Abstract:
An apparatus and method for dispensing and retrieving garments in a controlled manner. The apparatus retrieves the garments in a secure enclosure while accounting for the garments returned, and compacts the returned garments, all with a single, stand-alone apparatus. A paddle mechanism sweeps the garments into a horizontally extended storage compartment and compacts them with an upward movement. The paddle is articulated at a one-way joint to allow it to pass obstructions on its return path.

Description:
TECHNICAL FIELD 
     The present invention relates to a system for dispensing and retrieving garments, and particularly relates to dispensing garments in a controlled manner, receiving the garments in a secure enclosure while accounting for the garments returned, and compacting the returned garments, all with a single, stand-alone apparatus. 
     BACKGROUND ART 
     Some employers must provide special clothing to their employees, then collect and launder the clothing when it becomes soiled. Hospital scrubsuits are an example of such clothing. A problem associated with the use of scrubsuits is loss of inventory as a result of negligence, misuse and theft. Another problem is extra laundering of unused scrubsuits as a result of mishandling. 
     To avoid the labor costs and other disadvantages of staffed dispensing stations within a hospital, vending machines have been developed, such as that shown in U.S. Pat. No. 5,638,985. This apparatus effectively solves the problems involved in vending flexible cloth items one at a time. The dispenser includes a processor that tracks the inventory within the machine as scrubsuits are removed, and limits users to a maximum number of withdrawals with a magnetic card or “PIN” number access system. 
     The clothing collection apparatus shown in U.S. Pat. Nos. 5,713,270 and 5,829,349 also reduces inventory loss. Scrubsuits are checked in by the user, and a processor sends a credit to the user&#39;s account via a communications network. Thus, the return of a scrubsuit increases the scrubsuits available to that user from a scrubsuit vending machine also linked to the network. The apparatus also compacts the garments that are returned. 
     In large hospitals, placing individual dispenser units and receiving units at key locations has proved effective in controlling an inventory of scrubsuits. However, a system of separate dispensers and receiving units connected by a communications network may be too expensive for small hospitals, clinics, or hospital departments that need to maintain an inventory of scrubsuits independent of a large hospital organization. Thus, there is a need for a compact unit that can dispense and retrieve garments such as hospital scrubsuits. 
     Adapting the garment receiving apparatus of the unit shown in U.S. Pat. Nos. 5,713,270 and 5,829,349 into a compact unit presents difficulties, because the collection compartment into which the garments are compacted is located directly below the compacting mechanism. Thus, the volume of clothing that the collection area can hold is limited by the height and width of the unit. To increase the capacity of a garment collection compartment, a compaction system is needed that can move and compact garments into a laterally extending collection compartment. 
     SUMMARY OF THE INVENTION 
     The present invention seeks to provide an apparatus that can receive and pack goods, such as garments or the like, laterally with respect to their intake location. 
     This object is accomplished by providing an apparatus for receiving and packing goods, comprising a storage chamber including an outer wall defining an inlet opening, and an inlet chamber positioned adjacent to the storage chamber and communicating with the inlet opening. An articulated paddle is mounted for rotation about a pivot axis, the paddle being positioned at least partly within the inlet chamber and defining a one-way folding joint at a location between the pivot axis and an outer end of the paddle. A drive mechanism is connected to rotate the paddle in both directions about the pivot axis from an initial position at least partly within the inlet chamber toward the storage chamber and back to the initial position. The joint holds the paddle in an extended configuration against resistance when the paddle is rotating toward the storage chamber, and allows the paddle to fold when the paddle is rotating back toward the initial position. 
     In one embodiment, the drive mechanism is capable of rotating the paddle into the storage chamber. The initial position of the paddle may lie in a plane adjacent to a wall of the inlet chamber, and the drive mechanism may be capable of rotating the paddle into the storage chamber and through an angle greater than 210° (preferably about 220-225° or more) from the initial position. The apparatus may include a resistance sensor operative to reverse rotation of the paddle toward the storage chamber responsive to the paddle encountering a preset level of resistance from goods in the storage chamber. A first position sensor may be located along the rotation of the paddle at an angle indicating the storage chamber is full; and a controller may be connected to the first position sensor and generate a full signal in response to the paddle being reversed by the resistance sensor prior to reaching the first position sensor. 
