Abstract:
The present invention is a reverse vending machine which accepts non-metallic and metallic beverage containers for processing. The beverage containers are inserted by the user into an intake chute, where they are then compacted, sorted, and deposited in storage bins contained in the machine. A number of additional functions are provided by the reverse vending machine, including a self cleaning system, a video screen for displaying information to users, a bar code scanner for scanning bar codes, a user ID reader, and a coupon printer for issuing coupons to users. All transaction information is processed by a computer and stored electronically. The invention automatically returns non-empty containers and containers with unacceptable or unreadable bar codes to the user. The user is also provided warning messages when the storage bins are nearly full, or when a container is jammed in the machine.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    (Not Applicable.) 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
       [0002]    (Not Applicable.) 
       FIELD OF THE INVENTION 
       [0003]    This invention relates to beverage container recycling machines, and more particularly to a novel reverse vending machine. 
       DISCUSSION OF RELATED ART 
       [0004]    The present invention relates generally to beverage container recycling machines, and more particularly to a reverse vending machine for beverage containers which provides a significant variety of useful functions in addition to compacting and storing beverage containers. 
         [0005]    In recent times as various types of beverage containers have been produced in ever increasing quantities, a corresponding need has developed to recycle used beverage containers in the most cost effective and efficient manner possible. Legislation has been enacted in many states requiring that redemption deposits be imposed on beverage containers to encourage consumers to redeem their used beverage containers, thereby avoiding the environmental problems caused by discarded beverage containers. Other states have initiated programs to encourage voluntary recycling of beverage containers without imposing redemption deposits on beverage containers. Redemption of used beverage containers has thus necessitated the development of economical and effective beverage container recycling equipment. 
         [0006]    Recycling of used beverage containers, without the use of automated equipment, usually requires extensive manual labor, personnel costs, and production space in order to properly sort, compact, and count large quantities of used beverage containers. Such methods of recycling may require unacceptably high production costs, making the recycling process economically impractical. A need has therefore developed in the is recycling industry for convenient, efficient, cost effective container recycling equipment, capable of accepting a variety of beverage container types. 
         [0007]    U.S. Pat. No. 7,754,990 to Saether illustrates a reverse vending machine capable of receiving, sorting, and storing used beverage containers. A conveyor means is used to convey and sort the container objects. U.S. Pat. No. 5,161,661 to Hammond discloses a reverse vending apparatus which diverts inserted containers to one of two compaction roller sets, which compact the beverage containers and deliver them to receptacles. Current beverage container recycling technology has not properly addressed several requirements in the container recycling process. The present invention is a reverse vending machine providing a combination of advanced features which do not appear to be addressed by current technologies. The present invention includes the ability to detect and reject non-empty beverage containers or beverage containers with improper or unreadable bar codes. The invention also accepts beverage containers inserted from either the top or bottom of the beverage container. Other useful and/or novel features include a self cleaning system, the ability to print user coupons, and the ability to store all transaction data including the date, time, user ID, bar code data, and the user selected coupon. 
         [0008]    Clearly there is a need for a reverse vending machine which will offer the advanced features described above, thereby improving the efficiency and cost effectiveness of the container recycling process. The present invention accomplishes these objectives. 
       SUMMARY OF THE INVENTION 
       [0009]    The present invention is a reverse vending machine (RVM) which accepts plastic and metallic beverage containers for processing. The reverse vending machine provides a variety of functions including compacting, sorting, and storing the beverage containers. Other functions of the reverse vending machine include issuing coupons to users, storing all transaction information, and displaying messages and other information to users. 
         [0010]    Surveillance cameras are mounted at strategic locations on the frame of the reverse vending machine to record user interaction with the machine. If the machine is vandalized, the vandal may be identified using the recorded video output of the surveillance cameras. Using an Ethernet or other type of network connection, the videos can be viewed at remote locations. One or more video displays are mounted on the outside of the frame so that users may conveniently view machine user instructions, transaction information, public information, advertisements, etc. A self-cleaning system effects cleaning of the interior mechanical components of the reverse vending machine with the use of a cleaning solvent. 
