Abstract:
A coin recycling machine ( 10 ) for receiving, sorting and dispensing coins, comprising a coin dispenser having a rotatable coin magazine ( 23 ) for holding respective denominations of coins and having an electronic control ( 100, 107 ), said electronic control ( 100, 107 ) being operable in response to a commanded total to control position of said coin magazine ( 23 ) to selectively dispense coins to provide the commanded total, a queuing device ( 52 ) for receiving the coins and arranging the coins in a queue, the queuing device ( 52 ) having an exit ( 66 ) directed towards said coin magazine ( 23 ) and having associated sensors ( 65, 72 ) for identifying a denomination of a next coin to pass through the exit ( 66 ) and the electronic control being responsive to the sensors ( 65, 72 ) associated with the queuing device for positioning the coin magazine such that coins are sorted into the coin magazine ( 23 ) by denomination as the coins exit the queuing device ( 52 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   The benefit of priority is claimed for this application based on U.S. Provisional Appl. No. 60/407,437, filed Aug. 29, 2002. 

   BACKGROUND OF THE INVENTION 
   The invention relates to coin dispensers, and in particular to coin dispensers of the type for dispensing change. Such coin change dispensers are found, for example, at cashier checkout locations and ticket booths and many other places. 
   Perhaps the best known type of coin change dispenser has an in-line configuration in which a plurality of generally upright coin holding tubes are aligned in a row. Examples of such coin change dispensers are shown, for example, in Walton, U.S. Pat. No. 3,590,833 and Duplessy, U.S. Pat. No. 4,593,709. 
   Such dispensers are assembled from numerous small, mechanical parts requiring many machining operations during manufacture, especially the parts of the coin ejector mechanisms. A coin dispenser having nine coin tubes would typically provide nine coin ejector mechanisms and each of these would include many small parts. 
   An additional problem in the art is the need to replenish the dispenser during the work shift. This requires reloading coinage and performing cash settlement operations in a back room to account for the coinage being dispensed and the coinage being received at a cash register. 
   Several patent documents have disclosed machines to receive, sort and dispense coins. In a published European patent application EP 0 137 637 published Apr. 17, 1985, coins are sorted into four tubes, from which coins may be dispensed. Generally, this is a large apparatus, resembling the in-line coin dispensers described above, and further having a ramp of complex design and many additional mechanical parts. Four tubes are disclosed for sorting and dispensing of more than four denominations. To handle additional denominations, more coin tubes and still more internal parts would have to be included. 
   On the other hand, there are some lightweight devices which combine sorting and dispensing as disclosed in U.S. Pat. No. 5,106,337 and U.S. Des. Pat. No. 324,600. It appears that these devices would not handle the full coin set of any country without being enlarged. It is not clear that they would work well with a larger number of coin tubes or withstand heavy commercial use. 
   There is a need for a coin recycling dispenser that would receive, sort and dispense coins for a full coin set in busy cash handling locations. For global marketability, such a machine should be adaptable to the coin sets of many countries. Such a unit should have a relatively simple construction, and provide a lower manufacturing cost, and also be relatively compact in size. 
   SUMMARY OF THE INVENTION 
   The invention provides a coin recycling machine and method for receiving, sorting and dispensing coins for a plurality of denominations. 
   The coin recycling comprises a coin dispenser having a rotatable coin magazine for holding respective denominations of coins and having an electronic control that is operable in response to a commanded total to control position of the coin magazine to selectively dispense coins to provide the commanded total. A queuing device is provided for receiving the coins and arranging the coins in a single file. The queuing device has an exit directed towards the coin magazine and associated sensors are provided for identifying a denomination of a next coin to pass through the exit. The electronic control is responsive to the sensors associated with the queuing device for positioning the coin magazine such that coins are sorted into the coin magazine by denomination as the coins exit the queuing device. From there, the coins are dispensed from the coin magazine in a dispensing operation. 
   A general object of the invention is to provide a compact machine for recycling coins received from customers, so that they can be dispensed as change. This reduces the amount of time that cashiers or other employees need to perform cash settlement transactions in a back room, where new coins are received and monies are accounted for. As in other recycling operations, maximum efficiency is realized by better utilizing the cash resources available. 