     Preferably, the drive mechanism includes a motor coupled to rotate the paddle, and the apparatus further includes a second position sensor located along the rotation of the paddle at a predetermined angle from the initial position of the paddle. In this case the controller is connected to the second position sensor and disconnects energy to the motor in response to the second position sensor indicating passing of the paddle during return motion of the paddle toward the initial position, allowing the paddle to coast into the initial position. 
     The storage chamber may include a bag and the inlet chamber may comprise a chute positioned above the inlet opening of the bag. The bag may extend horizontally from the inlet opening. The inlet chamber can be equipped with a lockable receiving door, an input device for acquiring user identification information, and a controller operatively connected to unlock the door and to operate the drive mechanism in response to information received from the input device. Preferably, a sensor is positioned to provide a confirmation signal to the controller indicating the presence of goods in the inlet chamber. The controller updates an inventory of goods and an account of a particular user associated with the information received from the input device in response to the confirmation signal. 
     The present invention also provides a method for receiving and packing goods, comprising the steps of accepting goods into an inlet chamber; operating a sweep arm from an initial position through an angle of up to about 220° or more to sweep the goods from the inlet chamber into a storage chamber having an inlet opening communicating with the inlet chamber; monitoring movement of the sweep arm past at least first and second locations distant from the initial position; returning the sweep arm toward the initial position responsive to resistance to continued movement thereof at any angle from the initial position; allowing the sweep arm to coast back to the initial position from the first location; and if the sweep arm returns without passing the second location, terminating acceptance of goods into the inlet chamber. The step of operating the sweep aim to pack the goods may optionally be initiated less than upon every acceptance of goods into the inlet chamber for a predetermined number of acceptance cycles, to reduce the average cycle time for users, and thereafter the sweep arm may be operated after every acceptance to assure that the inlet chamber is cleared and the goods are properly packed. 
     The present invention also seeks to provide a compact unit that both dispenses and receives cloth items. 
     This object is accomplished by providing an apparatus for dispensing and receiving goods, comprising: a cabinet; a dispensing device for cloth items positioned in an upper portion of the cabinet; a receiving chamber positioned adjacent to the dispensing device in the upper portion of the cabinet and including an opening through which cloth items may be inserted into the receiving chamber; a storage chamber positioned in a lower portion of the cabinet and extending beneath both the receiving chamber and the dispensing device, the storage chamber defining an opening communicating with the receiving chamber; and a sweeping arm operative to move cloth items to a portion of the storage chamber beneath the dispensing device. In a preferred embodiment, the sweeping aim moves between a position within the receiving chamber to a position within the storage chamber. 
     Other objects, features and advantages of the present invention will become apparent upon reviewing the following detailed description of an embodiment of the invention, when taken in conjunction with the drawings and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a front plan view of a garment dispensing and retrieving apparatus embodying the present invention. 
     FIG. 2 is a pictorial view of the apparatus of FIG. I showing interior components. 
     FIG. 3 is a partial front plan view of the apparatus of FIG. 1 with doors removed to show interior detail. 
     FIG. 4 is a diagrammatic front view of the paddle and drive mechanism showing various positions of the paddle. 
     FIG. 5 is a block diagram of a control circuit for operating the apparatus of FIG.  1 . 
     FIG. 6 is a logic flow diagram of the steps in the operation of the apparatus of FIG.  1 . 
    
    
     DETAILED DESCRIPTION 
     Referring now in more detail to the drawings, in which like numerals refer to like parts throughout the several views, FIG. 1 shows a garment dispensing and retrieving machine  10  embodying the present invention. The machine  10  is contained within a cabinet  12  which holds both a dispensing mechanism  14  for dispensing garments or sets of garments, and a retrieving mechanism  16  for receiving garments returned by users. The retrieving mechanism  16  directs the returned garments into a storage compartment  18 . Users and attendants operate the machine  10  via a controller interface panel  20 , which contains input devices described below connected to electronic devices associated with the panel  20  and in an electronics compartment  22 , including a programmed microprocessor  35  in the compartment  22  and a programmed microprocessor  36  with the panel  20  (FIGS.  2  and  5 ). A portion of the storage compartment  18  extends under the dispensing mechanism  14 , as shown in FIG.  1 . 
