EP2414243B1 - Apparatus for forming stacks of sheet documents and corresponding method - Google Patents

Apparatus for forming stacks of sheet documents and corresponding method Download PDF

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Publication number
EP2414243B1
EP2414243B1 EP10713229.2A EP10713229A EP2414243B1 EP 2414243 B1 EP2414243 B1 EP 2414243B1 EP 10713229 A EP10713229 A EP 10713229A EP 2414243 B1 EP2414243 B1 EP 2414243B1
Authority
EP
European Patent Office
Prior art keywords
stack
separator member
documents
path
stacker
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Not-in-force
Application number
EP10713229.2A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2414243A2 (en
Inventor
Martinus Johannes Pieter Meersoek
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
De la Rue International Ltd
Original Assignee
De la Rue International Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by De la Rue International Ltd filed Critical De la Rue International Ltd
Publication of EP2414243A2 publication Critical patent/EP2414243A2/en
Application granted granted Critical
Publication of EP2414243B1 publication Critical patent/EP2414243B1/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B27/00—Bundling particular articles presenting special problems using string, wire, or narrow tape or band; Baling fibrous material, e.g. peat, not otherwise provided for
    • B65B27/08—Bundling paper sheets, envelopes, bags, newspapers, or other thin flat articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B13/00—Bundling articles
    • B65B13/02—Applying and securing binding material around articles or groups of articles, e.g. using strings, wires, strips, bands or tapes
    • B65B13/04—Applying and securing binding material around articles or groups of articles, e.g. using strings, wires, strips, bands or tapes with means for guiding the binding material around the articles prior to severing from supply
    • B65B13/06—Stationary ducts or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B13/00—Bundling articles
    • B65B13/18—Details of, or auxiliary devices used in, bundling machines or bundling tools
    • B65B13/24—Securing ends of binding material
    • B65B13/32—Securing ends of binding material by welding, soldering, or heat-sealing; by applying adhesive
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H31/00—Pile receivers
    • B65H31/32—Auxiliary devices for receiving articles during removal of a completed pile
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H2701/00—Handled material; Storage means
    • B65H2701/10—Handled articles or webs
    • B65H2701/19—Specific article or web
    • B65H2701/1912—Banknotes, bills and cheques or the like

Definitions

  • This invention relates to stacking apparatus for forming stacks of sheet documents, respectively.
  • the invention also encompasses corresponding methods therefor.
  • Document handling machines are used in many fields to process sheet documents such as banknotes, certificates, cheques, letters and other papers. Typical functions performed by a document handling machine include sorting, counting, storage, dispensing and authenticating sheet documents.
  • An example of a document handling apparatus is disclosed in WO2005/118443 , and available products of this sort include the KalebraTM, CobraTM (also known as the De La Rue 4000) and the CPS 1200 (also known as the De La Rue 7000), all made by De La Rue International Limited of Basingstoke, UK.
  • the primary function of the apparatus disclosed in WO2005/118443 is to sort banknotes into different denominations and/or currencies.
  • the apparatus includes differentiation means for distinguishing one banknote type from another, and a plurality of output pockets into which notes of each type are sorted.
  • Each output pocket includes a stacking apparatus which forms the notes directed to that pocket into a stack in which the notes are arranged face to face. The stack of notes can then be removed by a user and dealt with as necessary.
  • the next step in the handling process is to "strap" the stack of banknotes: that is, to fit a band around the stack so that the notes are held together as one cohesive unit.
  • the strapped stack may then be passed on for distribution by banks or vault storage, etc.
  • Conventional strapping apparatus form a strap around the stack of banknotes by use of a robotic arm which pulls a length of strap material around the notes, adjusts the tension and then joins the two ends of the strap material together, usually by means of heat sealing. Examples of such conventional strapping apparatus can be found in the aforementioned available products.
  • Such strapping apparatus may be provided as an extension of the document handling apparatus, with either a strapping device being located in each output pocket, or means being provided for transferring the stack of banknotes from the output pocket into a strapping apparatus, thereby achieving a level of automation.
  • the conventional strapping process also suffers from a number of further problems including inherent lack of reliability since the strapping apparatus includes a large number of moving mechanical parts which, in practice, are found to suffer failure frequently. Further, different customers have different strapping requirements and, as such, the apparatus must handle a number of different types of strap material and sealing means. It has been found that the robotic arm technique is not good at handling such different requirements and this frequently results in incorrect tensioning of the strap. Further, the conventional strapping apparatus is expensive due to its high part count and requires frequent maintenance.
  • a strapping apparatus for strapping a stack of sheet documents, the apparatus comprising:
  • the use of a robotic arm is done away with. Not only does this reduce the number of moving parts, thereby increasing the robustness and reliability of the apparatus, but is also inherently faster.
  • the configuration leads to the situation where the stack of documents to be strapped need not be present in the stack receipt zone when the loop of strap material is formed (unlike in the case of the conventional apparatus where the strap is formed by the robotic arm passing the strap around the stack of documents). This permits the loop of strap material to be formed before the stack of sheet documents arrives, thus further reducing the time required to complete the strapping procedure on receipt of a stack. In all, the strapping apparatus allows a stack of sheet documents to be strapped much faster than previously possible.
  • a stacking apparatus for forming stacks of sheet documents, comprising:
  • the separator member By providing a separator member which can be deployed between one sheet document and the next, the first stack (completed by the selected sheet document) is kept separate from a second stack of documents which can be formed on the separator member.
  • the separator member need not be horizontal in its holding position for a stack to be formed thereon, but simply presents a surface against which the documents can be stacked.
