Banknote Bundle Processing System with Intermediate Pile Ejection
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Solution Overview
Problem
Current methods for processing banknote bundles are complex, prone to jamming, and difficult to implement statistical process control, especially at high production speeds, leading to potential damage and errors in the final product.
Innovation Solution
A method and system that forms intermediate piles of bundles and ejects them one-by-one from the bottom, using a conveyor with spaced pusher members for separation and conveyance, allowing for efficient evacuation and separation while enabling statistical process control by removing and reintroducing sample bundles without disrupting the production flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to process banknote bundles at high production speeds, then productivity is improved, but the complexity of the system increases and jamming occurs
Solution Approach 1:
The system divides the bundle processing into distinct phases: forming intermediate piles, ejecting bundles one-by-one, and conveying with spacing. This segmentation simplifies the overall system by breaking down the complex high-speed processing into manageable, less complex sub-processes that can be executed sequentially rather than requiring a highly complex simultaneous multi-function system.
2Productivity
If conventional processing methods are used, then bundles are processed continuously, but jamming and damage occur
Solution Approach 1:
The system implements periodic action by ejecting bundles one-by-one from intermediate piles at regular intervals rather than continuous processing. This periodic ejection method, combined with conveying bundles with determined spacing, allows the system to maintain productivity while reducing jamming and damage by providing regular pauses and spacing in the processing flow.
3Measurement precision
If statistical process control is implemented in conventional systems, then quality control is improved, but the system becomes more complex and difficult to implement
Solution Approach 1:
The system forms intermediate piles of bundles before ejection, which serves as a preliminary preparation step. This preliminary action creates a buffer that facilitates easier implementation of statistical process control, as bundles can be sampled and inspected from the intermediate piles without disrupting the main production flow, thereby improving quality control while keeping the system relatively simple.
4Productivity
If bundles are processed in succession without spacing, then productivity is maintained, but separation and control become difficult
Solution Approach 1:
The system introduces an intermediary element - determined spacing between conveyed bundles - that acts as a mediator between continuous production and easy separation/control. This spacing allows bundles to be easily separated and controlled for statistical process control purposes while maintaining high productivity through continuous production flow, as the spacing is built into the conveyance system itself rather than requiring additional separation mechanisms.
Data Source
AI summary
There is described a method for processing bundles (5) of securities, in particular banknote bundles, during production thereof, the method comprising the steps of (a) processing stacks of sheets (SS), each carrying an array of multiple security prints arranged in a matrix of rows and columns, into successive sets (2) of consecutive bundles (5) of securities arranged side-by-side, (b) forming at least one intermediate pile (8; 8*) of consecutive bundles (5) by placing the consecutive bundles (5) of a set (2) one on top of the other, and (c) successively ejecting bundles (5) one-by-one from a bottom of the said at least one intermediate pile (8; 8*) and conveying each ejected bundle (5) with a determined spacing from a preceding and/or following ejected bundle (5). There is also described a bundle processing system to carry out the above method.