Abstract:
An apparatus and method for the efficient simultaneous loading and unloading a plurality of compact disc media into and out of a plurality of recording bays. The present invention provides a plurality of two position platters that allow the simultaneous rotation of a plurality of compact discs along horizontal planes defined by the platters above compact disc drive input trays for the transfer of the compact discs to a plurality of compact disc drives using a plurality of associated compact disc lifting devices that lift the compact discs off the platters allowing the platters to rotate along a central axis and then distributes the plurality of compact discs into the compact disc trays. One platter is used for each compact disc recording or writing drive. Loading and unloading of each disc platter is sequentially performed by pick and place systems while the compact disc writer drives are operating, thus eliminating delays in sequential loading and unloading while maximizing recording time per disc recording or writer drive.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     None. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     None. 
     REFERENCE TO A MICRO-FICHE APPENDIX 
     None. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     This invention relates to a method and apparatus for simultaneous automated loading and unloading of a plurality of disc handling machines, such as disc drives or compact disc recording (“CDR”) units, for the repetitive mass recording of compact discs, digital video discs, or other similar media. The present invention incorporates as part of a rotatable disc delivery component my previous invention, U.S. Pat. No. 5,873,692, for picking a single compact disc from a stack of blank compact discs and loading the selected disc into a predetermined platter bay. The rotatable disc delivery component also functions to pick a single recorded compact dick from a predetermined platter bay and depositing the recorded disc into a recorded disc module. 
     Existing equipment for loading and unloading disc handling machines is unnecessarily time consuming with considerable unutilized machine downtime as a result of these inefficiencies, and it remains desirable to find a low-cost, simple solution to this problem. 
     Present volume copying onto digital compact discs presents significant inefficiencies in disc drive utilization. Loading and unloading multiple disc drives or CDR units using existing methods and apparatus results in drive down-time while the automated loading devices empty and load each individual drive or CDR unit in succession. For multiple drive or CDR unit systems, this downtime can be as much as three to ten minutes, depending upon the mechanism and drive or CDR unit loading geometry employed by the system. Over the course of recording one thousand discs, this underutilization of recording drives or CDR units can limit the productivity and usefulness of the system from approximately three to eight hours. 
     The existing methods and apparatus also present delays and inefficiencies in handling recorded disc output, labeling and segregation. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with the invention claimed, one embodiment of a method and apparatus for automated simultaneous loading and unloading multiple disc drives during bulk recording operations of digital compact discs is provided in a novel construction and procedure that overcomes the deficiencies and limitations of prior art. 
     It is, therefore, one object of this invention to provide an improved apparatus and method for concurrent copying of recordable digital compact discs. 
     A further object of the present invention is to provide such an improved apparatus and method for simultaneous automated loading of a plurality of disc handling machines. 
     Another object of this invention is to provide such an improved apparatus and method for automated simultaneous loading of multiple disc recording devices or CDR units. 
     It is yet another object of this invention to provide such an improved apparatus and method for automated simultaneous unloading of multiple disc recording devices or CDR units. 
     A further object of this invention to increase the recording drive utilization during multiple, automated bulk disc recording operations. 
     Still another object of this invention is to improve the blank disc and recorded disc handling and storing efficiency during multiple, automated bulk disc recording operations. 
     Yet another object of this invention is to provide improved spatial and functional efficiencies during multiple, automated bulk disc recording operations. 
     A further object of the present invention is to provide such an improved apparatus and method for simultaneous automated unloading of a plurality of disc handling machines. 
     A further object of the present invention is to provide an apparatus and method to minimize underutilized machine downtime for a plurality of disc handling machines during bulk disc recording routines. 
     A further object of the present invention is to provide an apparatus and method to improve machine efficiency for a plurality of disc handling machines during bulk disc recording routines. 
     A further object of the present invention is to provide an apparatus and method to eliminate tedium associated with manual or direct human supervision of bulk disc recording routines. 
     A further object of the present invention is to provide an apparatus and method to eliminate human error associated with manual or direct human supervision of bulk disc recording routines. 