  • the first stack of documents can then be removed from the apparatus for strapping (or other handling) without stopping or slowing the stacking apparatus, which continues to output documents throughout. Documents which are not to form part of the first stack are kept separate from the first stack by the separator member.
  • the separator member comprises an elongate member having an arcuate shape, preferably of substantially the same form as a tine of the stacker wheel(s).
  • the separator member is hinged so as to provide a substantially flat surface forming the second stack thereon. That is, the separator member includes at least one hinge along its length. In a particularly preferred example, the separator member is hinged at approximately its mid-point. The separator member can thus maintain an arcuate shape as it rotates in line with the stacker wheels and then adopt a flatter profile (i.e. closer to rectilinear) for receipt of the notes forming the second stack.
  • the opening of the hinge(s) can be caused by gravity, the receipt of the notes forming the second stack, or a combination of the two.
  • the separation unit is further adapted to retract the separator member once the first stack has been removed from the stack support surface such that the second stack is placed on the stack support surface.
  • the second stack therefore takes the place of the first stack and continues being formed on the stack support surface.
  • the separator member can then be used again once the second stack is completed to separate it from the next.
  • the separator member is arranged to move from the home position to the holding position along a deployment path which follows the path of a sheet document through the stacking unit.
  • the movement of the separator member is entirely aligned with that of each sheet document such that its insertion into the stream of documents does not disrupt the stacking.
  • the separator member is arranged to move from the holding position to the home position along a retraction path which follows the path of a sheet document between the holding position and the stack support plate, and does not intercept the path of sheet documents through the apparatus between the stack support plate and the home position.
  • the stack formed on the separator member is effectively allowed to continue along its original path onto the stack support plate.
  • the stack support plate may include one or more apertures therethrough to permit passage of the separator member whilst "catching" the second stack. In other cases the separator member could pass by one or both sides of the stack support surface.
  • the separator member is arranged to follow a path which is a continuous loop.
  • the stacker unit could be formed in a number of different ways.
  • the stacking unit could operate according to a linear deceleration principle.
  • the stacking unit comprises at least one stacker wheel, the or each stacker wheel having a plurality of tines extending from a central hub, each pair of the plurality of tines defining a channel therebetween for receiving a sheet document from the transport path at a receipt position, and stacker drive means for rotating the or each stacker wheel such that, at a release position, the sheet documents exit the channel(s) facing one other to thereby form a stack, the receipt position being angularly displaced from the release position.
  • the separator member is arranged to follow a path which includes an arcuate portion concentric with the at least one stacker wheel such that the separator member follows the path of a sheet document carried by a channel of the at least one stacker wheel between the receipt and release positions.
  • a path which includes an arcuate portion concentric with the at least one stacker wheel such that the separator member follows the path of a sheet document carried by a channel of the at least one stacker wheel between the receipt and release positions.
  • the separator member is disposed in line with or behind the trailing tine of a channel of the stacker wheels at the receipt position, such that a sheet document arriving at the stacker wheel is not prevented from entering the channel.
  • the separator member could be driven using any suitable mechanical arrangement.
  • the separator member is moved between its home and holding positions by a timing belt driven by a motor, preferably a stepper motor.
  • the separator member could be directly mounted to the timing belt. However, preferably, the separator member is supported by a carriage mounted on the track along which the separator member is movable between its home and holding positions. This improves the accuracy of the separator member's positioning.
  • the separator unit further comprises a home sensor configured to detect when the separator member is at its home position.
  • a home sensor configured to detect when the separator member is at its home position.
  • This may typically comprise an optical detector, for example.
  • the separation unit is configured to stop the separator member at the holding position when a predetermined duration has elapsed since the separating member left the home position.
  • a further sensor may be provided at this location to identify when the separator member arrives.
  • the separator unit further comprises a stack sensor configured to detect when the first stack has been removed from the stack support plate.
  • a stack sensor configured to detect when the first stack has been removed from the stack support plate.
  • this may comprise an optical detector.
  • a document handling apparatus comprises a stacking apparatus in accordance with the invention and a strapping apparatus as described previously.
  • the stack support plate may be configured so as to form the first stack within the stack receipt zone.
  • a transport unit may be provided for transporting the first stack from the stack support plate of the stacking apparatus to the stack receipt zone of the strapping apparatus.
  • the stack support plate may be movable between a stacking position and a strapping position in which the stack is positioned in the stack receipt zone. Combining the two disclosed apparatus is particularly advantageous since a single output pocket can be used for each document type, whilst achieving high throughput and fast strapping.
  • the present invention further provides a method of stacking sheet documents, comprising
  • the deployment of the separator member between the selected sheet document and the next makes it possible to continue forming a second stack of sheet documents while the first stack is isolated for handling.
  • the separator member When the separator member reaches the holding position at which it receives the sheet documents forming the second stack, the separator member need not be halted entirely but could be decelerated such that a gap is formed between it and the selected sheet document which completes the first stack. However, in preferred embodiments, the method further comprises halting the separator member at the holding position until the first stack is removed from the stack support surface. This simplifies the control of the apparatus.
  • the method further comprises retracting the separator member once the first stack is removed such that the second stack is placed on the stack support surface.
  • the second stack can then be completed and the separator member reused to allow a third stack to be formed and the second stack moved on for handling.
  • the separator member is preferably moved from the home position to the holding position along a deployment path which follows the path of a sheet document through the stacking unit.
  • the separation member is moved from the holding position to the home position along a retraction path which follows the path of a sheet document between the holding position and the stack support plate, and does not intercept the path of sheet documents through the apparatus between the stack support plate and the home position.