   Another object of the invention is to provide a sorting device which can be assembled with an electronic rotary coin dispenser. In this combination, coins are sorted into a coin magazine from which they are also dispensed. 
   Another object of the invention is provide a minimum number of parts, thereby reducing costs when the dispenser is manufactured in significant volume. 
   One advantage of the invention is that it is easily adaptable to different national coin sets and to different change capacities, such as 
   0.99 and 
   4.99. One coin recycling machine could be used with different magazines, including magazines with coins from different countries. The machine is operable with different magazines through programmable electronic control. 
   The coin recycling dispenser of the invention can be used in many applications. For example, the coin dispenser can be used to dispense change at the checkout counter of a grocery store or a convenience store, or at the cashier of a restaurant. The coin dispenser can be provided as part of a system that provides change in exchange for paper currency, or it can be provided in tandem with a currency dispenser, for example, as part of an ATM. It also could be part of a point-of-sale terminal. 

   
     Other objects and advantages of the invention, besides those discussed above, will be apparent to those of ordinary skill in the art from the description of the preferred embodiments which follow. In the description, reference is made to the accompanying drawings, which form a part hereof, and which illustrate examples of the invention. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a coin recycling machine according to one embodiment of the invention; 
       FIG. 2  is an exploded side view in elevation of the coin recycling machine of  FIG. 1  with the cover removed; 
       FIG. 3  is a perspective view of a coin dispensing portion of the coin recycling machine seen in  FIGS. 1 and 2 ; 
       FIG. 4  is a side view in elevation of the machine seen in  FIGS. 1 and 2 ; 
       FIG. 5  is a top plan view of the coin queuing subassembly of the machine of  FIGS. 1 ,  2  and  4 ; 
       FIG. 6  is a second top plan view of the queuing assembly of  FIG. 5  with parts shown in phantom; 
       FIG. 7  is a block diagram of the electronic control included in the machine of  FIGS. 1-6 ; and 
       FIGS. 8   a  and  8   b  are flow charts of the operation of the coin recycling machine of  FIGS. 1-7 . 
   

   DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
   A preferred embodiment of a coin recycling machine  10  according to the present invention is illustrated in  FIGS. 1-8   b . As shown in  FIGS. 1 and 2 , the coin recycling machine  10  includes an outer, generally cylindrical cover  11  that is attached to a base  12 . The cover  11  can be opaque or transparent or can include a transparent part. The cover  11  can be locked to the base  12  to prevent access to the interior of the coin dispenser  10 . The base  12  is a molded plastic part with an integrally molded coin cup  13  and a coin dispensing channel  14  leading into the coin cup  13 . As an alternative, the cup  13  can be provided as a separate piece and mounted to the base  12  or other types of coin chutes or ramps can be used to transfer coins to a receptacle or device. A hopper  15  is provided in the top of the cover  11  for accepting coins into the machine  10 . 
     FIG. 2  shows an exploded view of the internal parts of the machine  10  with the cover  11  removed. The upper assembly is a queuing device  52 . The middle assembly is a coin magazine assembly cover  30  and manifold  31 . And, the lower assembly is an assembly of the coin magazine  23  and the base  12 . 
   As seen in  FIG. 3 , the coin magazine  23  is formed with a plurality of upstanding coin channels  24 , in this example, numbering twelve. As seen in  FIG. 1 , the coin channels  24  are empty, to allow a view of the underlying structure, however, in use, these channels  24  would hold stacks of coins, each channel  24  being dedicated to a corresponding denomination. It may be also be advantageous to have more than one stack coins for certain denominations, such as dimes for example, in making 
   0.99 change for one U.S. dollar. 
   The coin magazine  23  is mounted on a base  12  for rotation in a counterclockwise direction. As it rotates to move the coins along a circular coin path, a single coin ejector  80  is repeatedly operated to eject coins from the bottom of the coin channels  24  into the coin dispensing channel  14  and then into a cup  13 . 
