on the high-speed sorter itself directly comparable to the reduction in processing volume. This is significant in that the charges for maintenance on that device are normally passed on to the customer, and they are in addition to the processing charges. 
     Because the central site processing takes less time with the penny separation method as compared to alternate methods, there are fewer processing “bottlenecks” at the high-speed sorting station. The traditional method normally results in a significant processing backlog of coin vaults waiting for processing. This means that the coin vaults backlogged in the staging area are not available for redeployment until they are emptied of their contents and additional vaults must be purchased by the owner of the self-service machines to accommodate. 
     In addition to much faster processing, the penny separator vault offers an additional feature to reduce the problems associated with high-speed sorting backlogs. The mixed coin is captured in the vault in a mixed coin insert in one embodiment. In a backlog situation, it can be removed from the vault, placed in the staging area, and secured with its own locking cover. This way the pennies can be processed in bulk by weight. The vault then can be quickly emptied of all contents, and it can be immediately redeployed. With the penny separator vault, there is a reduced need to buy larger numbers of extra coin vaults only to have them collect in a staging area. Only the relatively inexpensive mixed coin inserts remain in staging and to a much lesser extent than with traditional processing methods. 
     Thus, it can be seen from the foregoing detailed description and accompanying illustrations that the coin processor of the present invention enables facile and relatively lower cost processing of mixed coins by segregation of the coin which comprises the largest percentage of such coins. Wear and tear on the high-speed sorters can be reduced, and processing of the segregated coinage enables various efficient options in workflow at the bank or armored car vault.