  • the movement of the separator member from the home position to the holding position and back to the home position follows a path which is a continuous loop.
  • the method further comprises detecting when the separator member is at its home position. This permits accurate control and timing.
  • the separator member is decelerated or halted at the holding position when a predetermined duration has elapsed since the separator member left the home position.
  • a further detector may be employed to determine when the separator member reaches the holding position.
  • the method further comprises detecting when the first stack has been removed from the first support plate.
  • the first stack is removed from the first stack support surface while the second stack is being formed.
  • the method of the second aspect of the present invention is particularly advantageous when used in combination with that of the first aspect of the present invention and hence the method preferably further comprises transporting the first stack to a strapping apparatus and strapping the first stack in accordance with the method of the first aspect of the invention.
  • document handling apparatus including stacking apparatus and strapping apparatus, may be used to handle many different types of sheet document, including currency, certificates, cheques, letters and paperwork.
  • sheet documents will be flexible sheet documents but, depending on the handling techniques used, this need not be the case. The following discussion will focus on the example of banknote handling, but it will be appreciated that the invention is not so limited.
  • the document handling apparatus 10 may be capable of a number of functions, including authenticating and discriminating documents. Its primary function is to sort banknotes of different denominations and/or currencies from a mixed input.
  • a mixed bundle of banknotes B is fed into the apparatus by an input module 20. This typically comprises means for taking one note at a time from the input bundle and feeding them into a transport path. As each banknote B is conveyed along the transport path, a number of checks may be carried out by a series of sensors, detectors and controllers, represented by block 30.
  • This may include imaging of printed patterns on the banknote, reading of codes such as serial numbers, checking of security features such as holograms and/or magnetic threads and measurement of IR or UV response, for example.
  • the position of each note in the system is kept track of by a series of sensors such as transmissive optical sensors which can detect the arrival or departure of a note at each sensor position.
  • each banknote is processed by a controller 31 to determine into which of a series of categories each banknote falls.
  • the categories may include different denominations or currencies as well as potential counterfeit notes, and notes which are unfit for reuse.
  • the categories may include mixed note type categories, if desired.
  • the notes are then passed via another transport path 40 to the output modules 50.
  • a plurality of output modules are provided, preferably one for each of the categories to be discriminated.
  • a first module may be designated for the output of 5 Euro notes, a second for 10 Euro notes, a third for 20 Euro notes, and so on.
  • Figure 1 shows three exemplary output modules 50a, 50b and 50c, but in practice there may be more or fewer.
  • each banknote is determined by one or more diverters 45a, 45b provided in the transport path 40.
  • the diverters 45 are controlled by controller 31 as represented by dashed lines 35.
  • the diverters can be switched from one position to another between the passage of each note so that each note in the stream can be individually directed to the appropriate output module.
  • the output modules 50 each comprise stacking means for forming the notes output by that module into a stack S, in which the notes are arranged face to face.
  • the apparatus 10 is generally programmed with a desired stack size: that is, the number of banknotes to be included in each stack. For example, the customer may require stacks of 100 banknotes in each.
  • each output pocket 50 has a dedicated strapping module 100.
  • the transfer of the stack from the output pocket 50 to the strapping module 100 could be performed in a number of ways.
  • the stack S could be presented to a user by the output pocket, the user then taking the stack from the output pocket and placing it in the strapping module.
  • this transfer should be automated and therefore transfer means may be provided between the output pocket and the strapping module, or the strapping module may be located within the output pocket itself. If the stack S is to be moved into a separate strapping apparatus, this can be achieved by use of a clamp arrangement for grabbing the completed stack S and transferring it into the strapping module 100.
  • Such transfer means are well known in the art.
  • Both the output pockets 50 and the strapping modules 100 may also be controlled by controller 31, as represented by dashed line 36.
  • FIG. 2 shows components of an example of strapping apparatus 100.
  • a guide channel 110 is arranged to encircle a stack receipt zone 101.
  • the guide channel 110 is configured so as to receive a length of strap material M from a strap feeding unit 160 and to form the strap material M into a loop. The manner in which this is achieved will be described in more detail below.
  • the apparatus also comprises a sealing unit 120 which is arranged to join the two ends of the loop of strap material M to one.
  • a cutting unit 130 is provided to separate the completed strap from the remainder of the length of strap material.
  • the apparatus may additionally comprise retardation means such as a brake 140 to assist in tensioning the loop of strap material.
  • retardation means such as a brake 140 to assist in tensioning the loop of strap material.
  • the apparatus may also include an adhesive station 150 for applying adhesive to the strap material M.
  • one or more sensors such as 170 may be provided for detecting the position of the strap material M in the system.
  • sensors such as 170 may be provided for detecting the position of the strap material M in the system.
  • optical transmission or reflection sensors may be suitable.
  • FIGS 3 and 4 show the guide channel 110 in more detail from upper and lower perspectives.
  • the guide channel 110 is formed so as to define an approximately rectangular space therein which can accommodate an edge of the stack S in use.
  • the stack S can pass through the area defined by the guide channel.
  • This region is referred to, for convenience, as the stack receipt zone 101.
  • a stack of banknotes S is represented in dashed lines to indicate its position relative to the guide channel during the strapping procedure. As will be described below, the stack S could be inserted into the stack receipt zone 101 either before the loop of strap material M is formed, during or after.
  • the stack of banknotes is supplied, it is supported in a position spaced from the guide channel (as shown in the Figures) by a support assembly located outside the guide channel (and not extending into the guide channel at least in the region where the loop of strap material will be formed).
  • a support assembly located outside the guide channel (and not extending into the guide channel at least in the region where the loop of strap material will be formed).
