Patent Publication Number: US-7722038-B1

Title: Retractable image camera mechanism for a document processing system

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to document handling equipment including systems for feeding and transporting documents. 
     2. Background Art 
     A typical system for feeding and transporting documents includes a feeder in the document feeding portion of the system, and a series of roller pairs or belts in the document transporting portion of the system. In the feeding portion of the system, the feeder acts to separate and feed documents singly, in order, from a stack. In the transporting portion of the system, the roller pairs and/or belts convey the documents, one at a time, through a track past other processing devices such as readers, printers, and sorters that perform operations on the documents. The feeder is typically a feed wheel, but may take other forms. Further, the components in the transporting portion of the system may take a variety of forms. An existing document feeder is shown in U.S. Pat. No. 6,199,854. That patent describes a document feeder with a variable speed separator. 
     In existing systems for feeding and transporting documents, operations that depend on the position of the document are generally performed in the transport stage, or transporting portion of the system. For example, U.S. Pat. No. 5,848,784 describes a document separation apparatus. That patent describes the downstream acceleration/deceleration of documents with pinch rollers to adjust document spacing. U.S. Pat. Nos. 5,419,546; 5,437,375; 5,439,506; 5,509,648; 5,671,919; and 5,908,191 describe examples of other document operations. 
     Image cameras in document handling equipment, like but not limited to, check sorters and postal letter sorters typically have the tallest document guide walls or trackwalls in general proximity of these devices. The tall guide walls are necessary for proper presentment of a document to an image camera (or contact image sensor). The typical trackwall width ranges from about 0.040 to 0.125 inches. The typical trackwall height by the image camera is in the 5 to 6 inch range. Typical documents traveling down the track past the image cameras range up to from about 2.375 to 5.5 inches in height. So most documents are hidden in the track from operator view by image cameras. 
     Document handling equipment requires periodic removal of documents along the document path. The narrow, deep track around image cameras makes it extremely difficult to remove document jams. The removal of documents is necessary due to jams caused by ripped or torn edges, staples, mutilated documents, rubber bands, folded edges and so on. 
     Document handling equipment also requires accessibility to the track for cleaning, adjustment and maintenance purposes. This could include debris removal and cleaning of the image glass/track interface. Build up of debris like paper dust and ink from documents on image glass degrades the image quality. The image quality is vital in the banking industry, especially since the implementation of “Check Clearing for the 21 st  Century Act” (Check  21 ). Accessibility is also necessary for camera calibration. Under Check  21 , image replacement documents (IRDs) and substitute checks are generated based in part on images from the image camera. 
     The current art typically has a document track with drive rollers and pinch rollers positioned along the document path to propel the document down the track. The document sidewalls are usually rigid and non-movable. When the document stops, jams or if devices, such as image cameras, positioned within the track need maintenance, this creates a difficult recovery or maintenance environment due to the lack of accessibility, and creates significant downtime for operations. The non-accessible track configurations reduce throughput of documents due to the difficulty and time spent in document removal and maintenance. 
     The typical document track is narrow and deep, typically with only the top portion of a document visible, or with no document visibility at all. Document removal in the current state of the art includes levers and knobs to retract pinch rollers for assisting document removal. This feature helps, but does not address hard document jams, maintenance, image camera glass cleaning and debris removal. The same is true for sidewalls that pivot. Document track sidewalls that pivot are helpful, but do not give complete accessibility to the document track and devices. Tools such as thin wands are needed for cleaning and debris removal in the current state of the art, and visibility into the document track is difficult, which makes document clearing, image camera cleaning, and adjustments and calibrations difficult and costly. Other solutions include removable track walls, which do give good access to the document track, but removal of track walls takes time and tools are required for removal. Removable track walls, especially those with electronic devices embedded into the walls (like sensors) are at risk for damage during multiple removals. 
     Covers and lids are necessary for protection of machine operators and are required by regulatory agencies, and are usually necessary for acoustical requirements and sometimes for electromagnetic interference protection. These covers may have to be opened to gain access for document removal or for access to levers, cams, pivots or any other devices necessary to remove documents or to perform operator maintenance. Cover and lid removal are time consuming and thus impact productive operations. 