     A further object of the present invention is to provide an apparatus and method to eliminate labor costs associated with manual or direct human supervision of bulk disc recording routines. 
     Related object and advantages of the present invention will be apparent from the following description. 
     Other features, advantages, and objects of the present invention will become apparent with reference to the following description and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a schematic view of a portion of the simultaneous automated loading tower apparatus of this invention with a perspective view of the rotating picker assembly loading a disc into a platter bay. 
     FIG. 2 is a top view of an individual platter with horizontally aligned bays and a disc loaded into one of the bays. 
     FIG. 3 is a side view of the vertical drive shaft with several platters attached and each platter having a disc in one bay. 
     FIG. 4 is a side view of several representative crankshaft arms positioned below open disc recording drive bays. 
     FIG. 5 is a side view of several representative crankshaft arms positioned to lift recorded discs from open disc recording drive bays and the edge of representative platters. 
     FIG. 6 is a full sized, top view of an individual platter with perpendicularly aligned bays and a disc loaded into one of the bays. 
     FIG. 7 a - 7   e  is a flow chart illustrating the operation of a preferred embodiment of the simultaneous automatic loading tower apparatus of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     For the purposes of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the present invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. 
     Referring to FIG. 1, the simultaneous automatic loading tower of the present invention is designated generally by the reference numeral  10 . The loading tower system  10  includes a host computer  15  connected to the loading tower unit  16 . The host computer comprises a programmable computer that includes computer software for providing a user interface for operating the components of the loading tower system. The host computer also contains the master disc transfer unit which reads digital master data from one or more discs and then transfers the digital data to loaded disc drives or CDR units. It is to be understood that the host computer may be incorporated into the loading tower system with the loading tower system having an input device such as a keyboard or other control panel for managing the operation of the loading tower system. 
     The loading tower system comprises a supporting framework that has a base platform or deck  17  which has a pivotal transport tower  18 , a cabinet or similar vertical housing for disc drives or CDR units  19 , a rotatable vertical platter assembly  20 , and a number of vertical disc stacking modules  21 . The tower framework is preferably made from standard sheet metal which is formed to provide front face, top face, and support base working surfaces. Other construction for the tower framework could include high strength poly-carbon or similar unitarily formed materials which could be adapted to the same base platform materials or metal by mounting into predetermined fitted bays or slotted positions with nut and bolt attachment. 
     Part of the tower framework front face  22  includes openings such that the disc recording or CDR units are mounted within such openings with conventional mounting hardware, such that the doors of the disc recording or CDR units  23  open outwardly from the front face  22  of the tower framework. Thus, the tower framework provides a cabinet or vertical housing  19  for the disc recording units or drives which includes a base with disc drives or units mounted thereon. The interior volume of the cabinet or vertical housing  19  contains the compact disc writing units and related wiring connections. The cabinet base could be modified to include an integrated controller. In the preferred embodiment of the present apparatus, eight disc drives or CDR units are arranged in vertical alignment of one cabinet or vertical bay  19 ; however the number of recording drives or units is arbitrary and is dictated by the physical or practical aspects of the individual drives or units, the type of digital media employed, or the performance requirements over time of the entire mass disc recording specifications. It is also conceivable that the principles disclosed herein are applicable to more than one tower of drives or CDR units by providing additional cabinets or vertical bays housing disc recording drives or CDR units within the framework. In such an embodiment, the present invention and method could service at least three such cabinets, wherein each such cabinet is configured at ninety degree alignment to its adjacent cabinet and oriented around the centrally positioned drive shaft of the rotatable vertical tray assembly  20 . 
     The aligned disc drives or CDR units are electro-mechanically controlled by the host computer or other microprocessor based controller using well known programming techniques. 
     As depicted in FIGS. 2,  3  and  6 , the nominal compact disc  30  with a 120 mm diameter is loaded into the platter disc bay  29 . The compact disc includes a center hole, nominally 15 mm, which is defined by a radial hub which extends orthogonally from the surface of the disc approximately 0.010 inches so as to avoid stacked discs from resting on recorded disc surfaces. The disc center hole is aligned with the disc center axis. Although this embodiment of the present invention depicts the 120 mm diameter disc, the same principles would apply to discs of smaller diameters. 