     The dispensing mechanism  14  is of the type shown in U.S. Pat. No. 5,638,985. Because the mechanism is described in detail in that patent, its structure and operation will be summarized briefly here. Referring to FIGS. 1 and 2, the dispensing mechanism  14  is positioned in the upper left corner of the cabinet  12 . A plurality of user doors  26  are defined in a main dispenser door  25 , which is secured by a locking latch  28 . A number of receptacles or slots  31  are arranged behind the user doors  26  on shelves  30 , forming an array of the dispensing slots  31  in which garments such as surgical scrubsuits are disposed. Receptacle doors (not shown) allow access to only one column of slots, so that when one user door  26  is open, only one slot is accessible. 
     Referring to FIGS. 2 and 3, receiving mechanism  16  is positioned in a portion of the cabinet  12  to the right of, and below the right hand portion of, the dispensing mechanism  14 . An inlet chamber or chute  40  is defined between an inner wall  42  separating the inlet chamber  40  from the dispensing mechanism  14 , and an outer wall  13  of the cabinet. A door  44  in the front of the cabinet allows users to deposit soiled garments into the inlet chamber after entering a proper identification via the interface panel  20 . Associated with the door  44  are a lock solenoid  38  and a limit switch  45  that indicates whether the door is closed (both shown diagrammatically in FIG.  5 ). When garments are deposited through the door  44 , they fall past a photosensor  43  which confirms that an article has in fact been deposited. As they continue to fall, the garments pass into the storage compartment  18  through an inlet opening  46  defined between (a) a front beam  47  extending across the top of the storage compartment, (b) a rear beam  48  parallel to the front beam and positioned against the back wall of the cabinet  12 , (c) the end wall  13  of the cabinet, and (d) an articulated paddle  50 . The falling garments are deflected toward the paddle  50  by an angled guide  49  extending across the end wall of the cabinet, best shown in FIG.  3 . 
     The articulated paddle  50  has an inner paddle member  52  and an outer paddle member  54  connected at a pivot joint  57 . The inner paddle  52  has a broad, flat surface and defines a pair of side flanges  53  for strength extending away from the inlet chamber. Similarly, the outer paddle member  54  has a broad, flat surface and defines a pair of side flanges  55 . FIG. 3 shows a cross section of the paddle  50 , with the paddle members biased into linear alignment by a spring  58 . The outer paddle member  54  extends past the joint and partly behind the inner paddle member  52 , so as to provide a stop, preventing the members  52  and  54  from bending about the joint  57  beyond linear alignment in one direction. However, pressure against the outer paddle member  54  will bend it about the joint, against the force of the spring  58 , in a Counterclockwise direction as viewed in FIG.  3 . The one-way knee joint thus formed by the pivot joint  57  may take on positions such as shown in FIG. 4, which is described in more detail below in connection with the operation of the apparatus. 
     The inner paddle member  52  is fixed to a pivot axle  60  that may be journaled in bearings (not shown) mounted on each of the rails  47  and  48 . The axle is positioned so that when the paddle  50  extends vertically upward, it is adjacent to the wall  42 . A sprocket  62  also is fixed on the axle  60 . The sprocket  62  is driven via a chain  64  by another sprocket  65  mounted on the drive shaft of a reversible motor/gear reducer  67 . The motor is mounted on a platform  68  extending between the rails  47  and  48  in a space below the dispensing mechanism  14 . If desired, the paddle can be driven clockwise by the motor and returned in the counterclockwise direction by a spring or other resilient device. An arm  69  also is mounted to the drive shaft of the motor  67 . The arm&#39;s path intersects a stop  70  mounted below the motor platform  68 . 
     As shown by the dashed lines in FIG. 3, the clockwise rotational path of the distal end of the paddle  50  about the axle  60  sweeps from an approximately vertical (or “home”) position, across the inlet chamber near the guide  49 , between the rails  47  and  48  closely adjacent to the cabinet wall  13 , through the storage compartment  18 , past 180° of rotation within about 2-3 inches of the floor of the storage compartment  18 , and to a final position about 225° from the home position, as indicated by the arrow A. When the paddle  50  is in the home position, the arm  69  abuts the left side of the stop  70  as viewed in FIG.  3 . When the paddle has rotated to its final position, the aim  69  abuts the right side of the stop  70 . The motor is equipped with a conventional resistance sensor  71 , shown diagrammatically in FIG. 5, connected to stop the motor when the motor must strain beyond a predetermined level attempting to rotate its drive shaft. This may occur when the arm  69  contacts the right side of the stop  70 , or earlier when the paddle  50  encounters resistance from stored garments as described below. 