  • the guide channel 110 has a substantially flat base portion 111 which receives the strap material M on its upper surface (which becomes the inner surface in the region of the stack receipt zone).
  • the base portion 111 extends underneath the stack receipt zone 101 and then traverses an approximate U-bend shape 112 before emerging into a substantially flat upper portion 113.
  • the upper portion 113 is substantially aligned vertically with the base portion 111 in the region of the stack receipt zone.
  • the guide channel 110 is closed by a second U-bend portion 114 which brings the guide channel adjacent base portion 111 again.
  • the guide channel continues for a distance parallel but spaced from the base portion 111 underneath the stack receipt zone, thereby forming an overlapping region 118 of the guide channel.
  • the guide channel could take any shape which encircles the second insertion zone 101.
  • the guide channel could be substantially circular, square or otherwise.
  • any corners of the guide channel are curved to assist the passage of the strap material M therethrough.
  • the strap material M is received on the innermost surface of the guide channel and as such there is nothing between it and the stack receipt zone 101.
  • the strap material is sufficiently stiff that the loop formed within the guide channel is self-supporting. As such, there is nothing to obstruct movement of the strap material away from the guide surface during (optional) tensioning of the loop or removal of the completed strap from the apparatus.
  • the "innermost" surface of the guide channel is its surface nearest to (and facing) the stack receipt zone in the region where the guide channel receives the strap material in use. Outside this region, there could be portions of the guide channel which protrude further towards the interior of the guide channel than the surface which receives the strap material, such as side edges of the guide which retain the strap material laterally.
  • the guide channel 110 need not be formed of a continuous component, as in the present example, but rather may be formed of a number of discrete guide elements.
  • the base portion 111 and first U-bend 112 may be detachable from the upper portion 113 and second U-bend 114 for easy access to the stack receipt zone should maintenance be required.
  • guide elements need not adjoin one another precisely but may have gaps therebetween, provided the gaps are not so large that the strap material M escapes the guide channel.
  • references to "upper” portions and “base” portions (and similar) above should not be taken to imply that the apparatus need be orientated in this way: it may be preferred, for example, that the guide channel be disposed such that the stack is passed into the stack receipt zone vertically rather than horizontally (or indeed in any other orientation).
  • the guide channel 110 includes a number of apertures 115, 116, 117 therethrough for interaction with the sealing means 120, cutting unit 130 and brake 140.
  • such apertures may not be necessary.
  • the guide channel need not extend across the full width of the strap material, allowing the sealing, cutting and/or braking components to access the strap material at either side.
  • the sealing, cutting and/or braking components may make use of such spaces.
  • the guide channel may also be provided with a recess along its length, arranged to coincide with an adhesive portion of the strap material, to avoid contact between the adhesive and the guide channel, so preventing sticking. This is not shown in the Figures, for clarity.
  • the guide channel could have a non-stick coating.
  • a sealing aperture 115 is disposed through the base portion 110 of the guide channel just outside the overlapping portion 118.
  • the aperture 115 is arranged to receive a pressure member in use, as will be described below.
  • a cutting aperture 116 is provided in the base portion 110 at a position upstream of the sealing aperture 115 (i.e. between the sealing aperture 115 and the strap feeder 160 supplying the strap material M).
  • the cutting aperture 116 is provided adjacent the sealing aperture 115, just within the overlapping region 118 of the guide channel so that the inner overlapping part of the guide channel 118a prevents the cutting means 130 cutting through both layers of the strap.
  • the cutting means could be located further upstream, for example upstream of the whole overlapping region 118, which would also avoid this problem. Nonetheless, positioning the sealing unit and cutting unit adjacent one another is preferred to avoid wastage of the strap material.
  • the apparatus makes use of a retardation means in the form of brake 140. As described below this is used to hold the loop of strap material in position while it is tensioned. In other examples, a brake 140 may not be necessary if there is sufficient friction between the strap material and the inserted stack S, which will depend on the dimensions of the guide channel 110 relative to the stack S.
  • the brake 140 is arranged to intersect the guide channel 110 in the region of the second U-bend 114, through a brake aperture 117.
  • the retardation means is preferably arranged as close to the leading edge of the strap material as possible, in order to ensure even tensioning of the loop. In practice, positioning the brake as shown in the Figures is therefore advantageous since it is close to the leading edge of the strap material whilst not encountering the overlapping region. However, the braking position could be located further upstream if desired.
  • Figure 5a shows the strap material M in a starting position prior to strapping.
  • the leading edge, LE, of the strap material M is at a known position, determined for example by the use of sensors 170 as shown in Figure 2 . In other examples, the use of sensors may be avoided by timing the feeding of the strap material.
  • the motion of the strap material M is controlled by feeder 160 which may comprise for example a storage roll 161 containing a supply of strap material M and one or more driven roller pairs 162 which can be controlled to convey the strap material off the storage roll 161 and toward the guide channel 110.
  • the guide channel 110 may extend all the way to the feeder 160, or additional guiding means may be provided to deliver the strap material from the feeder unit 160 into the guide channel.
  • the feeder unit 160 is preferably also able to reverse the strap material M back onto the storage roll 161 by reversing drive to the feeder rollers 162.
  • the feeder unit could be arranged to move the guide channel towards a length of strap material M: the relative motion between the channel 110 and the strap material M is analogous.
  • the strap material is to be sealed by adhesive and is not pre-glued, so an adhesive A is applied to the surface of the strap material M at an adhesive station 150.
  • This could comprise, for example, a roller supplied with adhesive which is movable toward and away from the strap material M at this position.
