Abstract:
A delivery system and method for delivering a processing solution to a processing tank in a processor containing a processing solution. The delivery system is designed to provide a replenishment solution to the processing tank from a package having at least two separate containers. Each of the containers having a processing solution that is to be provided to the at least one processing tank. The delivery system substantially empties each of the at least two separate containers in the package in an accurate predetermined rate so that all of the at least two containers in the package will be substantially empty at the same time. The delivery system includes a mechanism for filling and emptying the predetermined amount of replenishment solution from the retaining vessel in response to the liquid level sensing system.

Description:
FIELD OF THE INVENTION 
     The present invention is directed to photographic processors and more particularly to a replenishment system for accurately delivering replenishment solution from a package containing a plurality of discrete containers to the processing tanks. 
     BACKGROUND OF THE INVENTION 
     In many retail establishments there is provided a small mini-lab processor which is used for the processing of film. In such processors, it has been desirable to provide the replenishment solution used for replenishing the processing solutions in the processing tanks to be provided in a combined shipping and dispensing package such as illustrated in U.S. Pat. No. 5,577,614 which is hereby incorporated by reference. This type of package allows a low skill operator of the processing apparatus to quickly and easily provide fresh replenishment solution to the apparatus. Typically, the package has a plurality of individual containers, each having a different processing solution of different amounts that are designed to be emptied all at the same time such that a fresh package can be placed without any waste of processing solution. If too much remaining solution is left in any one of the containers this can present a problem with regard to appropriate disposal of the processing solution remaining therein. 
     In order to try to improve the emptying of all the containers at the same time, it has been suggested the providing of more accurate feed pumps for delivery of the processing solutions from the package to the processing tanks so that the appropriate amount of processing solution is delivered. While this has provided improvement, this solution is relatively expensive. An additional problem with current processors it that they do not provide any feedback to the operator if there is pump malfunction. The fluid flow or replenishment volume is not measured anywhere in the replenishment delivery system. Typically, the pumps are concealed and the customer has no visual indication of the amount of the replenishment solution delivered. It is assumed that the pumps are always delivering their normal predefined amount. With normal use and wear the pumps will eventually fail without providing a warning to the operator. In addition, there exists the possibility that over time these pumps due to normal wear and tear will eventually fail or become less accurate. 
     Prior art devices have also suggested various techniques for determining when the containers have been emptied. One such system relies on the placement of a sensor adjacent to the neck of the container and uses this information to determine when the container is empty. Typically, these rely on a collar that is moved in response to the position of the fluid contained therein. When empty, the collar goes to a position that activates the sensor to advise that the container is empty. Occasionally, defects in container manufacturing may cause the floating collar to stick and fail to drop when the package is empty. In other situations, a false empty alarm may be activated due to sensor failure or when the sensors are in need of cleaning or maintenance. An example of use of such sensors are disclosed in U.S. Pat. No. 5,694,991 which is hereby incorporated herein by reference in it&#39;s entirety. 
     The prior art has also disclosed the use of calibrated vessels for metering a desired amount of processing solution in large scale processing system. An example of such units are the Hostert Fotomata Inline/ED 15 replenishment unit found on Model DDP40/120 E6 processor and the Gretag Model E6-120 GL/VESS E-6 processor. These systems are directed to supplying processing solution from a single large supply container into an associated processing tank. These systems are operated in a continuous manner. When the solution in the supply container reaches a low level, a skilled attendant would simply provide more solution to the supply vessel. Packaged chemistry is not suitable for such systems nor is there any concern for associating the refilling of one supply vessel with another supply vessel in these systems. 
     Thus, there is a need to provide an accurate and economical fluid delivery system for providing replenishment solutions to photographic processors which utilize a replenishment package system having two or more processing solutions that are to be depleted simultaneously. 