     Additional background information may be found in U.S. Pat. No. 4,630,815. 
     For the foregoing reasons, there is a need for an improved approach to image camera maintenance in a document processing system. 
     SUMMARY OF THE INVENTION 
     It is an object of the invention to provide an improved retractable image camera mechanism for providing access to the image camera in a document processing system. 
     In carrying out the invention, a retractable image camera mechanism is provided. The mechanism provides the capability for the machine operator to open the track by depressing a push button, which in turn activates a mechanism that retracts the image camera and associated apparatus. That is, the invention comprehends an approach where assertion of a push button or other suitable assertable member activates the mechanism that retracts the image camera. 
     The track opening distance is set so an operator can easily remove document jams, stopped documents, staples and paper debris, and perform routine maintenance or device adjustment. The invention further comprehends an approach where the operator has a direct line of sight to the track bottom when the track is in the retracted state. In this way, the machine operator can perform maintenance on the system, and has easy access to image camera glass for fast and easy cleaning. 
     In another aspect of a preferred approach, the cover does not have to be removed to operate the retraction mechanism and perform system maintenance. To return the mechanism to the closed state from the open/retracted state, the machine operator closes the retractable image camera mechanism by pushing the mechanism forward until a precision locating device locks the mechanism in the closed position. In another aspect of a preferred approach, the entire opening and closing cycle is quick and easy and is a positive improvement on efficient operations and document throughput. This mechanism directly reduces machine downtime. Another major benefit is that the image camera may illuminate the track when the camera is retracted, providing enhanced visibility to the track bottom. 
     Further, in carrying out the invention, various combinations of the comprehended features may be employed in various arrangements to provide a retractable image camera mechanism. The mechanism retracts an image camera in response to assertion of a push button or equivalent. There are advantages to using a retraction approach as opposed to levers and knobs that retract pinch rollers, pivotable sidewalls, thin cleaning wands, or removable track walls. The retraction approach contemplated by the invention provides full access to the image camera as opposed to the rather limited access or overly complicated procedures provided by other approaches. 
     In an alternative approach, a fully-automatic retractable image camera mechanism may be provided. In this alternative, suitable sensors and/or system logic detects a problem and causes actuation of the image camera retraction mechanism. The retraction mechanism may be driven by, for example, a servomotor. After an operator addresses the situation, the mechanism may be pushed forward until the precision locating device locks the mechanism in the closed position. As well, the closing process may also be partially or fully automated. 
     Advantages associated with various embodiments of the invention are numerous. For example, preferred embodiments include a retractable image camera that provides unrestricted access to the document track, superior access to image glass for cleaning, illuminated track in the open position for enhanced visibility, improved access for camera calibration, a semi- or fully-automatic retraction mechanism, a precision locating device that positions and re-positions the camera, a suitable document drive that is compatible with the retraction system, and/or covers that do not have to be removed for camera and track accessibility. In an optimum configuration, the camera retracts a minimum of 1.750 inches to allow for an operator&#39;s hand to access the document track. It is appreciated that suitable modifications may be made to accommodate various image capture devices. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates a document processing system made in accordance with a preferred embodiment of the invention; 
         FIG. 2  is an enlarged view of a semi-automatic document handling mechanism; 
         FIG. 3  shows the semi-automatic document handling mechanism in the open position; 
         FIG. 4  shows the semi-automatic document handling mechanism in the open position with the cover removed, showing clear visual and physical access to the track; 
         FIG. 5  shows the semi-automatic document handling mechanism from the bottom; 
         FIG. 6  is another view of the semi-automatic document handling mechanism; in this view the precision locating mechanism is more clearly visible; 
         FIG. 7  is another view of the semi-automatic document handling mechanism from the bottom; 
         FIG. 8  illustrates a fully-automatic document handling mechanism that is used in alternative embodiments of the invention; 
         FIG. 9  illustrates a retractable image camera implementation in accordance with the invention, showing the semi-automatic document handling mechanism with both covers and the back track wall removed to expose the document drive and image camera in the closed position; and 
         FIG. 10  illustrates a retractable image camera implementation in accordance with the invention, showing the mechanism in the open position and with the front cover removed. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  illustrates a document processing system for feeding and transporting documents at  10 . System  10  includes a primary feeder  12  and a secondary feeder  14 . Cabinet  16  houses a computer running software for system  10 . System  10  further includes removable kneewell panel  18 . The feeders act to separate and feed documents singly, in order, from a stack. The remainder of the system is the transporting portion of the system, which includes a number of roller pairs and/or belts to convey the documents, one at a time, through a track past other processing devices that perform operations on the documents. 