     It is also conceivable that the principles disclosed herein could apply to any stack of flat substrates having uniform dimensions regardless of shape. 
     It is also conceivable that the principles disclosed herein could apply to control any variety of simultaneous disc handling operations as would be obvious to one skilled in this technology, such as labeling, archiving, jukebox, and the like. 
     The rotatable vertical tray assembly comprises a plurality of uniform, horizontal platters  24  perpendicularly attached to a drive shaft  25  at predetermined equal distances between each platter. As depicted in FIG. 3 each platter  24  has a central vertical axis  26 , a top side  27 , and a bottom side  28 . Each platter has a point of attachment to the drive shaft on each platter central vertical axis. As shown in FIGS. 2,  3  and  6 , each platter contains dual disc bays  29  which are equally sized and displaced from the platter cental axis to receive discs  30  from the top of the platter  27 . Each platter can be constructed from durable, high impact poly-carbon material or aluminum to minimize weight and load upon the drive shaft and motor. The bays for each platter may be in a straight line, or 180 degree, alignment with each other as depicted in FIG. 2, or in a perpendicular, or 90 degree, alignment as depicted in FIG.  6 . It is also conceivable that other platter bay alignment relative to each platter can be governed by the principles herein depending upon the spatial limitations and number of towers used in each system. Such platter bay alignment or configuration is dictated by space and material considerations of the relative scale of operations of the principles herein for each apparatus embodiment of the present invention. 
     In the preferred construction, each said disc bay comprises a front edge  31 , a back edge  32 , and a central core  33 . Each disc bay front edge  31  is open and said central core  33  is accessible from the top and the bottom of the platter. Each platter bay top  27  has four uniform raised pegs  34  which are equidistantly oriented from each bay center point at perpendicular angles from each other and at a distance just slightly greater than the radius of the compact disc  30 . In this manner, the discs are centered within each platter bay. In the preferred embodiment of the present invention, these pegs  34  are constructed from uniform extrusion of the platter material. 
     In the preferred embodiment, the platters  24  and drive shaft  25  are protected and separated from the exterior of the apparatus by a removable, translucent plexiglass or similarly constructed shield which rests upon and is supported by the framework base and extends vertically to a height equal to the top of the framework. Rotation of the drive shaft and horizontal movement of said platters along the vertical axis  26  of the drive shaft  25  is provided by a stepper motor and actuator attached to the bottom of the drive shaft. The action of the stepper motor is electro-mechanically controlled by the host computer or other microprocessor based controller using well known programming techniques. 
     As depicted in FIGS. 4 and 5, the cabinet or vertical housing  19  for the disc drives or CDR units  23  has a plurality of uniform, articulate arms  35  which are attached to and controlled by a vertically adjustable crankshaft  36 . The plurality of uniform arms  35  are perpendicularly attached to the crankshaft  36  at predetermined equal distances between arms. Attachment of the arms to the crankshaft may be by weldment or nut and bolt assembly, depending on the materials of construction. The arms of the crankshaft may be constructed from durable, high impact poly-carbon material or aluminum to minimize weight and load upon the drive shaft and motor. Each uniform arm comprises a top surface with a raised, stopper  37  centrally positioned thereon. Each stopper  37  top is tapered from top to bottom and sized to engage a disc by the disc center hole. Each stopper  37  is of a uniform height and diameter sufficiently sized to access a disc  30  loaded onto a platter bay  24  through an open recording drive or CDR unit bay  23 . The stoppers  37  may be constructed from a variety of lightweight, solid materials with high resistance to wear. Once engaged by a stopper  37 , the disc  30  is lifted by positive vertical movement of the uniform arm  35  as shown in FIG.  5 . Movement of the crankshaft  36  is electro-mechanically controlled along its longitudinal axis by a stepper motor and actuator housed in the framework base. The stepper motor and actuator are controlled by the host computer or other microprocessor based controller using well known programming techniques. Operation of the crankshaft  36  allows loading or unloading of the horizontal platters  24  and the disc drive or CDR unit bays  23 . 