   For details of the assembly of the coin magazine  23  to a base member  60 , and the operation of the coin magazine  23  and coin ejector  80  to dispense coins from the coin magazine  23  in response to a commanded total, reference is made to Adams et al., U.S. patent application Ser. No. 09/994,415, filed Nov. 27, 2001, and entitled “Electronically-Controlled Rotary Coin Change Dispenser,” the specification of which is hereby incorporated by reference. 
   As seen in  FIG. 3 , the coin magazine  23  is assembled with a ring-shaped magazine base member  60 . Both components are integrally molded from a high durability plastic material or can be made of metal. The coin magazine  23  is generally cylindrical in shape and forms a plurality of longitudinally extending coin-holding channels  24  around its periphery, with coin exit openings  24   b  through its outer surface. Each channel  24  has a sidewall  24   a  seen in a C-shape in cross section with an opening  24   b  in the channel sidewall  24   a  facing to the outside of the magazine  23 . The diameter of each channel  24  varies according to the denomination of coins it will hold. The channel openings  24   b  face in a rearward-looking direction in relation to the counterclockwise direction of rotation of the magazine  23 . 
   The coin magazine  23  is formed with channels having a taper of not greater than 0.2 degrees, having a plurality of circumferentially spaced, zero taper ribs  24   f  ( FIG. 3 ) running up inner sidewall surfaces  24   a  of the channels  24  for securely holding the coins, with the ribs  24   f  terminating a spaced distance from a top opening of the channels  24  to provide a slightly angled funnel  24   g  to allow for easier loading of coins. Normally, in molding a part such as the magazine  23 , the walls  24   a  of the channels  24  would be provided with some taper for molding purposes. That has been minimized in this construction. 
   On the bottom of the base member  60  are markers (not seen) corresponding to the respective channels  24 . These markers are of slightly differing length according to the diameter of their corresponding channel  24 . The markers are displaced by an angle in advance of their corresponding channels  24  so as to be sensed by the position sensors  45 ,  46  (represented schematically in  FIG. 7 ) in advance of the channel  24  reaching either the coin ejector  80  or the home/low coin sensing station  50  ( FIGS. 3 ,  7 ). The channel sync sensor  45  that cooperates with coin ejector  80  is positioned eighteen degrees in advance of the ejector  80  ( FIG. 3 ). The low coin sync sensor  46  that cooperates with a low coin sensor  51  in the home station  50  is positioned ten degrees in advance of the home station  50 . This means that the marker for the first channel is angularly displaced from the first channel approximately ten degrees so as not to encounter the sensors  45 ,  46  before the first channel is opposite either the beginning of the ejector  80  or opposite the low coin sensing/home station  50 . 
   The base member  60  also includes square posts  64  ( FIG. 3 ) that project upward from a top of the member  60  to be received in the slots  24   c  in the channel sidewalls  24   a  to be described. When the magazine base  60  is assembled to the magazine  23 , the square posts  64  fit into the slots  24   c  in the magazine  23  to locate the magazine base member  60  at the proper rotational position in relation to the magazine  23 . Bolts (not shown) are inserted through the magazine base  60  into the magazine  23 . 
   The magazine base member  60  forms partial floors  61  for each channel  24  which are separated by barrier projections  62 . When assembled with the magazine  23  ( FIG. 3 ), this member  60  forms an arcuate slot  63  for each channel  24  for receiving a pin  81  of a coin ejector  80 . The slots  63  are formed along a circular coin path followed by the stacks of coins as the magazine  23  is rotated. 
   The magazine  23  also forms the upright slots  24   c  that are located a short distance above the floors  24   d  in the bottom of each channel  24 . These slots  24   c  receive the posts  64  of the base member  60 , but have an open portion above that which forms a window  24   e  ( FIG. 3 ) for marking a low level of coins. A signal is transmitted through such a window  24   e  when the channel  24  is opposite the home station  50 . The home station  50  houses an emitter for the home/low coin sync sensor  51  represented schematically in  FIG. 7 . If the signal (logic “ 1 ”) is detected by the home station detector (positioned within the magazine  23 ) when a channel  24  has its window  24   e  aligned with the home station  50 , it means that the coin level is low, because it means the signal path is unobstructed by coins in the channel  24 . The use of one sensor  51  for both low coin and home position functions allows verification of the circuitry during each dispense cycle. 