  • the adhesive A is applied adjacent the leading edge LE of the strap material M on what will become the outer surface of the loop.
  • the adhesive A could be applied onto the opposite surface of the strap material M in the vicinity of what will become the trailing edge TE of the loop.
  • the adhesive station 150 will be situated on the opposite side of the strap material path to that shown.
  • Adhesive could be applied in both of the aforementioned locations, if desired, in which case two adhesive stations may be provided.
  • the strap material M then continues to be fed into the guide channel 110 by the feeder 160 as shown in Figure 5b ).
  • the adhesive station 150 could apply a continuous stream of adhesive to the strap material, e.g. for use with a contact adhesive which will bond only to like adhesive, but this is not preferred due to the use of unnecessary quantities of adhesive.
  • the strap material M is sufficiently stiff so as to follow the curvature of the channel without collapsing and no support or guidance of the interior surface of the strap material M (i.e. that facing the stack receipt zone) is required.
  • the overlapping region 118 of the guide channel then carries the leading edge of the strap material over the incoming upstream strap material, resulting in a portion of the strap material including the leading edge LE overlapping an upstream portion of the strap material M.
  • the resulting loop of strap material encloses the stack receipt zone only, with nothing else therebetween, particularly no portion of the guide channel or other component of the strapping apparatus.
  • the leading edge is moved past the overlapping region 118 of the guide channel by a distance so that at least part of the adhesive portion A faces the upstream overlapping portion of the strap material M without anything else in between.
  • next step is to tension the loop of strap material that has been formed as has been described with reference to Figure 5d ).
  • this is an optional step since in some cases the formed loop may already be of the desired dimension.
  • the stack S of documents to be strapped Before tensioning can occur, the stack S of documents to be strapped must be inserted into the stack receipt zone, as represented by the cross-hashed area S in Figure 5d ).
  • the insertion of the stack can occur before, during or after formation of the strap material loop as depicted in Figures 5a ), b) and c).
  • the loop of strap material M it is generally preferred for the loop of strap material M to be formed before the stack of documents is received.
  • the leading edge LE of the strap material is held substantially in place by pressing a portion of the strap material against the stack S in a non-overlapped region.
  • This is achieved using a brake member 140 which passes through aperture 117 in the guide channel 110 to sandwich the strap material M between it and the stack S.
  • the loop of strap material can then be pulled taut around the stack S by reversing the trailing edge region of the strap material M out of the guide channel. Since there is nothing restraining the strap material M against the guide channel, the size of the loop can be reduced without difficulty.
  • the trailing edge is that portion of the strap material upstream of the leading edge which overlaps the leading edge region. The trailing edge itself will not be formed until the loop is cut from the remaining length of strap material by cutting unit 130. However, the approximate location of the trailing edge relative to the leading edge can be deduced from knowledge of the size of the stack S.
  • the trailing edge is typically not reversed all the way out of the guide channel 110, but rather is pulled a distance towards the exit so as to achieve tensioning.
  • the reversal of the strap material M may be achieved by reversing the feeder unit 160.
  • one or more tensioning rollers can be provided between the feeder unit 160 and the guide channel which are arranged to move perpendicularly to the path of the strap material to thereby apply the appropriate tension.
  • Figure 5e shows the loop of strap material M having been pulled taut around the stack S.
  • the brake 140 may be released, or as in the case shown, it may stay in position whilst the final steps are completed.
  • the overlapping portions of the strap material M are joined to one another by the sealing unit 120.
  • this comprises a pressure member which is extendable through the sealing aperture 115 to contact the overlapping portion of strap material and press it against the stack S, as shown in Figure 5e ).
  • the adhesive A forms a bond between the two overlapping portions of strap material.
  • the sealing unit could alternatively or additionally apply heat to the overlapping portions either to activate an adhesive or to perform a heat seal.
  • the sealing unit could comprise a clamp, inserted from one of the open sides of the guide channel to apply pressure to both sides of the overlapping strap material, or to perform crimping for example.
  • the sealed loop can now be detached from the supply of strap material and this is performed by cutting unit 130 which includes typically a blade.
  • the cutting unit is extended through aperture 116 and applies a high pressure to the trailing edge region of the strap material, thereby detaching the completed strap and forming a new leading edge, as shown in Figure 5f ).
  • cutting could be performed by a punch, a serrated edge or blade drawn across the material or even a laser, as desired.
  • the strap material M can be reversed back out of the guide channel 110, for example by the feeder unit 160, and the strap stack S is ready for removal. It may be desirable to reverse the strap material M out of the guide channel by a distance so as to protect it from damage while the stack is removed, or simply to return it to its start position as shown in Figure 5a ) for application of adhesive to the new leading edge LE. However, if the adhesive is instead applied to the trailing edge of the strap material M, the steps shown in Figures 5a ) and 5g ) may be omitted entirely, with the adhesive being applied instead at a time between the points shown in Figures b) and c) above.
  • the guide channel 210 in this example is formed of three guide elements 211, 213 and 240 arranged in close relation to one another so as to form a guide surface of substantially the same shape as previously described. Any suitable number of guide elements could be used.
  • the first guide element 211 provides the base portion of the guide channel and the beginnings of the first U-bend, and is generally fixed in relation to the stack receipt zone 201 as will be described in more detail below.
  • the second guide element 240 is positioned adjacent the first guide element 211 and shaped so as to provide the end of the second U-bend and a portion overlapping the base portion of the channel.
  • the second guide element is pivotably mounted relative to the first guide element 211, as indicated by pivot point 245.
  • the second guide element 240 performs a second function of camping the leading edge of the strap material during tensioning, and so may also be referred to as the clamp portion of the guide channel. This is explained further below.