     The position of the paddle  50  is monitored using limit switches positioned on a plate  76  mounted adjacent to the axle  60 . A home position limit switch  73  is located approximately vertically above the axle  60 , a full position sensor  74  is located at about 120° counterclockwise from the vertical, and a coast position sensor  75  is located about 70° from the vertical. As the axle  60  rotates, a cam  78  mounted on the axle  60  trips each of the three limit switches. 
     The home position is designed to have a fairly wide range to allow for differences in overtravel of the paddle as it coasts. Therefore, the home position limit switch  73  is positioned so that it is tripped at some point before the arm  69  contacts the stop  70 , and will stay tripped from that point for the entire travel distance of the arm  69  to the stop. 
     The storage compartment  18  may be lined with an impervious storage bag  84  hanging on hooks  85  positioned along the rails  47  and  48 . The bag  84  is generally the shape of the storage compartment, for example, rectangular, and defines an opening  86  at the opening  46  leading from the inlet chamber  40 . An operator can access the bag  84  for removal and replacement through doors  87 , on which is a limit switch  88  (shown diagrammatically in FIG. 5) that indicates whether the door is closed. The bag opening  86  may be closed when removed from the compartment  18 . 
     The controller interface  20  includes a bar code or magnetic card reader  90  and a keypad  91  for allowing a user to input identification information, as described in U.S. Pat. Nos. 5,638,985, 5,713,270, and 5,829,349, which are incorporated herein by reference in their entirety. For example, a user can be required to initiate a dispensing or return operation by swiping a card or by entering a user number and then keying in a PIN. An LCD or LED display  93  shows information to the user, such as whether the user is authorized, whether the requested size is available, and whether or not the user has credits available. The display may also present instructions to the user on how to operate the apparatus  10 . Optionally, a video or still camera  94  may be positioned behind a horizontal window  95  within the cabinet  12  above the door  44  to look down into the inlet chamber  40 . The camera may be connected to a video tape recorder  96  and/or a television monitor  97  located in the electronics compartment  22 . This equipment may be used to record transactions for security and verification. A printer may also be located in the compartment  22  to allow easy printing of data stored in the memory of the processor  36 . 
     FIG. 5 shows a block diagram of a control system  100  for operating the combined dispensing and receiving apparatus  10 . The microprocessors  35  and  36  includes memory (not shown) for storing software modules for operating the apparatus  10 . This software is responsive to various inputs from sensors and input devices described above and issues signals to operate various components of the apparatus. The dispensing mechanism  14  is operated in the manner described in U.S. Pat. No. 5,638,985. Input signals  102  from the dispensing mechanism  14  are shown diagrammatically. Software drivers  101  for operating the motors, solenoids, etc., of the dispensing mechanism  14  are also shown diagrammatically. 
     The same microprocessors  35  and  36  may control both the dispensing and receiving mechanisms. The processor  36  at the panel  20  includes a memory that stores information about the location and contents of each receptacle, such as whether the receptacle is full and the sizes of the garments it contains. A program in the processor  36  allows an operator who is loading the machine with new scrubsuits to use the keypad  91  to modify the full/empty status of each slot in the memory. In the alternative, a remote computer  104  may program the sizes for each slot. The memory of the processor  36  also stores the “credits” allocated to each user and not previously used. 
     At the interface panel  20 , the card reader  90 , keypad  91 , and display  93  are controlled by the processor  36 , the memory of which holds a list of authorized card numbers. Each user can initiate a dispensing operation by entering a user number and personal identification number (PIN) at the user interface panel  20  in a manner described below. The processor  36  is programmed to determine whether a set of garments meeting the needs of that user is in inventory, and in which receptacle that set is located. If the correct garment is present, the processor  36  instructs the processor  35  to operate the mechanism to move the receptacle doors to expose the column of receptacles  31  in which that slot is located, and unlocks the user door  26  at that row. After the user withdraws the set of garments in the receptacle and closes the door, the processor  35  locks the door and updates the memory to reflect the empty status of that receptacle, and updates the user&#39;s credit account. 
