Abstract:
A modular card production safety interlock system limits disruption of a modular card production system by limiting operational disturbances to a desired system module and only its neighboring system modules upon opening the hood of the desired system module.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Cross-Reference to Related Applications  
         [0002]     The present application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/739,764 entitled “MODULAR MATERIAL PROCESSING SYSTEM SAFETY INTERLOCK SCHEME AND METHOD OF OPERATION,” filed on Nov. 23, 2005, which is herewith incorporated by reference in its entirety.  
         [0003]     2. Field of the Invention  
         [0004]     This invention relates generally to the field of modular material processing systems. More particularly, the invention relates to a modular material processing system safety interlock scheme that limits disruption of a modular material processing system by limiting operational disturbances to a desired system processing (function) module and only its neighboring system modules upon opening the hood of the desired system module.  
         [0005]     3. Description of the Prior Art  
         [0006]     Modular material processing systems are used to produce large volumes of a variety of different types of personalized identity documents including, but not limited to, credit cards, licenses, personal identification cards, calling cards, and booklets such as passports, among other types of documents. Generally, these systems include a number of different modules that perform various functions. These functions can include but are not confined to magnetic encoding, embossing, smart card programming, laser printing, cleaning, and laminating of personalized documents. Examples of modular material processing systems are numerous.  
         [0007]     In a system with multiple modules, where each module has its own hood, it is typical that if one hood is opened, it will affect the operation of the other modules throughout the modular material processing system.  
         [0008]     Although modular material processing systems are becoming more technologically advanced, a need still exists for a modular material processing system safety interlock scheme that limits disruption of a modular material processing system by limiting operational disturbances to a desired system module and only its neighboring system modules upon opening the hood of the desired system module.  
       SUMMARY OF THE INVENTION  
       [0009]     The present invention is directed to a modular material processing system safety interlock scheme that limits disruption of a modular material processing system by limiting operational disturbances to a desired system module and only its neighboring system modules upon opening the hood of the desired system module.  
         [0010]     The material processing system most preferably includes a plurality of function modules and a DC voltage supply bus that allows peer-topeer interlock control solely between adjacent function modules within the material processing system.  
         [0011]     According to one embodiment, a modular material processing system comprises a plurality of sequentially ordered modules, wherein each module is coupled to an adjacent upstream and/or downstream module. This system may also comprise a main or primary controller in electrical communication with each of the modules. Those skilled in the art will readily appreciate the controller could be any suitable control unit such as, but not limited to, a CPU, personal computer, microprocessor, microcomputer, microcontroller, and many other types of data processing control units. Each system module is protected via an enclosed hood (cover) to prevent accidental access to the material(s), e.g. cards, being processed via the module. Upon opening the hood associated with a desired system module, and without assistance from the main controller, the desired system module controls via the safety interlock system, operation of its adjacent system modules. Modules that are not adjacent to the desired module are unaffected by the hood opening, and continue to process material(s) elsewhere in the modular material processing system. Localizing the disruption allows the modular material processing system to minimize material scrap when a hood is opened for inspection, maintenance, upgrading, and the like.  
         [0012]     Accordingly, one feature of the invention is directed to providing a modular material processing system that operates in accordance with safety requirements specified, for example, by predetermined organizations, e.g., UL or TUV. When a module hood is opened, for example, it is most preferable to also disrupt power to adjacent modules such that accidental mechanical or electrical injuries originating from an adjacent module can be prevented during maintenance operations associated with the module being serviced.  
         [0013]     Another feature of the invention is directed to providing a modular material processing system that operates to localize module operational disruptions resulting in reduced material scrap whenever a module hood is opened to provide manual access.  