  • the third guide element 213 provides the upper guide portion and completes both U-bends.
  • the third guide element is removable and can be moved away from the first and second guide elements so as to "open" the guide channel.
  • This can be achieved using any convenient means.
  • the third guide element is shown to be hingedly attached to the first guide element such that the guide channel can be opened by pivoting the third guide channel toward the position shown in dashed lines.
  • the third guide element could be lifted away from the channel.
  • sheet documents can enter the stack receipt zone (either as a ready formed stack or individually) through the opening left by the third guide element 213.
  • the same function could be achieved, for example, by providing the guide channel of the first embodiment with a removable portion.
  • Figure 7 shows the first and second guide elements 211 and 240 in perspective view with the third guide element removed.
  • the position of a stack of documents S ready for strapping is depicted in dashed lines.
  • the stack S can be formed directly within the stack receipt zone such that no transfer means is required.
  • One or more of the guide elements could be used as the stack support surface for forming and supporting the stack thereon.
  • a stack support assembly such as a lift or clamp mechanism which positions the stack after it has been formed.
  • the stack support assembly could take the form of two (or more) stack support platforms arranged either side of the guide channel, such that the stack is formed on the platforms at a slightly raised position relative to the guide elements.
  • Figure 7 also shows in more detail the arrangement of the second guide element 240, which may be supported on a shaft 246 which is rotatable so as to pivot the second guide element between the positions shown in Figure 6 .
  • Figure 8 shows steps in the operation which differ from those already described. However many of the steps are unchanged and these are depicted in Figure 5 .
  • Figure 8a shows a stack S being formed within the stack insertion zone.
  • the guide channel 210 is "open" in that the third guide element has been removed.
  • banknotes B are received from a stacking apparatus above but as previously noted the banknotes may not arrive along a vertical path but could have some other orientation, in which case the guide channel would be re-orientated as desired.
  • the stack S is spaced from the guide elements by means such as those described above.
  • the guide channel is closed by replacing the third guide element 213, as shown in Figure 8b .
  • the strap material M can now be fed into the guide channel and around the stack to form a closed loop in precisely the same manner as previously described with reference to Figures 5a , b and c .
  • the clamp portion 240 of the guide channel is pivoted above point 245 into the position shown in Figure 8b .
  • This is used in place of the brake 140 provided in the first embodiment to hold the leading edge of the strap material during tensioning of the strap.
  • By pivoting the clamp portion as shown its end presses a portion of the strap material close to the leading edge LE against the stack of documents.
  • the strap material M can then be reversed out of the guide channel, as previously described, to tension the strap.
  • the use of a portion of the guide channel to provide the retardation means is not limited to the three guide element configuration as described here.
  • the clamp member could be used in combination with a single other guide element performing the functions of the first and third guide elements.
  • a single unitary element could be used with the clamp portion being flexibly movable relative to the rest.
  • the overlapping portions of the strap material can then be sealed and finally cut, as described above with reference to Figures 5e , f and g .
  • the strapped stack is removed and passed on for further handling as desired.
  • the clamp portion 240 is returned to its original guiding position and the third guide element 213 is removed ready for the receipt of a new stack of documents.
  • Suitable adhesives include pressure adhesives and contact adhesive. Particular examples include Elmer's Permanent Dot LineTM or the "Dot n RollerTM by Kokuyo. This latter adhesive has been found particularly well suited to the application since it produces consistently reproducible results, without any threads of glue being created.
  • the adhesive station comprises a cassette with two reels supporting between them a tape having dots of adhesive thereon. The first reel supports unused tape (with the glue dots still on), and the other collects the used tape. A small roller between the two reels is used to press the tape against a surface to which glue is to be applied (here the strap material), in order to transfer the glue dots from the support tape onto the surface.
  • FIG. 9 shows schematically a stacking module 50 which receives banknotes B from transport path 40 and outputs these as stacks S in which the banknotes are arranged face to face.
  • a transport path 40 will convey banknotes side by side, one after the other along the same transport plane.
  • the stacking apparatus therefore includes a stacking unit 60 which rearranges the incoming banknotes B into the desired stack format.
  • the stacking apparatus 50 and transport unit 40 are in communication with the controller 31.
  • the stacking unit 60 can operate according to a number of different principles. For example a linear deceleration unit can be used to form stacks, as will be described in more detail below.
  • the stacking unit 60 comprises one or more stacker wheels 61.
  • Stacker wheels such as these are well known and are described, for example, in WO2005/118443 .
  • Each stacker wheel 61 comprises a hub mounted on a shaft 61 a, for rotation thereabout, and a number of radially extending tines 63.
  • Each adjacent pair of tines 63 defines a channel 64 therebetween.
  • the tines 63 preferably curve backwards (i.e. opposite to the sense of rotation of the wheel) at their extremities, as shown schematically in Figure 10 . It will be appreciated that the wheel 61 depicted in Figure 10 is shown with only a small number of tines 63 for clarity; in practice the tines will be closely spaced.
  • Banknotes arrive at the stacker wheel 61 at a receipt position X from the transport path 40. An incoming banknote is received into whichever of the channels 64 is at the appropriate position.
  • banknote B designates a note which has just been received into the stacker wheel and banknote B o designates the next banknote to be received.
  • the received banknote B is carried by the tines 63 around at least part of one rotation of the wheel 61, before it exits the tines at a release point Y. The location of release point Y will depend on the configuration of the wheel 61, the stacker pocket housing and other factors including the speed at which the wheel 61 is driven.