     The present invention provides an accurate delivery system at relatively low costs without the need for expensive metering pumps to dispense the solution and also provides the ability to detect delivery problems in an easier manner than previously allowed. The present invention also provides a delivery system that does not rely on pumps for determining the amount of fluid that has been delivered and once calibrated the amount of solution delivered over time does not change. The present invention further allows a visual indication that a predetermined amount of replenishment solution has been delivered. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention there is provided a photographic processor, comprising: 
     a processing tank for containing a processing solution through which a media is passed for processing of a media; 
     a delivery system for providing a replenishment solution to the processing tank from a package having at least two separate containers, each of the containers having a processing solution that is to be provided to the at least one processing tank, the delivery system substantially emptying each of the at least two separate containers in the package in an accurate predetermined rate so that all of the at least two containers in the package will be substantially empty at the same time, the delivery system having a retaining vessel, a liquid level sensing system for sensing a predetermined amount of the replenishment solution in the retaining vessel to be delivered to the processing tank, a delivery mechanism for filling and emptying the predetermined amount of replenishment solution from the retaining vessel in response to the liquid level sensing system. 
     In accordance with another aspect of the present invention there is provided a method for delivering a replenishment solution to a processing tank in a photographic processor having at least one processing tank and is designed to provide replenishment solution to the at least one processing tank from a package having a plurality of containers each having a processing solution therein, comprising the steps of: 
     dispensing the processing solutions from each of the containers into an associated retaining vessel until a signal to stop is received; and 
     dispensing a predetermined amount of the processing solution from the retaining vessel for delivery to one of the processing tanks. 
     In accordance with yet another aspect of the present invention there is provided a photographic processor, comprising: 
     a plurality of processing tanks for containing a processing solution through which a media is passed for processing of a media; 
     a delivery system for providing a replenishment solution to the plurality of processing tanks from a package having at least two separate containers, each of the containers having a processing solution that is to be provided to one of the plurality of processing tanks, the delivery system substantially emptying each of the at least two separate containers in the package in an accurate predetermined rate so that the at least two containers in the package will be substantially empty at the same time, the delivery system having a retaining vessel, a liquid level sensing system for sensing a predetermined amount of the replenishment solution in the retaining vessel, a delivery mechanism for filling and emptying the predetermined amount of replenishment solution from the retaining vessel in response to the liquid level sensing system. 
     In accordance with still another aspect of the present invention, there is provided a delivery system for providing a replenishment solution to one or more processing tanks from a package having at least two separate containers, each of the containers having a processing solution that is to be provided to the one or more processing tanks, the delivery system substantially emptying each of the at least two separate containers in the package in an accurate predetermined rate so that all of the at least two containers in the package will be substantially empty at the same time, the delivery system having a retaining vessel, a liquid level sensing system for sensing a predetermined amount of the replenishment solution in the retaining vessel to be delivered to the one or more processing tanks, a delivery mechanism for filling and emptying the predetermined amount of replenishment solution from the retaining vessel in response to the liquid level sensing system. 
     These and other aspects, objects, features, and advantages of the present invention will be more clearly understood and appreciated from a review of the following detailed description of the preferred embodiments and appended claims, and by reference to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In the detailed description of the preferred embodiments of the invention presented below, reference is made to the accompanying drawings in which: 
     FIG. 1 is a diagram representation of the processing apparatus made in accordance with the present invention; 
     FIG. 2 is a schematic diagram of the delivery system of the apparatus of FIG. 1; 
     FIG. 3 is a schematic diagram of the delivery system for a single container and associated retaining vessel; 
     FIG. 4 is a schematic diagram of a modified delivery system made in accordance with the present invention; 
     FIG. 5 illustrates yet another modified delivery system made in accordance with present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to FIG. 1 there is illustrated an apparatus  10  made in accordance with the present invention. In the particular embodiment illustrated, the apparatus  10  is a stand alone processing apparatus for processing a photosensitive media such as film, paper etc. However, the apparatus  10  may be a part of a larger apparatus such as a mini-lab wherein images are also exposed onto a photosensitive media which is processed in a similar manner. 
     The apparatus  10  includes a plurality of processing tanks  12 ,  14  and  16  each designed to hold a processing solution. A processing path  18  is defined which passes through tanks  12 ,  14  and  16  along which a photosensitive media travels for processing of the media, such as photographic film and/or paper. The apparatus  10  also includes a dryer  20  wherein the media is dried. After the media has been dried it is delivered outside of the apparatus  10  through an appropriate outlet  22  as is conventionally done for further treatment (for example, but not limited to scanning, cutting, packaging, etc). In the particular embodiment illustrated, three processing tanks are provided. Processing tank  12  being a developer tank for containing a develop solution; tank  14  being bleach/fix tank for containing a bleach/fix processing solution, and processing tank  16  for holding a wash processing solution. It is of course to be understood that any desired number of processing tanks may be provided containing the appropriate processing solutions as may be required by the photosensitive media being processed. 