         [0011]    A dual level intake chute assembly is configured to accept non-metallic and metallic beverage containers. A unique feature of the invention allows the user to insert a beverage container either top first or bottom first, without requiring a specific insertion direction. Gravity is utilized to move the beverage container down the intake chute. A bar code scanner scans the bar codes of the beverage containers inserted in the dual level intake chute. If for any reason the beverage container is rejected by the machine, the intake chute is raised thereby returning the beverage container. 
         [0012]    Several types of sensors provide data to the PLC computer in order to monitor and control the operation of the machine. A chute position detection sensor provides data as to the position of the intake chute. An ingress-egress sensor provides data to ensure that no objects are blocking the entrance of the intake chute when the intake chute needs to be raised or lowered. Should a beverage container fail to exit the intake chute, the motor activation is disabled and a warning message is displayed to the user. 
         [0013]    A load cell sensor within the intake chute assembly is configured to produce beverage container weight data. Beverage container weight data is processed by a special software algorithm running on the PC. If a beverage container exceeds a certain threshold weight, indicating that the container is not empty, then the beverage container is returned to the user via the intake chute. 
         [0014]    The compacter sub assembly, which compacts the beverage containers, includes a back panel, a side panel, and a container remover. A geared motor, chain sprocket, and gear sprocket provide the drive mechanism for the compacter sub assembly. An inverter controls the direction and rotation speed of the geared motor. The inverter receives commands from a PLC. The PLC will disable operation of the reverse vending machine when the front panel door is open. 
         [0015]    Within the compacter sub assembly, rotating impeller shafts are configured with protruding impeller arms. The impeller arms push the beverage containers down and into the rotating spur gears thereby compacting the beverage containers. The container remover utilizes protruding nails to prevent any beverage containers from becoming stuck to the impeller arms. 
         [0016]    In one embodiment of the invention, separate storage bins for metallic beverage containers and non-metallic beverage containers are included in the frame of the invention. The invention stores compacted bottles in the bottle storage bin, and compacted cans are stored in the can storage bin. A full bin sensor detects when the storage bins have filled up with compacted beverage containers, and provides the data to a PC. When the storage bins have filled up, an empty bin message is displayed on the video monitor. 
         [0017]    The compacted beverage containers are delivered into the sorter sub assembly, which is includes a back panel and a side panel. A sorting flap rotates on a shaft mounted on bearings, and is driven by a geared motor mounted on a motor bracket. The sorting flap is configured to divert each beverage container to either the bottle storage bin or else the can storage bin. 
         [0018]    A controller box contains the control system components of the invention, including a PLC (programmable logic controller) to control the reverse vending machine. The PLC controls the motion of various components of the machine. 
         [0019]    An IBM compatible PC (personal computer) is configured for processing, storing and retrieving data from the various sensors on the machine. The proprietary software program also controls the motion of the reverse vending machine and displays messages to the users on the video displays. For example, data produced by the container weight sensor is processed by the PC. If a non-empty beverage container is inserted in the intake chute, the beverage container is returned to the user, and an appropriate message is displayed on the video screen. 
         [0020]    Other status conditions may be processed by the PC software algorithms, including data received from the bar code scanner and from various sensors on the reverse vending machine, such as the ingress-egress sensor, the full bin sensor, and the like. If the bar code scanner is unable to scan a beverage container, or else if the beverage container bar code is unregistered, or else if the beverage container is non-recyclable, the algorithm running on the PC will cause the beverage container to be returned to the user. 