   The ejector  80  is a single mechanism located at a single location along the circular coin path. The actuation of a solenoid (not shown) will cause a pin  81  to move vertically upward through slot  63  ( FIG. 3 ) such that it will contact the edge surface of the lowermost coin in that receptacle  24 . The pin  81  engages the coin at a point approximately midway between the opposite portions of the sidewall  24   a  of the channel  24 . This will push the coin out of the channel  24 , through the dispensing channel  14  and into the change cup  13 . The solenoid is then de-energized and the force provided by a return spring will move the pin  81  vertically downward to its starting position. If the pin  81  does not fully retract, the pin  81  will be urged downward by a bottom surface of the magazine  23 . The pin  81  will not engage the lowermost coin in a next channel unless the solenoid  82  is energized again. The coin ejection pin  81  moves linearly in a direction substantially parallel to the (vertical) rotation axis of the magazine  23  between an extended position and a retracted position. 
     FIGS. 5 and 6  show a top plan view of a queuing device  52 . This device  52  includes a body  52   a  and a first rotatable disc  53  mounted in the body  52   a  for receiving coins  16  from the hopper  15 . Coins  16  follow a coin path  57  in a clockwise direction until reaching a point at which an overlapping drive disc  55  with radial fingers  56  pushes the coin onto a stationary exit member  54  also mounted in the body  52   a , where the coin path  57  continues in a counterclockwise direction. A coin point  67  is provided over the first disc  53 . This tends to separate stacked coins and allow only one layer of coins to move around the disc  53  so that a single file or queue is formed where the coins  16  are picked up by drive member  55 . 
   The exit member  54  has an exit aperture  66  at about 9 o&#39;clock as seen in  FIGS. 5 and 6 . The coins  16  proceed around the exit member  54 , passing over a coin size sensor  65  and then passing through the exit aperture  66 . The coins are contained on the exit member by protruding arcuate ridges  58 ,  59 . Slots  68  receive tabs on a rim which is flexed to curve around the outside edge of the exit member  54 , where it provides an outside reference edge for coins traveling around the member  54 . Size sensor  65  measures the diameter of the coin from the smallest to the largest, and is offset from the reference edge by a distance less than the diameter of the smallest anticipated coin to be measured for size. The size sensor  65  is typically a linear array of optical elements which sense the coin by sensing shadow from the coin passing over it. Within the exit aperture  66  is a coin transfer sensor  72  represented schematically in  FIG. 7 . As seen in  FIG. 6 , both discs  53  and  55  are driven by a common belt  69  which transfers power from the feeder drive motor  33 , which is coupled to a shaft driving the drive disc  55 . A pulley  70  is provided at the other end of the belt  69  for supporting the belt  69 . 
   The feed drive motor  33  ( FIG. 7 ) is started when coins are sensed on the first disc  53  through the coin present sensor  71  ( FIG. 7 ). The feed drive motor  33  moves the coins a distance along coin path  57  until coin size is measured at size sensor  65 . The feed drive motor  33  will then be stopped and some checks performed (including positioning the coin magazine, if necessary) before causing the coin to be pushed through aperture  66 , where its passage is sensed for counting purposes by a coin transfer sensor  72  ( FIG. 7 ). 
   It can be further seen that the queuing device  52  moves the coins along a path disposed above the coin magazine  23  and disposed substantially parallel to a supporting surface for the coin recycling machine  10 . The coins are moved along a path substantially perpendicular to the axis of rotation for the coin magazine  23 . 
     FIG. 7  shows the electronic controls for the dispenser  10 . A main processor and control circuit board  100  ( FIG. 7 ) is mounted in the base  12  of the machine  10  seen in  FIGS. 1 and 2  and is connected to an RS-232 communication cable  101 . Also mounted in the base  12  is an auxiliary interface circuit board  102 , which is connected to an auxiliary interface cable  103 . The auxiliary interface circuit board  102  provides alternative and enhanced capabilities to the electronic system to increase the machine versatility. It is a plug-in “daughter board” to the main processor and control circuit board  100 . It can incorporate a flash memory for firmware program changes. 