     As shown in FIG. 1, the framework base  17  also supports and includes a rotatable arm  18  which houses a compact disc picker assembly  38 . The picker assembly  38  is positioned along the vertical axis of the rotatable arm  18 , and said picker assembly  38  moves vertically up and down said rotatable arm  18 . In the preferred embodiment of the present invention, the rotatable arm  18  rotates freely up to  300  degrees along its vertical axis. The rotational movement of the arm  18  is controlled by a stepper motor and actuator housed in the framework base. The vertical movement of the disc picker assembly  38  within the arm  18  is controlled by a separate stepper motor, photo eye, and actuator within the rotatable arm. Both stepper motors and actuators and the photo eye of the rotatable arm are controlled by the host computer or other microprocessor based controller using well known programming techniques. The photo eye of the disc picker detects disc height position and provides this control input to the controller. Disc picker assembly mechanisms are well known in the art. The preferred embodiment of the present invention uses the disc picker assembly apparatus disclosed in my prior invention, U.S. Pat. No. 5,873,692. By addition of components to the preferred embodiment, the rotatable arm  18  and picker assembly can be used to transport blank compact discs from a bulk supply hopper to the disc stack modules  21  and to transport recorded discs from stack modules  21  to labeling components or a bulk recorded disc hopper. 
     It is also conceivable that the degree of rotation for the rotatable arm  18  along its vertical axis can vary according to the principles herein depending upon the spatial limitations and number of disc stack modules  21  of each system. 
     As shown in FIG. 1, the framework base  17  of the depicted embodiment of the present invention also includes and supports disc stack modules  21  disposed in an arcuate arrangement and configured semi-circularly around the rotatable arm  18 . The preferred embodiment of the present invention includes four such stack modules  21  and also includes and one disc spindle, not shown in FIG. 1, also disposed in an arcuate arrangement and configured within the same semi-circular arc around the rotatable arm  18 . For the preferred embodiment of the present invention, the disc spindle is located closest towards the drive shaft and platters, with the stack modules  21  spaced equidistant around the rotatable arm within a 270 degree arc. The disc spindle includes a vertical post affixed to the framework base, for example by nut and bolt, wherein the post diameter is slightly smaller than the disc hub center hole. Each stack module  21  includes three vertical posts affixed to the framework base, for example by nut and bolt. Each of the posts are vertically oriented and spaced apart from each other. The spacing and orientation of the vertical posts for each stack module  21  are such that an equilateral triangle is formed by the three posts with space within the posts to just accommodate the diameter of a compact disc when the center of the disc is aligned with the center point of the equilateral triangle. In the preferred embodiment of the present invention, the disc spindle and stack module posts heights are 18 inches each. In the preferred embodiment of the present invention, the four stack modules are initially loaded with 250 blank discs each. As the recording process continues, the finished, recorded discs are first loaded by the disc picker module  38  from the platter bays  29  onto the spindle. Once a blank disc stack module  21  is completely empty, the space provided therein is used to store additional finished, recorded discs. Thus when the recording process is completed, the spindle and three stack modules each contain 250 finished, recorded discs. 
     The operation of the apparatus for simultaneous loading a plurality of discs into a plurality of disc recording drives, wherein each disc has a hub defining a center hole such that the center hole in a stack of said discs define a central cylindrical bore having a longitudinal axis, is now described. The logic necessary to control the steps for the simultaneous automatic loading tower apparatus operation as depicted in FIG. 7 a - 7   d  is programmed into the microprocessor located in the tower base and into the computer software on the external host computer. 
     In step  100 , the method for using the apparatus for simultaneous loading a plurality of discs  30  into a plurality of disc recording drives  23  begins by providing at least one blank disc stack module  21  having at least one vertical support for a plurality of blank discs. In the preferred embodiment of the apparatus for the present invention, four blank disc stack modules  21  are loaded with approximately 250 blank discs per module. As the method continues through loading and unloading the recording or CDR unit drives, the blank disc stack modules  21  empty and become converted to recorded disc stack modules. 