     As shown in  FIG. 1 , a number of processing devices are located in the transporting portion of the system  10 . Magnetic ink character recognition (MICR) reader  20  and optical character recognition (OCR) reader  22  are located in the document track following secondary feeder  14 . As well, upstream imaging devices  24  and  26  image each passing document. The operator display is indicated at  28 . 
     With continuing reference to  FIG. 1 , system  10  further includes a post-read view station  30 , and a low-speed document encoder  32 . As well, a multi-jet endorser (MJE) is located at  34 . Further down the document track, an amount-only or full-field high-speed encoder  36  and downstream imager  38  process the passing documents. Finally, a 12-pocket stacker module  40  is provided for the actual sorting of the documents into pockets. The drawings illustrate the preferred system, which is depicted as an NDP Quantum Series transport available from Unisys. 
       FIGS. 2-7  and  8  illustrate document handling mechanisms for use in a document processing system. In these Figures, the imaging assembly is removed, and the associated following description explains the general operation of the document handling mechanisms. 
     In  FIGS. 9-10 , an exemplary document handling mechanism, in accordance with the invention, is outfitted with an imaging assembly to illustrate the preferred embodiment of the invention. The invention involves a retractable imaging assembly in a document handling mechanism. 
     With reference to  FIG. 2 , the semi-automatic document handling mechanism is indicated at  50 . Each half of the mechanism has a cover  52 , 54 , and the track area is indicated at  56 . Push button  58  is asserted to cause the mechanism to retract, opening up the track area for operator access.  FIG. 3  shows the semi-automatic document handling mechanism in the open position. 
       FIGS. 4-7  illustrates various components of the semi-automatic document handling mechanism in the preferred construction in greater detail. With continuing reference to these figures, the retractable document handling mechanism  50  provides access to the track area  56  in the document processing system  10 . The mechanism provides the capability for the machine operator to open the track area  56  by depressing the push button  58 . Pressing push button  58 , in turn, activates a mechanism that retracts the rigid document track walls. The track open distance is set so that an operator can easily remove document jams, remove stopped documents, remove staples and paper debris, and perform routine maintenance or device adjustment. 
     Advantageously, the operator has a direct line of sight to the track bottom. Advantageously, covers  52  and  54  do not have to be removed. The machine operator closes the semi-automatic retractable document handling mechanism  50  by pushing cover  54  until the precision locating device locks the mechanism in the closed position. The entire open and closing cycle is quick and easy and is a positive improvement on efficient operations and document throughput. This mechanism directly reduces machine downtime. 
     In more detail, by depressing button  58 , repositioning device  60  is actuated. Button  58  pushes a connecting rod  62  that is located in a housing  66  and is guided by two precision bushings. At the opposite end of connecting rod  62  is a precision pin  68  pressed into connecting rod  62  at a 90° angle. Connecting rod  62  also has a tapped hole with a locating counterbore that receives a shoulder screw  70  that passes through a special slot  72  on housing  66 . 
     This feature provides anti-rotation in use, yet can still be rotated 90° for assembly purposes in the fully depressed mode of assembly  60 . Connecting rod  62  has compression spring  80  acting on it to urge button  58  to the deasserted or upward position. The entire repositioning device  60  rests and is positioned on a moving base  82 . Pin  68  on the end of connecting rod  62  nests in a groove in slot  92  on a wear plate  86  mounted on fixed base  84  (in the closed position). 
     This arrangement gives the precision location needed to properly locate the track walls for operation. Depression of connecting rod  62  by pushing button  58  causes pin  68  to clear the groove in slot  92  in wear plate  86 , and allows for the moving base  82  to retract by means of an assist spring  88 . A counter spring  90  acts as a dampener and absorbs any potential mechanical shock during the semi-automatic opening of the retraction mechanism. Wear plate  86  has slot  92  through the center of wear plate  86  to allow for travel of moving base  82 . The wear plate  86  is preferably constructed of hardened tool steel to provide long life and also has a surface finish that provides a low coefficient of friction, as the locating pin  68  slides back and forth on the surface. 