   A power supply  104  ( FIG. 7 ) is provided in a package similar to a battery-charging adapter for a notebook computer. The power supply  104  receives 120-volt AC power through a power cord  105  and supplies 12-volt DC power to the main processor board through a cover interlock switch  106 . When the cover  11  is open, the interlock switch  106  is open to disconnect power to the coin recycling machine  10 . 
   The main processor board  100  connects to the ejector solenoid  80 , to the magazine drive motor  32 , to a “channel sync” position sensor  45  for synchronizing the position of a selected channel to the coin ejector  80 , a “low coin sync” position sensor  46  for synchronizing the position of a selected channel to the home position/low coin sensor  51 , which is also connected to the main processor board  100 , and to the coin exit sensor  48 . 
   Whenever AC input power is applied to the 12-volt DC power supply  104  or whenever the cover  11  is closed to lock the cover interlock switch  106 , twelve DC volts are supplied to the main processor board  100 . As a result the main processor executes an initialization routine to rotate the magazine  23  to the home position, stopping after a predetermined delay following detection of the home position and loading memory locations on the main processor board  100  with values representing magazine coin channels  24  with full stacks of coins. The delay is determined so as to ensure that the magazine  23  stops in a position that will allow it to be accelerated to the operational speed just prior to reaching the “home” position during an actual dispense cycle. This position is defined as the “pre-accelerate” position. 
   Also seen in  FIG. 7  is the feeder processor board  107  and sensors  65 ,  71 ,  72  and  73 . The functions of sensors  65 ,  71  and  72  were explained previously. The alignment sensor  73  senses alignment of the exit aperture  66  with a particular channel  24  of the coin magazine  23 . 
   As seen in  FIGS. 8   a  and  8   b , which provide flow charts of the operation of the machine  10  under the control of the main processor board  100 , after power-up, the machine  10  will be initialized and then enter a ready mode for processing coin as represented by start block  80 . The main processor will test for a dispense request (a commanded total) as represented by decision block  81 . In the event there is no such request, as represented by the “NO” branch from decision block  81 , it will loop back and test again on a periodic basis. 
   Assuming that a dispense request (a commanded total) is received, as represented by the “YES” result, then the processor will test for sufficient coin levels to provide the total amount of coin requested as represented by decision block  82 . If the coin level is suitable, as represented by the “YES” result, then the processor will process the dispense request by operating the dispenser as described in U.S. patent application Ser. No. 09/994,415, cited above, as represented by process block  83 . If the coin level is insufficient, as represented by the “NO” result from decision block  82 , then the processor will cause a prompt to be displayed to the user to feed sufficient coins of a denomination “X” into the hopper  15  seen in  FIG. 1 . The processor will then sense through the coin present sensor  71  that the coins have been fed into the machine, by checking the sensor  71  as represented by decision block  85 . Where a new coin of the identified denomination “X” is detected by the coin size sensor  65 , the main processor will execute program instructions to energize the motor  32  and rotate the coin magazine  23  so that the coin channel for denomination “X” is aligned with the coin exit  66  from the exit member  54 . After each power movement, a check is made for proper alignment of the coin channel by using the alignment sensor  73 , and this is represented by decision block  87 . If the alignment is satisfactory the routine proceeds to the rest of the programmed routine in  FIG. 8   b . If the alignment is sensed as misaligned, as represented by the “NO” result from decision block  87 , then the processor performs another movement of the coin magazine  23  by looping back to execute block  86  again. 
   After the coin magazine is positioned to accept a coin of denomination “X,” the feed motor  33  driving the rotating disc  55  is energized to jog (move in an increment) the coin  16  around the coin track  57  until it is sensed by the size sensor  65 , as represented by process block  90 . 
   If the coin is sensed as not being a coin of denomination “X,” but of denomination “Y,” in decision block  91 , the coin feed operation is halted as represented by process block  92  and the identity of the coin being processed is changed to denomination “Y,” as represented by decision block  93 . The routine then returns to connection point “B” in  FIG. 8   a  to position the coin magazine to accept a coin of denomination “Y”. 