     The processor  35  controls the operation of all the motors and solenoids for the apparatus  10 , and receives input signals from switches as needed to open the correct slot requested by the processor  36 . For the retrieving mechanism  16 , the processor  35  also includes retriever drivers  103  for operating the door solenoid  38  to lock and unlock the door  44 , and for operating the sweep motor  67  to move the paddle  50 . To determine when to operate these devices, the processor  35  utilizes inputs from the load sensor  71  associated with the motor  67 , the paddle position limit switches  73 ,  74 , and  75 , the door limit switch  45  on the door  44 , and the photosensor  43  in the inlet chamber. Inputs to the processor  36  include data read by the card reader  90  and input via the keypad  91 . The processor  35  sends signals to control the VCR  96 . Separately, the processor  36  controls the display  93  and the printer  98 . The apparatus  10  may be linked to other systems, for example a remote central computer  104 . The processor  36  may obtain information on individual user accounts from the central computer  104 , and return data regarding usage at the apparatus  10 . The processor  36  also may be networked along a data link  105  to other dispensing/receiving machines with links  106  to the central computer  104 . This data communication facilitates operation of a multi-station system within a large hospital or covering more than one small hospital or clinic. Further details of network operation are found in U.S. Pat. No. 5,638,985 and 5,713,270, and 5,829,349. 
     Operation of the combined dispensing and receiving apparatus  10  will be described with the aid of the flow diagram of FIG. 6. A user approaches the apparatus  10  and at step  601 , swipes a bar code or a magnetic card through the card reader  90 , or at step  602 , enters a card number and PIN number at the keypad  91 . The user selects the desired mode of operation (withdraw or return garments) at the keypad  91 . These entries may be prompted by the display  93 . At step  603  the processor determines whether the bar code or the magnetically entered user number or keypad entered user number and PIN number are valid. If not, the program returns to the ready mode. If so, the processor at step  604  allows the user to select whether or not to withdraw or return garments on his or her account. 
     If the choice is to withdraw garments from the dispensing mechanism  14 , the program proceeds to step  605  where the processor determines whether the user has credit available to make a withdrawal. If so, the dispensing process continues as described in U.S. Pat. No. 5,638,985. The steps there described will not be repeated in detail, such as receiving a requested size and determining and reporting whether the requested size is available and proper for the user. The dispensing process may proceed at step  607  to dispense a garment from one of the slots  31 , and the inventory and user credit history may be updated at step  608 . 
     If the user has chosen to return garments at step  604 , the The processor activates the video camera  94  at step  610  to record what is actually deposited into the inlet chamber  40 , and unlocks the return door solenoid  38  at step  611 . At step  612 , the user opens the return door  44  and deposits the garments into the door and closes it. The door limit switch  45  detects the closing of the door  44 , and the processor locks it by releasing the solenoid  38  which allows a spring latch (not shown) to lock the door at step  613 . As the garments fall through the inlet chamber  40 , they trigger the photocell sensor  43  at step  614 , which sends a signal to the processor  35  which sends data to the processor  36  confirming that a deposit did accompany the door opening and closing. If the sensor  43  does not detect a passing article, the processor  36  determines at step  615  that no credit will be given to the user&#39;s account. 
     When garment confirmation is made at step  616 , the processor  36  adds one set of garments to the user&#39;s credit account. Also, after a garment has triggered the sensor  43 , the processor  35  causes the motor  67  to begin rotating the axle  60 , and with it, the paddle  50  and the cam  78 . 
     Referring to FIG. 4, as the paddle rotates from the home position, it pushes garments G within the inlet chamber  40  into the storage compartment  18 , preferably into the bag  84 . Continued rotation of the paddle sweeps the garments toward the inner portion of the storage compartment  18  under the dispensing mechanism  14 . The paddle  50  may or may not pass the full limit switch  74 , depending on the contents of the storage chamber. If so, a signal is received by the processor  35 . During this clockwise rotation, the paddle  50  remains straight, and rotates until it encounters resistance from compacted garments if sufficient garments are present. The movement of the paddle on encountering resistance will compact the garments first in the inner, upper corner of the compartment  18  with an upward movement of the paddle, as shown in FIG. 4 with the paddle in dashed outline. Then, sufficient resistance triggers the resistance sensor associated with the motor  67 , which signals the processor to reverse rotation of the paddle at step  619 . If only a few garments are in the storage compartment, the paddle will reach its maximum travel at the angle A (225°) and the arm  69  will engage the stop  70 , causing the motor to reverse in the same way. 