     Step  102  in this operation is providing at least one recorded disc stack module having at least one vertical support for a plurality of recorded discs. In the preferred embodiment of the apparatus for the present invention, one recorded disc stack module is initially available with capacity for approximately 250 recorded discs. As the method continues through repeated loading and unloading of the recording drives, the blank disc stack modules  21  empty and become available to be used as recorded disc stack modules. 
     In step  104 , operation is furthered by providing a plurality of blank discs  30  in each said blank disc stack module  21 . In the preferred embodiment of the present invention, 250 blank discs are initially loaded into each of four blank disc stack modules  21 . 
     In step  106 , operation is furthered by providing a plurality of vertically stacked, uniform disc recording drives or CDR units  23 . In the preferred embodiment of the apparatus for the present invention, eight such disc or CDR unit drives are provided. 
     In step  108 , operation is furthered by providing a plurality of vertically stacked, uniform platters  24  perpendicularly connected to a vertical support member  25 , with a controlled horizontal range of motion around the central axis of said vertical support member  26 , each platter further comprising dual, uniform disc bays  29 . In the preferred embodiment of the apparatus for the present invention, eight such platters are provided. 
     In step  110 , operation is furthered by providing a rotatable arm  18  which houses a disc picker module  38  with a controlled range of motion among said blank disc stack modules  21 , recorded disc stack modules, and said platters  29 . In the preferred embodiment of the apparatus for the present invention, said disc picker module is applicant&#39;s invention described in U.S. Pat. No. 5,873,692. 
     In step  112 , operation is furthered by providing a crankshaft module  36  to control the vertical movement of a plurality of uniform arms  35 , each said arm comprising a stopper  37  with its top tapered from top to bottom and sized to fit into said disc center hole and thus engage said disc  30 . 
     In step  114 , operation is furthered by controlling said platter movement so that a plurality of empty platter bays  29  are aligned to be loaded with blank discs  30 . 
     In step  116 , operation is furthered by controlling said disc picker module  38  to load one blank disc into each empty aligned platter bay  29  from a blank disc stack module  21 . 
     In step  118 , once each aligned platter bay  29  has been loaded with one blank disc  30 , operation is furthered by controlling said disc recording drive or CDR unit bays  23  to simultaneously open. 
     In step  120 , once said bays  23  are open, operation is furthered by controlling said platter bays  29  to rotate horizontally to a position wherein the center of said blank discs are positioned directly over the center of said open disc recording drive or CDR unit bays  23 . 
     In step  122 , once the blank discs loaded into said platter bays  29  are positioned directly over the center of said open disc recording drive or CDR unit bays  23 , operation is furthered by controlling said crankshaft module  36  to simultaneously engage the plurality of blank discs  30  in said platter bays  29  and lift said blank discs  30  from said platter bays  29 . 
     In step  124 , once the plurality of blank discs  30  in said platter bays  29  have been lifted from said platter bays  29  and are held by said crankshaft module  36 , operation is furthered by controlling said platter bays  29  to rotate horizontally away from said open disc recording drives or CDR units  23 . 
     In step  126 , after said platter bays  29  have been rotated horizontally away from said open disc recording drives or CDR units  23 , operation is furthered by controlling said crankshaft module  36  to simultaneously lower the plurality of blank discs  30  into said disc recording or CDR unit drives  23  and to then simultaneously disengage from said blank discs  30 . 
     In step  128 , after the blank discs  30  have been lowered into said disc recording or CDR unit drives  23  and the crankshaft module  36  has disengaged from said blank discs  30 , operation is furthered by simultaneously closing said plurality of disc recording or CDR unit drives  23 . 
     In step  130 , once the disc or CDR unit drives  23  are closed with the blank discs  30  now in place for receiving digital data, operation is furthered by recording digital media onto said plurality of loaded discs. 
     In step  132 , while the disc are receiving digital data, operation is furthered by repeating the loading steps of this method for a plurality of blank discs into said platter bays  29 . 