     A computer  24  is provided for controlling operation of the apparatus  10  as is conventionally done. Thus, appropriate computer programs are provided for controlling operations of the various components that are provided in apparatus  10  and for controlling the appropriate sequence of operation of the various components as required for processing the particular photosensitive media being processed. As is typical, the media enters the apparatus through inlet  26  and is transported along the processing path  18  and delivered outside of the apparatus  10  through outlet  22 . The transport mechanism may be of any type suitable for transporting of the media, for example but not by way of limitation, roller assemblies. 
     The apparatus includes a replenishment and delivery system  30  for providing replenishment solution to each of the tanks  12 ,  14  and  16 . In the particular embodiment illustrated, the apparatus is designed to receive a package  32  containing a plurality of individual discrete containers  34 ,  36 ,  38  and  40 , each containing an appropriate replenishment solution to be used to replenishment the processing solution in each of the processing tanks  12 ,  14  and  16 , respectfully. In the particular embodiment illustrated, the containers  34  and  36  are appropriate processing solutions that are to be measured and forwarded to the processing tank  12  whereas the processing solution in container  38  is to be provided to processing container  14  and processing solution in container  40  is to be provided to processing tank  16 . As can be seen, containers  34 ,  36 ,  38  and  40  each contain a different amount of processing solution. This is because different amounts of processing solution are required for processing a predetermined amount of media that is being processed. Thus, the size and quantity of these processing containers are designed such that when fully empty each will provide the appropriate amount for replenishment of the respective processing solution for processing a predetermined amount of media. 
     The package  32  is placed on an appropriate support surface  41  Each of the containers  34 ,  36 ,  38  and  40  is provided with an appropriate valve assembly or connection  42 ,  44 ,  46  and  48 , respectively, for allowing the processing solution to be emptied from each of the containers. In the particular embodiment illustrated, each container  34 ,  36 ,  38 , and  40  are appropriately connected by a conduit to respective pumps  50 ,  52 ,  54  and  56 . Each of the pumps  50 ,  52 ,  54  and  56  are, through respective appropriate conduits  58 ,  60 ,  62  and  64 , are fluidly connected to respective retaining vessels  70 ,  72 ,  74  and  76  which are in turn are fluidly connected to respective pumps  80 ,  82 ,  84  and  86 . Valves  90 ,  92 ,  94  and  96  are provided such that one valve is associated with the outlet  71 ,  73 ,  75  and  77  of each of the retaining vessels  70 ,  72 ,  74  and  76 , respectively (see FIG.  2 ). 
     Each of the retaining vessels  70 ,  72 ,  74  and  76  are also provided with an associated sensing system for determining when a predetermined amount of processing solution has been supplied to the retaining vessel for use in controlling the dispensing of a predetermined amount of processing solution from the associated container to its respective associated processing tank. 
     In the particular embodiments illustrated the sensing system comprises a plurality of sensors associated with each of the retaining vessels  70 ,  72 ,  74 , and  76 . In particular, three sensors  102   a ,  102   b ,  102   c    102   d ,  104   a ,  104   b ,  104   c ,  104   d  and  106   a ,  106   b ,  106   c  and  106   d  are associated with each of the respective retaining vessels  70 ,  72 ,  74  and  76 . The subscripts “a, b, c and d” simply identify which of the associate retaining vessels the sensors are associated therewith. For example, subscript “a” indicates the sensors  102   a ,  104   a , and  106   a  associated with retaining vessels  70 , subscript “b” indicates the sensors  102   b ,  104   b , and  106   b  are associated with vessel  72  and subscript “c” associates the sensors  102   c ,  104   c , and  106   c  with retaining vessel  74  and subscript “d” indicates the sensors  102   d ,  104   d , and  106   d  are associated with retaining vessel  76 . The sensors  102   a-d ;  104   a-d ; and  106   a-d  are all connected by appropriate circuits to computer  24  for the providing of appropriate signals as discussed later herein. In the particular embodiment illustrated, three sensors  102 ,  104 , and  106  are provided with respect to each of the retaining vessels  70 ,  72 ,  74  and  76 . The sensors  102   a-d  is a reference sensor which allows for the operation of the other sensors. The sensors  104   a-d  provide a first reference point and the sensors  106   a-d  are provided at a second reference point. 