         [0021]    The reverse vending machine includes a coupon printer whereby coupons may be printed for users after they have recycled beverage containers. A coupon selection switch allows the user to select up to twelve different coupons, or else receive credit instead of a coupon. Coupon instructions will appear on the display screen after the user has processed their beverage containers. The reverse vending machine can limit the number of coupons issued when necessary. A sensor within the coupon printer detects when the diameter of the coupon printer paper roll reaches a minimum threshold. A low paper condition signal is then sent to the PC, which displays a message on the display screen, and also sends a message via wired or wireless a network connection. 
         [0022]    Users may accumulate credit for beverage containers by means of an ID reader configured to produce user data to be processed by the PC algorithms. The ID reader may utilize a magnetic strip, a smart IC, and/or RFID technology to produce user ID data. 
         [0023]    A number of switches in the control box allow manual operation of the reverse vending machine components. An auto/manual operation switch, may be set to “auto” to allow normal operation of the reverse vending machine. The auto/manual switch may be set to “manual” to cause the geared motor in the compacter sub assembly to operate continuously. The compacter forward/reverse switch will then control the direction of the geared motor. A sorter CAN/PET switch allows the user to change the position of the sorting flap from CAN containers to PET containers, or vice versa. 
         [0024]    Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0025]      FIG. 1  is a perspective view of the present invention; 
           [0026]      FIG. 2  is a perspective view of the frame of the present invention; 
           [0027]      FIG. 3  is a perspective view of the intake chute assembly of the present invention; 
           [0028]      FIG. 4  is a perspective view of the compacter assembly of the present invention; 
           [0029]      FIG. 5A  is a front perspective view of the sorting assembly of the present invention. 
           [0030]      FIG. 5B  is a rear perspective view of the sorting assembly of the present invention; 
           [0031]      FIG. 6  is a flowchart of the PC software of the present invention in auto mode; 
           [0032]      FIG. 7  is a flowchart of the PLC software of the present invention in auto mode; 
           [0033]      FIG. 8  is flowchart of the PLC software of the present invention in manual mode; 
           [0034]      FIG. 9  is a functional block diagram of the present invention; and 
           [0035]      FIG. 10  is a diagram of the controller box layout of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0036]    The present invention, a reverse vending machine  10 , is shown in  FIG. 1 . The reverse vending machine  10  accepts non-metallic and metallic beverage containers for processing, which includes compacting, sorting, and storing the beverage containers. 
         [0037]    Other functions of the reverse vending machine  10  include issuing coupons to users, storing all transaction information including the date, time, user ID, beverage container bar code, coupon data, and ingress/egress status. 
         [0038]    Turning to  FIG. 2 , the frame  20  of the reverse vending machine is shown. A front panel door  12  allows access to the interior of the reverse vending machine  10 . A plurality of surveillance cameras  21  are mounted at strategic locations on the frame  28  of the reverse vending machine  10  to record user interaction with the machine. If the reverse vending machine  10  is vandalized, the vandal may be identified using the recorded video output of the surveillance cameras  21 . Using a wired or wireless Ethernet network connection  222  on the reverse vending machine  10 , the videos can be viewed at remote locations. 
         [0039]    One or more video displays  22  are mounted on the outside of the frame  28  so that users may conveniently view reverse vending machine  10  user instructions, transaction information, public information, advertisements, etc. 
         [0040]    The self-cleaning solvent tank  47 , a component of the self-cleaning system, is shown near the top of  FIG. 2 . Solvent is poured or pumped into the solvent tank, where it then traverses the interior of the reverse vending machine  10  via a plurality of fluid connections. Cleaning solvent exits through a plurality of nozzles  43 , 45  to effect cleaning of the interior mechanical components of the machine. Used cleaning solvent is then collected in a cleaning solution drainage pan  27  near the bottom of the machine. 
         [0041]    The intake chute assembly  30  in  FIG. 2  is a beverage container chute configured to accept non-metallic and metallic beverage containers. A detailed view of the dual level chute assembly  50  is shown in  FIG. 3 , including the side panel  52 , the bottom panel  76 , the sliding door  66 , the motor platform  58 , and the spacer  54 . 
