Suction Element Emptiness Detection for Media Containers

Solution Overview

Problem

Existing methods for determining the empty state of media containers in self-service terminals, such as ATMs, are prone to errors due to the cost and reliability issues of multiple sensors and can generate false readings, especially when dealing with perforated items or stuck pusher plates.

Innovation Solution

A method using a suction element at the pick-up region with a source of negative pressure to determine the container's condition by measuring pressure and comparing it to thresholds, integrating pressure values over time, and checking if the container is in a low content state before determining its condition, thereby minimizing false readings and identifying stuck pusher plates.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple sensors are provided in or close to the container to determine when the container is empty, then the reliability of empty state detection is improved, but the cost and device complexity increase substantially

Engineering Contradiction:

Improveempty state detection reliabilityVSAvoidsensor and circuitry complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The suction element is designed to perform multiple functions: it serves as both the pickup mechanism for removing media items from the container and the detection mechanism for determining container emptiness. By integrating these functions into a single component, the patent eliminates the need for separate sensors and circuitry, thereby reducing device complexity and cost while maintaining reliable empty state detection capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The suction element performs self-detection by monitoring its own operational characteristics (current, force, pressure) during the pickup attempt. When the container is empty, the suction element experiences different physical conditions (no media item to pick up) which can be detected through these self-monitored parameters, eliminating the need for external sensing systems

Inventive Principle:

Principle #25Self-service

2Reliability

If multiple sensors are provided in or close to the container to determine when the container is empty, then the reliability of empty state detection is improved, but the cost increases substantially

Engineering Contradiction:

Improveempty state detection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The suction element is designed to perform multiple functions: it serves as both the pickup mechanism for removing media items from the container and the detection mechanism for determining container emptiness. By integrating these functions into a single component, the patent eliminates the need for separate sensors and circuitry, thereby reducing device complexity and cost while maintaining reliable empty state detection capability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces expensive, complex sensor systems with a simpler, more cost-effective solution using the existing suction element and basic measurements (current, force, pressure) that are already part of the pickup mechanism. This substitution significantly reduces manufacturing costs while achieving the same detection reliability

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Speed

If sensors are used to detect the empty state of the container, then the empty condition can be signaled promptly, but false condition signals can be generated when items of media do not entirely match expected parameters

Engineering Contradiction:

Improveempty condition notification speedVSAvoidcondition signal accuracy

Core Design Contradiction:

SpeedVSReliability

Solution Approach 1:

The patent employs dynamic measurement during the actual pickup attempt rather than static sensing. By monitoring parameters (current, force, pressure) that change dynamically as the suction element attempts to pick up a media item, the system can distinguish between a truly empty container and one containing atypical media items. The dynamic nature of the measurement allows the system to adapt to variations in media characteristics while maintaining accurate empty state detection

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses feedback from the suction element's operational parameters (current consumption, applied force, pressure readings) to determine container emptiness. This feedback mechanism allows the system to continuously monitor the pickup process and accurately identify empty conditions based on the absence of expected physical interactions, thereby reducing false signals while maintaining prompt detection

Inventive Principle:

Principle #23Feedback

4Ease of operation

If a pusher plate mechanism is used to urge items of media into the pick up region, then the items can be presented for removal, but the pusher plate can become stuck or fail to operate predictably leading to false empty container diagnosis

Engineering Contradiction:

Improvemedia item presentationVSAvoidcontainer condition diagnosis accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent performs preliminary detection measurements before concluding that the container is empty. By attempting to pick up a media item and measuring the suction element's operational parameters, the system can distinguish between a genuinely empty container and one where the pusher plate has failed to present an item. This preliminary action prevents false empty container diagnoses caused by pusher plate malfunctions

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system uses feedback from the suction element's operational parameters (current consumption, applied force, pressure readings) to determine container emptiness. This feedback mechanism allows the system to continuously monitor the pickup process and accurately identify empty conditions based on the absence of expected physical interactions, thereby reducing false signals while maintaining prompt detection

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach accurately determines the container's condition without additional sensors, reduces false readings, and automatically identifies and resolves stuck pusher plates, ensuring reliable operation and efficient service.

Implementation Method 1

selectively connecting a source of negative pressure to the suction element; determining a pressure at the suction element

Methodology Applied

Scientific EffectNegative pressure: Vacuum

Data Source

PatentUS8727336B2Condition determining

Publication Date: 2014.05.20 NCR ATLEOS CORP

AI summary

A method and apparatus are disclosed for determining a condition at an item of media container. The method includes the steps of locating a suction element at a pick up region of a container, selectively connecting a source of negative pressure to the suction element, determining a pressure at the suction element, and determining a condition of the container responsive to the determined pressure.