         [0014]     Yet another feature of the invention is directed to providing a modular material processing system that operates to discourage a system operator from manually adjusting material handled by the system during a disrupted operational state. This feature importantly prevents inaccurate material creation or material tracking errors due to manual adjustments of materials being processed elsewhere in the system during disruption of one or more modules in a different system location.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]     Other aspects and features of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which like reference numerals designate like parts throughout the figures thereof and wherein:  
         [0016]      FIG. 1  is a schematic diagram illustrating a modular material processing system safety interlock scheme according to one embodiment of the present invention; and  
         [0017]      FIG. 2  is a perspective view illustrating a modular material processing system. 
     
    
       [0018]     While the above-identified drawing figures set forth alternative embodiments, other embodiments of the present invention are also contemplated, as noted in the discussion. In all cases, this disclosure presents illustrated embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0019]     Looking now at  FIG. 1 , a schematic diagram illustrates a modular material processing system  10  including a safety interlock system  12  according to one embodiment. Material processing system  10  has a first material processing module  14 , a down-stream module  16 , and an up-stream module  18 . The safety interlock system  12  can be seen to have a generic architecture suitable for use with each system module  14 ,  16 ,  18 . The generic safety interlock system  12  associated with each module obtains its power from a +12VDC power transmission device associated solely with its respective module. Exemplary power transmission devices may include, but are not limited to, lasers and laser devices, hazardous light devices, pneumatic devices, hydraulic devices, voltage controller devices, current controller devices and ultraviolet light devices.  
         [0020]     This architecture advantageously eliminates the necessity for providing a common power source that must be configured to supply power to all of the modules in the material processing system  10 .  
         [0021]     Another advantage provided with such an architecture is the provision of enhanced isolation between the system modules, thus enhancing also the system modularity. Historically, such systems have used a common DC power source to enable all of the module interlocks within the system  10 . Such common DC power sources have been difficult to scale in terms of architecture and available interlock power, especially when applied to large, modular material processing systems.  
         [0022]     Operation of the safety interlock system  12  will be described now below with reference to a single module  14  in order to enhance the clarity in describing features of the safety interlock system  12 . It shall be understood however, that each module  14 ,  16 ,  18  operates in the same fashion.  
         [0023]     Looking now at module  14 , a 12VDC power transmission device  20  is provided on a module interlock board  22 . A power transmission device voltage  20  passes through an interlock switch  24  that is configured to open when the module  14  hood is opened, and that is configured to close when the module  14  hood is closed. As illustrated in  FIG. 1 , interlock switch  24  is interpreted to also represent the module  14  hood. When interlock switch  24  is in its closed position, a 12VDC voltage will connect via a DC bus  26  to interconnect pin  3  of modules  14  and  18 , and loop back to interconnect pin  2  of modules  18  and  14  via a loop back switch  28  in module  18 . Loop back switch  28  is energized solely via the 12VDC power transmission device  42  associated with module  18 . So long as the hood of module  18  is closed, interlock switch  30  will be closed to supply the requisite power to maintain closure of interlock switch  30  and loop back switch  28 . In like fashion, so long as the hood of module  14  is closed, interlock switch  24  will be closed to supply the requisite power to maintain closure of interlock switch  24  and loop back switch  32 . Closure of loop back switches  28  and  32  will result in 12VDC appearing at interlock terminals  34  and  36  via interlock switches  38  and  40  respectively, to supply power to various module components such as motor circuits related to the material processing operations associated solely with modules  14  and  16 .  
         [0024]     The modular material processing system  10  architecture importantly eliminates the use of a single primary power source to provide power to the modules in the system  10 . This feature allows the system  10  to grow or shrink to any desired size, since the use of individual module power sources eliminates the necessity to scale and rescale the size of the primary power source to meet the changing needs of the system  10  as the size of the system  10  changes.  
         [0025]     This system  10  architecture also provides the requisite safety features necessary to meet or exceed regulatory requirements set by agencies such as Underwriters Laboratories (UL) and TUV. Opening the hood of one module, for example, will disable the motor drive circuits associated with the module as well as the motor drive circuits associated with any adjacent modules. In this way, an operator can manually interrogate the module having the open hood without concern for mechanical or electrical related injuries resulting from nearby modules.  