  • the note B 2 is shown exiting the stacker wheel in an approximately horizontal orientation in which the continued rotation of the wheel causes the note to be dropped.
  • the dropped notes such as B 3 , form a stack S, below the stacker wheel 61 on a stack support surface 70 (shown in Figure 9 ).
  • a stack support plate may be provided in front of the stacker wheel, at an angle to the horizontal (as shown for example in W02005/118443 ) with means being provided to direct the banknotes out of the channels 64 and towards the plate 70.
  • FIG 11 shows an embodiment of a stacking apparatus 50 in which this is achieved.
  • the stacking unit (stacking wheels 61 being represented as solid for clarity) is provided with a separation unit 80.
  • This comprises a separator member 81 which is able to be deployed between a selected note and the next.
  • a stack of n banknotes is desired so the selected banknote is designated as B n .
  • a separator member 81 here in the form of a flexible arm, is mounted via a carriage 82 to a track 83.
  • a timing belt 84 is provided to transfer drive to the separator member 81 from a stepper motor 87 and drive roller 86.
  • the track 83 and timing belt 84 pass round a idler roller 85 which has substantially the same circumference as the hub of the stacker wheel 61.
  • the separator member 81 has a form substantially akin to one of the tines 63 of the stacker wheel 61, as will be described in more detail below. While a stack of documents S, is being formed on stack support plate 70, the separator member 81 is retained at a home position P 1 , as shown in Figure 11 . Here, the separator member does not obstruct the passage of documents through the stacking unit 60.
  • the home position could be located at any point around the track 83 which does not obstruct documents, but preferably the home position is immediately adjacent the receipt point X of the stacker wheel 61.
  • each banknote is received by the stacker wheel, it enters a channel 64 immediately in front of the separator member 81.
  • the arrival of the selected document B n is notified to the separation unit 80 by controller 31. Since the controller 31 knows the location and type of each note in the document handling apparatus 10, it can inform the separating unit of the instant that the selective document B n is received. Thus, as soon as the selected document B n is received by the stacker wheel 61, the motor 87 is activated to drive the separator member 81 forward.
  • the motor 87 is synchronised with the motor driving the stacker wheel 61 and may in some embodiments be replaced by a clutch arrangement adapted to receive drive from the motor which drives the stacker wheels, so that the speed is exactly matched.
  • the separator member 81 then driven in the same direction as the stacker wheel 61, following the selected banknote B n closely behind.
  • FIG 12 shows the location of the next banknote B n+1 , immediately behind the separator member 81.
  • the next banknote B n+1 may not be directly behind the separator member 81 as this will depend on when the output module receives the next note.
  • the separator member travels along an arcuate path around the pulley 85 thus following exactly the path of a banknote around the stacker wheel 61.
  • the track 83 is configured so that the separator member 82 departs from the route of the tines 63 at the point where notes begin to exit the stacker wheel, following the path of the notes as they are released from the stacker wheel 61 at release point Y. This is shown in Figure 13 .
  • the separator member continues to be driven to a holding position P 2 which is between the home position P 1 and the stack support surface 70 on which the stack S, has been formed.
  • the deployment of the separator member 81 between the selected note B n and the next note B n+1 enables the selected note B n to continue to the stack support surface 70, thereby completing the first stack S, whilst the next document B n+1 , cannot pass the separator member 81.
  • the separator member 81 is either halted or decelerated such that subsequent banknotes are caught thereon.
  • the banknotes can therefore continue to be output by the stacking unit 60, forming a new stack S 2 on the separator member 81, which is kept separate from the first stack S 1 .
  • the completed stack S, of n banknotes can then be removed from stack support plate 70 in the confidence that no additional notes have been inadvertently been included.
  • the stack S is removed and transported to a strapping apparatus as described above with respect to Figures 2 to 5 for strapping.
  • the separator member 81 is reactivated (or accelerated) to return to its home position P 1 by completing its circuit of the track 83, travelling around the drive roller 86. In doing so, the separator member 81 lowered the second stack S 2 which is being formed thereon onto the stack support surface 70. The second stack can then continue to be formed on surface 70 until it too reaches n documents. From passing the stack support surface 70 to returning to the home position P 1 , the separator member 81 does not intersect the path along which the notes travel through the stacking apparatus and so does not interfere with the processing. The return to the home position can therefore be completed at any desirable time. Once at the home position P 1 , the separator member is ready for redeployment when notified of the arrival of the next selected banknote B n .
  • Sensors are preferably provided to assist in the accurate control of the separator member 81.
  • an optical sensor may be provided, for example in the form of a transmissive sensor 89 comprising an emitter 89a and a receiver 89b, the light path between which is obstructed by the presence of stack S 1 .
  • the removal of the stack detected by sensor 89 can therefore be used to trigger the separator member 81 to be returned from the holding position to its home position.
  • a home position sensor 88 may be provided at the home position P 1 to ascertain when the separator member 81 has returned to its home position.
  • the holding position P 2 may likewise be identified by use of a similar sensor.
  • the arrival of the separator member 81 at the holding position P 2 is determined by timing the motion of the separator member 81 from the home position, and halting the separator member 81 (or decelerating it) when a predetermined time has elapsed (or, analogously, permitting a certain number of steps of the motor 87 to elapse).
  • the separator member 81 it is desirable for the separator member 81 to follow precisely the path of the document though the stacker unit. This causes the minimum of disruption to the stacking process since no forces in directions other than the transport direction are experienced by the notes.
  • the stacker unit comprises stacker wheels (as described above) it is desirable for the separator member 81 to take substantially the same shape as one of the tines of the stacker wheel, i.e. a curved elongate member.