     As the paddle  50  moves counterclockwise, some garments it has compressed may fall back from the corner. Such garments will be packed into the corner again on the next cycle of the paddle. Also during return motion, the paddle may engage garments G within the storage compartment. The full line position of the paddle  50  in FIG. 4 shows the paddle members  52  and  54  articulated about the joint  57  to pass by garments G. Sufficient force has been placed on the paddle member  54  to bend it about the joint  57 . As soon as the paddle clears the garments G, the spring  58  will straighten the paddle members, so that in the home position the paddle will be approximately vertical, and will not be in the path of garments deposited into the inlet chamber  40 . 
     During return movement of the paddle  50  counterclockwise toward the home position, the paddle triggers the coast limit switch  75 . At step  620 , the processor  35  monitors the coast limit switch. Until it is triggered, the motor  67  continues to drive in reverse. When the limit switch  75  is triggered by the cam  78 , power to the motor is disconnected at step  621 , allowing the paddle to coast into the home position. If there is enough coast, the arm  69  on the motor meets the stop  70 . When the home limit switch  73  is triggered, the processor checks at step  622  to determine whether the full limit switch  74  was passed during the preceding paddle cycle. If not, this indicates the storage compartment  18  is full, and further operation of the receiving mechanism  16  is disabled at step  623  until the compartment  18  is cleared (for example, by removing and replacing the bag  84 ). A signal indicating the apparatus  10  is full is sent to the processor  36  and may be sent to the central computer  104 , and a “FULL” message may be shown on the display  93 . If the full limit switch was passed during the previous cycle, then the compartment  18  has more capacity and the program returns to the ready state until another user logs in. 
     An operator may check on the apparatus  10  periodically, or when the inventory data maintained on the central computer  104  indicates the storage compartment  18  is full, or the dispensing mechanism  14  is empty or needs restocking in certain sizes. The operator has key access to the storage doors  87  and to the latch  28  of the dispenser main door  25 . The operator may restock the empty slots. The programming of which size should be loaded into which slot is performed at the computer  104  and displayed on the display  93  to the operator. However, if the apparatus  10  is not connected to a computer  104 , the operator logs in the slots that are loaded using the keypad  91 . 
     The operator may also remove and close the bag  84 , and install another bag  84  in the storage compartment  18 . The receiving mechanism  16  is automatically reset when the limit switch  88  indicates that the door  87  has been opened. In this case a door open signal is sent to the processor  35 , which informs the processor  36  that the storage compartment  18  has been emptied. Safety switches (not shown) on the doors  87  prevent operation of the motor  67  while the doors  87  are open. When the operator finishes servicing the apparatus  10 , he or she resets the control circuit  100  to allow further access by users as described above. 
     In one embodiment of the invention, the processor  36  is programmed to operate the paddle mechanism only periodically when the storage chamber  18  is relatively empty. There is no need under these conditions to pack the garments after every deposit, and the packing steps can be skipped for all but one of every five to ten cycles of accepting returned garments. This procedure eliminates the time of operation of the paddle from the majority of deposit cycles, and therefore beneficially reduces the average cycle time that users must wait for the apparatus to become ready for another deposit. After a predetermined number of deposit cycles, for example between  50  and  60  deposit cycles, the receiving mechanism may pack the garments after every deposit to insure that the scrubsuits do not back up into the inlet chamber  40  and are properly packed. 
     It is possible to use a stock confirmation terminal of the type shown in U.S. Pat. No. 5,638,985 in connection with the apparatus  10 , but this may not be desired with the smaller dispensing mechanism  14 . 
     The present invention may be practiced using variations in the embodiment described above. As will be clear from the foregoing, an apparatus can be constructed that can receive and pack goods, such as garments or the like, laterally with respect to the location of the intake and compacting mechanisms. Also, a compact apparatus can be constructed that will that both dispense and receive cloth items.