     The replenishment and delivery system  30  for apparatus  10  in the embodiment illustrated in FIGS. 1 and 2 is made of four separate delivery systems  31 ,  33 ,  35 , and  37 . Reference is now made to FIG. 3 where there is illustrated one of the delivery system, in particular delivery system  31  for the associated with a container and the associated processing tank. For ease of understanding, a discussion will be provided with respect to one of the container and its associated processing tank. It being understood that the remaining processing containers and associated tanks operate in a similar manner. In particular,  102   a  is an electrode which can be used for determining the liquid level based on conductivity of the liquid within the retaining vessel  70 . Likewise, the sensor  104   a  is also an electrode that provides a first measuring point  110 . An adjustable electrode  106   a  is provided wherein the end  112  of the electrode provides a second measuring point  114  which defines a predetermined amount of replenishment solution between sensors  104   a  and  106   a  as indicated by the numerals  116 . It is of course to be understood that the size of the retaining vessel and the distance which the sensors  104   a  and  106   a  are spaced apart will provide a predetermined amount of processing solution. In the preferred embodiment, the retaining vessel  70  is provided with calibration indicia so that the amount of liquid between the two sensors  104   a  and  106   a  can be directly read. Appropriate level sensing circuits  120 ,  122  are provided for providing information to computer  24 . Initially, the retaining vessel  70  is filled with a predetermined amount of processing solution. This is accomplished by activating pump  50  the processing solution reaches the level indicated by numeral  124  within the container. The pump passes the processing solution through valve  130 . However, valve  130  simply performs the function of allowing fluid flow from the associated container  34  to the retaining vessel  70 . However, the pump  50  itself may serve as a valve. The processing solution is pumped from the container  34  until reaching the appropriate level  124 . In embodiment illustrated the conductivity between the sensors  104   a  and  106   a  provided by the liquid extending between the two electrode produces a signal that advises the computer  24  that the liquid has been provided at the desired level. Once this level is reached, the pump  50  is stopped. When it is desired to deliver processing solution from the retaining vessel  70  to the associated processing tank, pump  51  is activated and it continues until the liquid level falls to the position indicated at point  110 . This produces another signal which is sensed through use of the reference sensor  102   a  and the sensor  104   a . Thus, based on the conductivity between these two electrodes the computer  24  can determine when the desired amount of processing solution has been provided to the processing tank. Once this has been done, the pump  51  is turned off stopping any further delivery. As can be seen, a precise metered amount will have been delivered to the processing tank. The refilling operation is again conducted as previously discussed by pumping in processing solution by pump  50  until the fluid once again contacts electrode  106   a  . As previously discussed level sensing circuits are provided for determining the appropriate conductivity between the appropriate sensors are reached thus providing the required information to the computer  24  for turning on and off the pumps and valves appropriately. The same procedure is provided for each of the associated containers, retaining vessels and tanks. The use of electrodes provided for precise metering of solution into and out of the retaining vessel  70  on a repeatable basis. 
     As can be seen, the adjustable sensor  106  can be raised or lowered to provide any desired predetermined amount and rate of dispensing of the processing solution from the container to the associated processing tank. This will of course be dependent upon the type of replenishment solution being supplied and the processing parameters of the processing solution within the processing tank. 
     Referring to FIG. 4, there is illustrated a modified delivery system  126  made in accordance with the present invention with like numerals indicating like parts and operation as previously discussed. In this particular embodiment, gravity is used for dispensing of the replenishment solution from the containers  34 ,  36 ,  38  and  40  into the processing tanks  12 ,  14  and  16 . In this embodiment, only valves  42 ,  44 ,  46  and  48  are needed to supply processing solution to the retaining vessels as gravity is used to cause fluid to flow from the containers to their respective retaining vessel. Valves  90 ,  92 ,  94  and  96  control gravity flow from the retaining vessels to the respective tanks  12 ,  14  and  16  . The valves need only to be opened and closed as appropriate. The retaining vessels and associated sensors would operate in the same manner except in providing the flow by the pumps. This embodiment provides a less expensive delivery system. 