         [0026]     This system  10  architecture further advantageously substantially eliminates or minimizes the production of scrap associated with the material processing operation. Since, as stated herein before, opening the hood of a single module affects only the operation of the single module and any adjacent modules, the remaining modules in the system  10  continue to operate and process any materials passing through those remaining modules. In this way, materials being processed elsewhere in the system  10  are not wasted, and the efficiency of the material processing operation is optimized for maximum throughput. This feature becomes even more important as the size of the system  10  increases with respect to the number of modules in the system  10 . This features becomes more important also as the cost associated with the materials being processed by the system  10  increases.  
         [0027]      FIG. 2  depicts a perspective view of a modular material processing system  100 . Material processing system  100  can be seen to include a plurality of processing (function) modules  14  that are configured in a sequential arrangement to process material such as identification cards discussed herein before. Material processing system  100  can also be seen to include an operator station  120 , an input hopper  130 , and an output hopper  150 . A system controller  122 , illustrated in dashed lines in  FIG. 2 , resides in the housing  127 . The controller  122  controls operation of the system  100  and transfers data to and from the input hopper  130 , the modules  14 , and the output hopper  150 . The controller  122  can be a computer or any central processing unit suitable for transferring data and processing information, as stated herein before. Operator interface means  123 ,  123   a  are connected to a data port system  123   b  of the controller  122  to permit control commands and data input to the controller  122 . Preferably, the interface means  123 ,  123   a  are a keyboard and mouse, as depicted in  FIG. 2 . However, it will be appreciated that other suitable interface means may be employed. Each module  14  also includes its own module controller (not shown) that controls the functions and operation of the respective module.  
         [0028]     The input hopper  130  preferably includes at least one tray  137  configured to hold a supply of cards  137   a . The input hopper  130  works by picking a card  137   a  from the supply tray  137  and transferring the card into the adjacent downstream processing module  14  to begin the card (material) processing. A cover  131  protects the inside of the input hopper  130 .  
         [0029]     As with the input hopper  130 , each function module  14  includes a cover  141 . The covers  141  may include a transparent surface allowing a user or operator to view the inside of each of the processing modules  14 . A variety of processing modules  14  may be employed in the system  100 , including, but not limited to 1) a magnetic stripe module for writing data to and reading data from a magnetic stripe on the cards, 2) an embossing module for forming embossed characters on the cards, 3) a smart card programming module for programming an integrated circuit chip on the cards, 4) a printer module for performing monochromatic or multi-color printing, 5) a laser module for performing laser personalization on the cards, 6) a graphics module for applying monochromatic data and images to the cards, 7) a cleaning module for cleaning the cards, 8) a topping module for applying a topcoat to the cards, and 9) a card punching module to punch or cut a hole into the cards and/or to punch the card into a specific shape.  
         [0030]     In summary explanation, a modular material processing system includes a plurality of function modules, wherein each module has an access cover, a plurality of interlock switches, and a power transmission device integrated therein. The interlock switches are configured together as a safety interlock system such that opening a single module access cover operates to disable the respective module power transmission device and deactivate hazard related circuits associated with the respective module and solely any adjacent modules.  
         [0031]     The invention may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not limitative. The scope of the invention is indicated by the appended claims rather than by the foregoing description; and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein.  
         [0032]     The modular material processing system  10 , for example, may also employ a bypass sense feature  50  that is configured to allow under certain predetermined operating conditions, continued processing of material(s), even when a module hood is opened. Further, each function module may be accessed manually via a door, covering, shield, or other type of entry mechanism rather than via a hood as discussed herein before. It shall also be understood that although various switches are depicted as coil activated devices, the present invention is not so limited; and solid state devices, among other types of switching devices, could just as easily be employed to achieve the desired results according to the principles described herein before.