         [0042]    Turning to  FIG. 3 , beverage containers are inserted by the reverse vending machine  10  user into the intake chute  72 . A unique feature of the invention allows the user to insert a beverage container either top first or bottom first, without requiring a specific insertion direction. Gravity is utilized to move the beverage container down the intake chute  72  on top of the feed rollers  78 . The sliding door  66  holds the container until the reverse vending machine  10  accepts or rejects it. The chute position sensor  68  informs the reverse vending machine  10  of the position of the intake chute  72 . The intake chute  72  moves to its upper level when the reverse vending machine  10  is returning an inserted beverage container. When the intake chute  72  moves to its lower level, the reverse vending machine  10  is either measuring the beverage container weight or else waiting for a beverage container to be inserted in the intake chute  72 . 
         [0043]    A bar code scanner  32  ( FIG. 2 ) scans the bar codes of the beverage containers inserted in the dual level intake chute  72 . If for any reason the beverage container is rejected by the machine, the intake chute  72  is raised thereby returning the beverage container. The intake chute  72  is mounted on bearings  74 , and is raised to its upper level through the action of a carriage  70  ascending a pair of rails  60 , where the carriage  70  is powered by a motor  56 , a motor shaft  62 , and a gear  64 . 
         [0044]    Several types of sensors provide data to the PC (personal computer shown in  FIG. 9 ) in order to monitor and control the operation of the machine. A chute position detection sensor  68  provides data as to the position of the intake chute  72 . An ingress-egress sensor  75  provides data to insure that no objects are blocking the entrance of the intake chute  72  when the intake chute  72  needs to be raised or lowered. Should a beverage container fail to exit the intake chute  72 , the motor activation is disabled and a warning message is displayed to the user. 
         [0045]    In  FIG. 3  is shown the load cell  77 , which is a type of sensor configured to produce beverage container weight data. Beverage container weight data is processed by a special software algorithm running on a PC ( FIG. 9 ). If a beverage container exceeds a certain threshold weight, indicating that the container is not empty, then the beverage container is returned to the user. If the threshold weight is not exceeded, then the reverse vending machine  10  can proceed to compact the beverage container. Non-empty beverage containers are returned by raising the intake chute  72  thereby returning the containers to the user. 
         [0046]    The compacter assembly  34 , which compacts the beverage containers, is shown in  FIG. 2 . Turning to  FIG. 4 , a detailed view of the compacter assembly  80  is shown. The compacter assembly  80  includes a back panel  90 , a side panel  82 , and a container remover  96 . A geared motor  84 , chain sprocket  86 , and gear sprocket  88  provide the drive mechanism for the compacter sub assembly. An inverter  220  ( FIG. 10 ) controls the direction and rotation speed of the geared motor  84 . The inverter  220  receives commands from the PLC  214 , described below. A door closing sensor  48  includes a reed switch connected to the PLC  214 , so that the PLC  214  will disable operation of the reverse vending machine  10  when the front panel door  12  is open. 
         [0047]    Within the compacter sub assembly  80 , a plurality of rotating impeller shafts  92  are configured with a plurality of protruding impeller arms  93 . The impeller arms  93  push the beverage containers down and into the rotating spur gears  94  thereby compacting the beverage containers. The container remover  96  utilizes protruding nails to prevent any beverage containers from becoming stuck to the impeller arms  93 . 
         [0048]    In one embodiment of the invention, separate storage bins  26 , 40  for metallic beverage containers and non-metallic beverage containers are included in the frame of the invention. As shown in  FIG. 2 , the invention stores compacted bottles in the bottle storage bin  26 , and compacted cans are stored in the can storage bin  40 . A plurality of full bin sensors  42 , 44  detect when the storage bins  26 , 40  have filled up with compacted beverage containers, and provide the data to a PC  210 , described below. When the storage bins  26 , 40  have filled up, an empty bin message is displayed on the video monitor  22 . 
