Coin Carrier Chain Sorting Mechanism for High-Throughput Processing
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Solution Overview
Problem
Existing coin counting machines are inefficient in processing large quantities of coins quickly and accurately, often requiring significant user time and being unsuitable for large batches, which discourages consumer usage.
Innovation Solution
A coin processing apparatus featuring an endless coin carrier chain with sensors for discrimination and actuators to sort coins, allowing for rapid counting and sorting of large batches by circulating coins through a system of sprockets and sensors, enabling high-speed processing of up to 1000 coins per minute.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coins are processed one at a time through a slot, then the machine structure remains simple, but the throughput is low and processing time is excessive
Solution Approach 1:
The coin processing system is segmented into multiple functional modules: a coin carrier chain with multiple carriers, separate discrimination sensors, actuators for ejection, and sorting mechanisms. Each module performs a specific function, allowing the system to process multiple coins simultaneously through parallel operation of individual carriers while maintaining modular simplicity for manufacturing and maintenance.
Solution Approach 2:
The system transitions from linear sequential processing (one coin at a time through a slot) to a multi-dimensional parallel processing approach using an endless carrier chain that circulates coins through the processing zone. Multiple coins are positioned at different locations along the chain, enabling simultaneous discrimination and ejection operations across multiple carriers, thereby increasing throughput without proportionally increasing overall system complexity.
2Productivity
If large quantities of coins are processed quickly, then throughput increases, but processing accuracy and discrimination reliability may deteriorate
Solution Approach 1:
Coins are loaded onto carriers in advance before entering the discrimination zone. The carrier chain positions each coin stably on its designated carrier, ensuring proper orientation and spacing before discrimination occurs. This preliminary positioning prevents processing errors that could arise from coins moving or overlapping during high-speed operation, maintaining accuracy while enabling rapid throughput.
Solution Approach 2:
Discrimination sensors detect coin characteristics and provide feedback signals to the control system, which then actuates specific carriers to eject coins into appropriate bins. The system uses real-time feedback from sensor data to make immediate ejection decisions, ensuring accurate coin classification even at high processing speeds. The feedback loop operates continuously as coins circulate on the carrier chain, maintaining discrimination reliability throughout rapid processing.
3Ease of operation
If consumers use coin counting machines, then coin processing service is provided, but significant user waiting time discourages usage
Solution Approach 1:
The endless carrier chain operates continuously, circulating coins through the discrimination and ejection zones without interruption. Coins are constantly being processed, sorted, and collected in bins, eliminating idle time between processing batches. This continuous operation allows large quantities of coins to be processed in a single loading cycle, significantly reducing the total time consumers must wait compared to batch-by-batch processing methods.
Data Source
AI summary
Coin processing apparatuses, such as consumer or commercial coin processing apparatuses for counting and/or sorting coins, are described herein. The apparatuses can include coin conveyors having a plurality of individual coin carriers linked together to form a chain. In some embodiments, each of the coin carriers includes a corresponding pocket that is configured to receive a coin from a coin hopper as the carrier chain passes through the coin hopper during its cycle. The coin carriers can carry the coins past one or more sensors for identification or “discrimination” of the coin denomination. After discrimination, the coins can be knocked from the carrier pockets and into, e.g., a selected coin chute for transfer to a collection bin.