     Referring to FIG. 5 there is illustrated yet another modified delivery system  230  made in accordance with the present invention with like numerals indicated like parts and operation. In this particular embodiment, a single retaining vessel  240  is used in place of all of the retaining vessels  70 ,  72 ,  74  and  76  previously discussed and a single processing tank  270  is provided in place of the tanks  12 ,  14 , and  16 . In this embodiment additional sensors are provided in retaining vessel  240  as required for each of the processing solutions contained therein. Thus, in this embodiment, six sensors would be provided. Sensor  250   a  would be a reference sensor. Sensors  250   b ,  250   c ,  250   d ,  250   e  and  250   f  would each be associated with one of the containers provided. Thus, the sensors  250   b  and  250   c  would be used for providing the amount of processing solution from container  34  whereas sensors  250   c  and  250   d  would provide the appropriate amount of replenishment solution from container  36 , sensors  250   d  and  250   e  would provide the appropriate amount of processing solution from container  38  and sensors  250   e  and  250   f  would provide the appropriate amount of processing solution from container  40 . The positioning of each of these sensors can be adjustable so that the appropriate sensors are engaged for determining the appropriate delivery amount for each of the containers. In this embodiment, the process of replenishment solution from each of the containers  34 ,  36 ,  38  and  40  would be provided successively in turn as appropriate. Upon completion of providing all the replenishment solution desired then appropriate solution would be delivered to the single processing tank to which it is to be provided for. 
     In another form of the present invention there is provided means for visually viewing the retained vessels to see if the appropriate amount of processing solution has been delivered. In particular, a window may be provided for viewing only that portion of the retaining vessels that are necessary for viewing of the processing solution contained. The retaining vessels  70 ,  72 ,  74 , and  76  are provided in an away from the light-tight environment of the processing tanks of the processor. The retaining vessels, as previously discussed can also be provided with calibration marks/indicia  160  for ease of quickly determining the amount of replenishment solution being provided. Also the calibration marks  160  can be used for adjusting the positioning of the appropriate sensors as desired for adjusting the amount of the processing solution to be delivered to the processing tank. 
     It is to be understood that various changes and modifications may be made. For example, while in the preferred embodiment electrodes are used for sensing of the liquid level, various other types of sensing devices can be used for determining the amount of replenishment solution provided in retaining vessels. For example, ultra sonic sensors could be used for determining the level of the processing solution within the retaining vessel. Any desired number may be provided for determining various different heights within the retaining vessel. If desired, float sensors could be used as an alternative. Any reliable type sensing system may be used for determining when the liquid level in the retaining vessel goes from a first reference point to a second reference point. 
     It is to be understood that various changes and modifications may be made without departing from the present invention, the present invention being defined by the following claims. 
     PARTS LIST 
       10  apparatus 
       12  processing tank 
       14  processing tank 
       16  processing tank 
       18  processing path 
       20  dryer 
       22  outlet 
       24  computer 
       26  inlet 
       30  delivery system 
       31  delivery system 
       32  package 
       34  delivery system 
       35  container 
       36  delivery system 
       37  container 
       38  delivery system 
       40  container 
       41  container 
       42  support surface 
       44  connection 
       46  connection 
       48  connection 
       50  connection 
       51  pump 
       52  pump 
       53  pump 
       54  pump 
       55  pump 
       56  pump 
       57  pump 
       58  conduit 
       60  conduit 
       62  conduit 
       64  conduit 
       70  retaining vessel 
       71  outlet 
       72  retaining vessel 
       73  outlet 
       74  retaining vessel 
       75  outlet 
       76  retaining vessel 
       77  outlet 
       80  pump 
       82  pump 
       84  pump 
       86  pump 
       90  valve 
       92  valve 
       94  valve 
       96  valve 
       102   a-d  sensor 
       104   a-d  sensor 
       106   a-d  sensor 
       110  first measuring point 
       112  end of electrode 
       114  second measuring point 
       116  amount of replenishment solution 
       120  sensing circuit 
       122  sensing circuit 
       124  level indicated within the container 
       126  modified delivery system 
       130  valve 
       160  calibration marks/indicia 
       230  modified delivery system 
       240  retaining vessel 
       270  processing tank 
       250   a-f  sensor