     The operator closes the re-positioning device by simply pushing the retracted assembly forward, and the pin  68  snaps into the groove, giving the repeatable location necessary for proper track gaps, sensor alignment and for alignment of other electronic devices including, but not limited to, magnetic read heads and pressure devices, drive and pinch rollers, optical cameras and the like. Advantageously, cover removal is not required to open the apparatus, access the track, and close the apparatus back to the precision location. 
     The semi-automatic re-positioning device for the document handling apparatus  10  can be opened and closed in seconds and gives true and unrestrictive access to the document track area  56 . The device allows easy document removal by the operator and allows the operator to perform maintenance previously done by field engineers. The device reduces machine downtime and enables increased document throughput. 
     In addition to the advantages described above, it is appreciated that the apparatus retracts multiple pinch rollers upon the machine operator pressing button  58 . When button  58  is pushed, multiple pinch rollers retract via the spring-assisted mechanism. As shown, pinch rollers  100 , 102 , 104  retract to a position that provides physically unrestricted access to the track area  56  for document removal, cleaning and maintenance, and device adjustment. 
     An operator can easily put his hand into the track and do whatever tasks are necessary in a very short time frame. The operator can see directly into the track and would have no problem clearing documents, cleaning out debris or performing other maintenance procedures. 
     To close the apparatus, the machine operator pushes cover  54  forward and the retracted assembly snaps back into a repeatable precise closed position. The operation of the apparatus is ergonomically intuitive for any machine operator to use. The apparatus not only enables increased document throughput due to less machine downtime but allows for maintenance procedures to be performed by the operators instead of field engineers. 
       FIG. 8  illustrates a fully-automatic document handling mechanism  110  that may be used in alternative constructions. As with the other described configuration, the mechanism includes first and second halves  112  and  114  where one part of the handling mechanism forms the fixed base while the other part of the handling mechanism forms the movable base. Sensors  116  and system logic  120  are configured to detect a problem occurring in the cooperating portion of the document track. Detection of a problem causes actuation of the retraction mechanism, which is shown being driven by servomotor  118 . After an operator addresses the problem situation, the mechanism may be manually urged back together until the precision locating device locks the mechanism into closed position. In addition, the closing process may also be partially or fully automated. 
       FIGS. 9 and 10  illustrate a retractable image camera implementation in accordance with a preferred embodiment of the invention. The retractable mechanism is generally indicated at  150 . The document path is indicated at  154 , and retractable mechanism  150  cooperates with a portion of the document track. Each side of the document track is carried by a separate base member of mechanism  150 . As shown, movable base member  152  carries one side of the document track, while the other side is carried by a fixed base member. In  FIG. 9 , the overall document handling mechanism is shown with both covers and the back track wall removed to expose the document drive and image camera in the closed position. In  FIG. 10 , the mechanism is shown in the open position and with the front cover only removed. In  FIG. 10 , the track bottom is visible at  156 . Pushbutton plunger mechanism  158  is the assertable member that causes retraction of the opposing track walls when asserted. 
     In accordance with the invention, an imaging assembly composed of an imaging device and an image glass positioned as one side of the document track at the retractable mechanism is provided. In the preferred implementation which is illustrated, retractable camera  170  and image glass  172  are carried on retractable base  152  of retractable mechanism  150 . Light source  174  operates to illuminate the surrounding track area when the track is open. Preferably, the imaging device is an image camera. It is appreciated that a contact imaging device could be utilized in the alternative. In the retracted position, retraction of the imaging assembly is sufficient to provide a direct line-of-sight to a bottom of the track. 
     The proximity of the retractable image camera  170  and image glass  172  to other components is best shown in  FIG. 9 , where drive rollers are indicated at  180  and pinch rollers are indicated at  182 . It is appreciated that all of the preferred implementation is shown in  FIGS. 9 and 10 , the invention comprehends that various different implementations are possible and the retractable mechanisms described herein are exemplary. 
     While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.