         [0049]    The compacted beverage containers are delivered into the sorter sub assembly  38 , shown in  FIG. 2 . Turning to  FIG. 5A  &amp;  FIG. 5B , a detailed view of the sorter assembly  100  is shown. The sorter assembly  100  includes a back panel  110  and a side panel  112 . A sorting flap  102  rotates on a shaft  114  mounted on bearings  104 , and is driven by a geared motor  106  mounted on a motor bracket  108 . The sorting flap  102  is configured to divert each beverage container to either the bottle storage bin  26 , shown in  FIG. 2 , or else the can storage bin  40 . The sorting flap position sensor  116  is shown in  FIG. 5B . 
         [0050]    As shown in  FIG. 2 , a controller box  24  contains the control and electronic system components of the invention, including a PLC (programmable logic controller)  214  to control the reverse vending machine  10 . A detailed layout of the controller box  24  is shown in  FIG. 10 . The PLC  214  controls the motion of various components of the reverse vending machine  10 . The PLC operation is detailed in the flow charts in  FIG. 6A  to  FIG. 7 . An A/D converter  216  converts analog output signals from the load cell  77  to a digital signal, which is then sent to the PLC  214 . The PLC  214  can then determine the relative weight of a beverage container acting on the load cell  77 . Included in the controller box  24  is a main power switch  200 , strain gauge amplifier  212 , A/D converter  216 , 24 VDC power supply  218 , inverter  220 , and network adapter  222 . 
         [0051]    An IBM compatible PC (personal computer)  210 , including a storage system configured for storing and retrieving data, and a computer operating system running a proprietary software program, are responsible for processing and storing data from the various sensors on the machine.  FIG. 6  shows a flowchart of the PC software of the invention in auto mode. The PC is not used while the reverse vending machine  10  is in manual mode. The proprietary software program also controls the motion of the reverse vending machine  10  and displays messages to the users on the video display  22 . For example, data produced by the container weight sensor is processed by the PC  210 . If a non-empty beverage container is inserted in the intake chute  72 , the beverage container is returned to the user, and an appropriate message is displayed on the video screen. 
         [0052]    Other status conditions may be processed by the PC  210  software algorithms, when data has been received from the bar code scanner  32  and from various sensors on the reverse vending machine  10 , including the ingress-egress sensor  75 , the full bin sensors  42  &amp;  44 , and the like. For example, if the bar code scanner  32  is unable to scan a beverage container, or else if the beverage container bar code is unregistered, or else if the beverage container is non-recyclable, the software algorithm running on the PC  210  will cause the beverage container to be returned to the user. 
         [0053]    The reverse vending machine  10  includes a coupon printer  36  whereby coupons may be printed for users after they have recycled beverage containers. A coupon selection switch  37  allows the user to select up to twelve different coupons, or else receive credit instead of a coupon. Coupon instructions will appear on the display screen after the user has processed their beverage containers. The reverse vending machine  10  can limit the number of coupons issued when necessary. A sensor within the coupon printer  36  detects when the diameter of the coupon printer  36  paper roll reaches a minimum threshold. A low paper condition signal is then sent to the PC  210 , which displays a message on the display screen  22 , and also sends a message via a network connection. 
         [0054]    Users may accumulate credit for beverage containers by means of an ID reader  35  configured to produce user data to be processed by the PC  210  algorithms. The ID reader may utilize a magnetic strip, a smart IC, and/or RFID technology to produce user ID data. 
         [0055]    A number of switches in the control box  24  allow manual operation of the reverse vending machine  10  components. An auto/manual operation switch  202 , is set to “auto” to allow normal operation of the reverse vending machine  10 . The auto/manual switch  202  may be set to “manual” to cause the geared motor  84  in the compacter sub assembly  80  to operate continuously. The compacter forward/reverse switch  206  will then control the direction of the geared motor  84 . A sorter CAN/PET switch  208  allows the user to change the position of the sorting flap  102  ( FIG. 5A ) from CAN to PET, or vice versa.