  • the separator member is required to provide a surface against which the stack S 2 can form.
  • a curved surface is generally undesirable for stacking and so in a particularly preferred embodiment, the curved elongate separation member 81 is provided with a hinge 81a at approximately its mid-point.
  • the hinge 81a is arranged to allow the separator member to become substantially flat (e.g. parallel to the stack support plate 70) once it exits the arcuate portion of the track 83.
  • the hinge 81 a is configured, or stops are provided, to prevent opening beyond a substantially flat position. In other embodiments, two or more hinges 81a could be arranged at different positions along the separation member 81 to achieve a similar effect. Whilst the separator member 81 travels around the arcuate portion, the angular velocity is such that the separator member is urged into its curved configuration as shown by the dotted lines in Figure 15 .
  • the elongate member is preferably also flexibly attached to the carriage 82, for example via a hinge 81 b.
  • Hinge 81 b permits the separator member an additional degree of flexibility which enables it to form a more compact unit as it turns the corner around the drive roller 86 and returns to the home position P 1 , but does not permit movement relative to the carriage past the substantially horizontal position shown in Figure 15 .
  • the carriage 82 to which the separator member 81 is mounted includes attachment means 82a for attaching the carriage to the timing belt 84.
  • a typical stacker unit making use of stacking wheels 61 may comprise two such wheels 61 disposed on a common drive shaft, and it is preferable to provide two separating members 81, as shown, to support each side of the banknote B.
  • the two separator members 81 are preferably controlled and driven by the same means so that their movement is exactly synchronous.
  • the stack support plate 70 on which the first stack S, is formed may be located between the two separator members 81, so that they pass either side of the plate 70, or could be provided with apertures 71, as shown in Figure 16 , to allow the passage of separator members therethrough.
  • the stack support surface could take the form of two spaced surfaces to allow the separator members to pass therebetween and, preferably, the provision of a strapping apparatus as depicted in Figure 7 .
  • the stack support plate may itself be movable between a stacking position, in which the first stack S 1 , is formed, and a strapping position, in which the formed stack is positioned within the stack receipt zone of the strapping apparatus.
  • FIG 17 shows schematically the basic components of a second embodiment of a stacking apparatus 300.
  • Documents in this case, banknotes B
  • the documents are driven along the path at high speed such that, when they reach the end of the path, they follow a trajectory towards a fixed surface 320.
  • each note is decelerated, losing all of its forward momentum, and falls onto a stack support surface 70 where a stack S 1 forms.
  • FIGs 18a and 18b show two alternative ways in which a separation unit, akin to that described above, can be incorporated.
  • a separator member 330 is provided in the form of a plate which, in its home position is retracted into the fixed surface 320 within a recess 335. In its holding position (shown in Figure 18a ), the separator member extends out of the surface 320 and intercepts the path of the banknotes falling into the stack S 1 . In doing so, a second stack S 2 is formed on the separator member 330, whilst the first stack S, can be strapped. Once the first stack S 1 has been removed, the separator member can be retracted and the second stack continues on to the stack support surface 70.
  • a separator member 340 could be provided in the form of a "trap door" in a surface 345 positioned above the stack support surface 70.
  • the door 340 is closed, either via a pivoting motion (as shown) or sliding.
  • a second stack S 2 can then be formed on the door 340 whilst the first stack is removed for strapping.
  • the door 340 is then opened, allowing the second stack S 2 to drop onto the stack support surface 70.
  • the deployment of the separator member 330 or 340 is controlled by the arrival of the selected note, B n , at the exit of the transport path 40. There may be a fixed time delay between the exit of the selected note and the instant at which the separator member is deployed, to account for the time taken for the note to reach the stack S 1 . Alternatively, a sensor may be provided to detect the passage of the selected note past the deployment position (e.g. just below the recess 335 or surface 345) which confirms that the note has passed before the separator member is deployed.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Basic Packing Technique (AREA)
  • Pile Receivers (AREA)
EP10713229.2A 2009-04-02 2010-04-01 Apparatus for forming stacks of sheet documents and corresponding method Not-in-force EP2414243B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PCT/GB2009/000887 WO2010112794A1 (en) 2009-04-02 2009-04-02 Apparatus and method for forming and strapping stacks of sheet documents
PCT/GB2010/000649 WO2010112860A2 (en) 2009-04-02 2010-04-01 Apparatus for strapping stacks of sheet documents- apparatus for forming stacks of sheet documents and corresponding methods

Publications (2)

Publication Number Publication Date
EP2414243A2 EP2414243A2 (en) 2012-02-08
EP2414243B1 true EP2414243B1 (en) 2013-07-31

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EP10713229.2A Not-in-force EP2414243B1 (en) 2009-04-02 2010-04-01 Apparatus for forming stacks of sheet documents and corresponding method

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US (1) US20120098189A1 (es)
EP (1) EP2414243B1 (es)
JP (1) JP2012522692A (es)
CN (1) CN102448827B (es)
AU (1) AU2010231148A1 (es)
ES (1) ES2426415T3 (es)
WO (2) WO2010112794A1 (es)

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AU2010231148A1 (en) 2011-10-27
WO2010112794A1 (en) 2010-10-07
WO2010112860A2 (en) 2010-10-07
CN102448827A (zh) 2012-05-09
EP2414243A2 (en) 2012-02-08
JP2012522692A (ja) 2012-09-27
AU2010231148A2 (en) 2012-03-08
ES2426415T3 (es) 2013-10-23
US20120098189A1 (en) 2012-04-26
WO2010112860A3 (en) 2010-12-29
CN102448827B (zh) 2014-06-18

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