   If the coin is sensed as being a coin of denomination “X,” in decision block  91 , there is a further test to see if it has dropped through the coin exit aperture  66  within a timeout period, as represented by decision block  94 . If the coin was sensed by coin size sensor  65 , but is not sensed at the coin exit aperture  66  by a coin transfer sensor  72 , as represented by the “NO” result from decision block  94 , there has been a misfeed or some other error. In that event, an error message is displayed on the display of the control for the machine  10 , as represented by output block  97 . 
   Assuming that the coin is sensed by the coin transfer sensor  72  within the timeout period as represented by the “NO” result from decision block  94 , then a test is made to see if a maximum limit for a denomination “X” has been reached. In the event that the maximum limit has not been reached, the routine will loop back to look at the next coin to see if it is of denomination “X.” If a limit has been reached, the coin feeding is halted, and the routine returns to the “A” connection point in  FIG. 8   a  to look for a dispense request and test the coin supply. 
   From this description it can be seen how the coin magazine  23  is first positioned to accept coins of a particular denomination, and then the queuing device is jogged and each coin sensed to verify that is of the denomination for which the coin magazine  23  has been positioned. This arrangement makes a ramp unnecessary in the preferred embodiment, thereby saving cost and complexity, however, a ramp could be added in other embodiments without departing from the full scope of the invention. 
   The mix of coins contained in the magazine  23  is such that one complete dispensing rotation can provide up to 99 cents (or $4.99) in change. According to one preferred embodiment, the magazine assembly  22  is rotated at 30 RPM. If the change is dispensed in one revolution, this occurs in a time period of two seconds. Where necessary, the magazine  23  can be rotated through a second revolution to complete the dispensing of the requested amount of change. The magazine does not need to stop in order to complete a dispense cycle. If coins from multiple channels  24  in more than once revolution must be ejected to complete the payment of change, the motor  31  can be driven until payment is made and then index to the pre-accelerate position once again. 
   The dispenser  20  can be used with a variety of different magazines  23  containing different mixes of coins. For example, one magazine  23  could have coin channels with different sizes (diameters) to hold a mix of coins (pennies, nickels, dimes, quarters, dollar coins), while another magazine  23  could have coin channels with equal sizes (e.g., all holding quarters or tokens, which would be useful at an arcade). 
   Preferably, the low coin sensor  51  is located at an appropriate height such that it will no longer sense coins in a coin channel  24  when there are a small number (e.g., 3-6) of coins remaining in the channel  24 . The machine  10  can then avoid selecting channels  24  having a low supply (for example, if one quarter channel is low, a different quarter channel is selected, or two dime channels and one nickel channel are selected). The dispenser also preferably provides an audible or visual alarm indicating that the magazine  23  should be replaced. Since the magazine  23  moves the channels  24  past the low-coin station  50 , it is only necessary to provide a single low coin sensor. However, as an additional feature, it is also possible to provide a second low coin detector located approximately halfway up the height of the magazine  23  in order to provide a signal indicating that a receptacle is about half-empty. If the magazine  23  is made from an opaque material, the magazine  23  will include the slots  24   c  in the channels  24  so that the low coin detector can sense the coins. However, if the magazine  23  is made from a transparent plastic material, for example, it is not necessary to include slots  24   c  in the channels  24 . 
   Another advantage of the disclosed construction is that it is easily adaptable to different coin mixes (i.e., to different magazines  23  having different numbers and sizes of slots). One coin dispenser  20  could be used with different magazines  23 , including magazines with coins from different countries, simply by programming the coin dispenser  20  with data indicating the different types of coin mixes (including data on the coin denomination and the number of coins dispensed with one actuation of the coin ejector  80 —usually one or two coins at a time) contained in the different magazines. 
   This has been a description of preferred embodiments of the invention. Those of ordinary skill in the art will recognize that modifications might be made while still coming within the scope and spirit of the present invention. 
   For example, although optical sensors are disclosed for the preferred embodiment, sonic sensors or proximity sensors might be substituted without departing from the scope of the broadest aspects of the invention. As another example, while the coin path is preferably circular, looped coin paths of non-circular shape might also be used. 
   And while tabs are used as the markers for position sensing of the magazine assembly, other types of markers can be used. Therefore, for the scope of the invention, reference is made to the following claims.