     In step  134 , operation is furthered by completing the recording of digital data onto the plurality of discs loaded into the disc or CDR unit drives  23 . 
     In step  136 , once all digital data has been recorded onto the discs loaded into the discs drives  23 , operation is furthered by controlling said disc recording drive or CDR unit bays  23  containing the recorded discs to simultaneously open. 
     In step  138 , after the disc or CDR unit drives  23  are completely open, operation is furthered by controlling said crankshaft module  36  to simultaneously engage the plurality of recorded discs in said recording drive or CDR unit bays  23  and lift said recorded discs from said recording drive or CDR unit bays. 
     In step  140 , after the recorded discs have been lifted from said recording drive or CDR unit bays  23 , operation is furthered by controlling said empty platter bays  29  to rotate horizontally to a position directly under said recorded discs held by said crankshaft module  36  wherein the center  33  of each said empty platter bay  29  is aligned with the center of each said recorded disc. 
     In step  142 , once the empty platter centers  33  and recorded disc centers are so aligned, operation is furthered by controlling said crankshaft module  36  to simultaneously lower the plurality of recorded discs into said empty platter bays  29  and to then simultaneously disengage from said recorded discs. 
     In step  144 , once all recorded discs are residing in said platter bays  29 , operation is furthered by controlling said platter bays to rotate horizontally to a position wherein the center of said blank discs  30  are positioned directly over the center of said open disc recording drive or CDR unit bays  23 . 
     In step  146 , once the blank disc centers and disc recording drive or CDR unit bay centers  23  are so aligned, operation is furthered by controlling said crankshaft module  36  to simultaneously engage the plurality of blank discs  30  in said platter bays  29  and lift said blank discs  30  from said platter bays  29 . 
     In step  148 , once the blank discs  30  have been so lifted from said platter bays  29 , operation is furthered by controlling said platter bays  29  to rotate horizontally away from said open disc recording or CDR unit drives  23 . 
     In step  150 , after the bays  29  have been rotated away from said open disc recording or CDR unit drives  23 , operation is furthered by controlling said crankshaft module  36  to simultaneously lower the plurality of blank discs  30  into said  20  disc recording or CDR unit drives  23  and to then simultaneously disengage from said blank discs. 
     In step  152 , once the recording drive or CDR unit bays  23  are thus loaded, operation is furthered by simultaneously closing said plurality of disc recording or CDR unit drives  23 . 
     In step  154 , once the disc or CDR unit drives  23  are closed with the blank discs  30  now in place for receiving digital data, operation is furthered by recording digital media onto said plurality of loaded discs. 
     In step  156 , after recording digital media onto said loaded discs has begun, operation is furthered by controlling said platter bays containing the recorded discs to rotate horizontally to a position wherein said recorded discs are accessible by said disc picker module  38 . 
     In step  158 , once the recorded discs have been rotated horizontally to the desired position for access by the disc picker module  38 , operation is furthered by controlling said disc picker module  38  to unload each platter bay  29  containing a recorded disc into said recorded disc stack module. 
     In step  160 , operation is furthered by repeating the loading steps of this method for a plurality of blank discs into said platter bays during the recording phase for a plurality of discs. 
     In step  162 , operation is furthered by repeating the unloading and loading steps of said disc recording or CDR unit drives  23  of this method until the desired number of discs have been recorded. 
     In step  164 , once the desired number of discs have been recorded, the method is terminated. 
     It should be noted that this operational routine is run iteratively, and that additional positions may be defined, for example by including more than one tower of drives or CDR units  23 , or, if additional serviced modules are interconnected, by using one rotatable picker assembly module  38  and one rotatable vertical tray assembly to service any additional tower modules  23  or stacked disc modules  21 . Steps  138  through  154  are thereby exemplary for a desired embodiment of the present apparatus and may be repeated for different apparatus embodiments by modifying the method sequence accordingly. 
     It should be understood that the invention is not intended to be limited by the specifics of the above-described embodiments, but rather by the accompanying claims.