Multi-component coin assembly system and method

Abstract

Methods and systems are provided for assembly of coin components. Two or more coin components are received in an assembly station having at least two assembling members. The assembling members may be configured to form a chamber comprising the cavities and at least one assembling member may be movable over an assembling path. A merging force may be applied for assembling the coin components together to allow continuous production of joined coin components such that when the movable assembling member travels along the assembling path, one coin component locates within the other, thereby forming a coin assembly over a non-zero distance.

Claims

1. A method of assembling coin components, the method comprising: a. providing the coin components in an assembly station, the assembly station being moveable along a non-zero distance; and b. continuously assembling the coin components over the non-zero distance along an assembling path by exerting two opposing forces generally coaxially with a central axis which is perpendicular to a face of one of the coin components, the two opposing forces exerted by at least one stationary cam, wherein the assembled coin components are fed into a second assembling station for assembly with at least one additional coin component.

2. The method as in claim 1, wherein the assembling path is non-colinear with a central axis of at least one of the coin components.

3. The method as in claim 1, wherein the coin components are assembled over the non-zero distance by at least one merging force, the at least one merging force being exerted from about 0 to about 89.99 relative to the central axis.

4. The method as in claim 1, wherein at least one of the coin components experiences axial tilt along the non-zero distance.

5. The method as in claim 1, wherein the non-zero distance is linear, non-linear, or circular.

6. The method as in claim 1, wherein the assembled coin components are discharged at a terminus of the assembling path.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the present disclosure will now be described, by way of example only, with reference to the attached Figures.

(2) FIG. 1 is an exploded perspective view of a quad component composite coin blank.

(3) FIG. 2 is a perspective view of a quad component coin blank.

(4) FIG. 3 is a schematic front view of single-contact positioning.

(5) FIG. 4A-B is a schematic front view of multi-contact positioning.

(6) FIG. 5A-B is a schematic of offset horizontal centres and coincident vertical centres of contact datum references.

(7) FIG. 6A-D is a plan view of a dynamic assembly with cam-based merging forces and axial tilt over an assembling path.

(8) FIG. 7 is a cross-sectional perspective view of the dynamic assembly with cam-based merging forces.

(9) FIG. 8 is a cross-sectional perspective view of the dynamic assembly with cam-based merging forces.

(10) FIG. 9 is an isometric view of a two-component assembly device.

(11) FIG. 10A-C is a schematic plan view of a cascading assembly.

(12) FIG. 11 is a partial cross-sectional elevation view of the cascading assembly of FIG. 10.

(13) FIG. 12 is a perspective view of a four-component assembly system.

(14) FIG. 13 is a perspective view of a coin blank assembly system.

(15) FIG. 14A-C is a schematic plan view of a dynamic assembly method with cam-based merging forces and straight insertion.

(16) FIG. 15 is an exploded perspective view of a dynamic assembly with cam-based merging forces and straight insertion.

(17) FIG. 16 is an exploded detail view of the dynamic assembly with cam-based merging forces and straight insertion of FIG. 13.

(18) FIG. 17 is a detail plan view of a coin blank assembly system.

(19) FIG. 18 is a cross-sectional elevation view of a coin blank discharge guide.

(20) FIG. 19 is a perspective view of the coin blank assembly system.

(21) FIG. 20 is a partial perspective view of a coin blank assembly device with a circular assembling path.

(22) FIG. 21 is an exploded perspective view of a coin blank assembly device with a circular assembling path.

DETAILED DESCRIPTION

(23) For simplicity and clarity of illustration, reference numerals may be repeated among the figures to indicate corresponding or analogous elements. Numerous details are set forth to provide an understanding of the embodiments described herein. The embodiments may be practiced without these details. In other instances, well-known methods, procedures, and components have not been described in detail to avoid obscuring the embodiments described. The description is not to be considered as limited to the scope of the embodiments described herein.

(24) This disclosure generally relates to coin or coin blank assembly systems and methods, and more particularly to assembly of multi-component coins, tokens, chips and the like. For the purposes of this description, the terms blank, component, and subcomponent may be used interchangeably. Additionally, the terms merging and assembling may also be used interchangeably.

(25) The coin assembly systems and methods of the present disclosure may permit the assembly or coining of a plurality of coin components over a distance. One or more assembly stations may be configured to assemble coin components simultaneously or in a stepwise fashion.

(26) For example, FIG. 1 and FIG. 2 show an exploded view of a quad-component composite coin blank and perspective view of the quad-component composite coin, respectively. In this example, the coin blank or coin may comprise an inner stack comprising two inserts 2,3 facing each other, an outer ring 4 annularly surrounding the inner stack; and a separator 1 disposed between the outer ring 4 and the inner stack, separating the outer ring from the inner stack and separating the inserts 2,3 from each other. As can be seen from this example, the coin blank or coin may have components of varying thicknesses and geometry. Additionally, the separator 1 may have a partial or full inner web separating stacked inserts from each other.

(27) At least one of the components of the quad-component composite coin may be a receiving component. In FIG. 1 for example, the outer ring 4 may be a receiving component, the central axis of which is indicated by line O. In this example, the separator 1 and inserts 2,3 may be insertable coin components.

(28) Guide Channel and Array

(29) A coin blank array may be an edgewise stack of coin blanks, components, or subcomponents. Each array may be housed within a guide channel to align coin blanks, components, or subcomponents for loading into a respective receiving cavity.

(30) Optionally, retainer plates 36,37,38 may be disposed between the guide channels 5,6, 26, 27 to prevent the coin blanks, components, or subcomponents from prematurely assembling into a mating coin blank in an adjacent array.

(31) Receiving Cavities and Contact Datum Points

(32) FIG. 3, FIG. 4A and FIG. 4B show front views of a receiving cavity. FIG. 3 shows a receiving cavity containing one contact datum point while FIG. 4A and FIG. 4B each contain two contact datum points.

(33) A receiving cavity may be formed from a cavity in an assembling member. In embodiments comprising a first and second assembling member having a first and second cavity, respectively. Individual components may be housed in individual cavities, or where cavities align and form a chamber, the components may be housed together in the chamber. The offset planes of the cavities may define the insertion distance X as shown in FIG. 5A.

(34) One or more contact datum points may be contained in the receiving cavity and position a coin component held therein by, for example, abutting or buttressing the coin component. FIG. 5B shows that the relative positioning of contact datum points in adjacent receiving cavities may position components housed in the adjacent receiving cavities along the desired horizontal axes and vertical axes, for example, to allow for coincident vertical centres.

(35) Aligning the coin components in a desirable configuration prior to assembly, such as along a central axis of a receiving component, can facilitate the application of a lateral or coaxial force or merging force to assemble the coin components together.

(36) Assembling Path

(37) Lateral merging forces or forces, for example those coaxial with a central axis of the aligned coin components, may occur over an assembling path. The assembling path may be linear or non-linear, for example, or circular. A circular assembling path may result in a rotary coin assembly system of station.

(38) Though components may be aligned about a central axis of a receiving coin component, certain components, for example, insertable coin components, may experience axial tilt as they travel along the assembly path. Such axial tilt may facilitate mating between complementary components as described below.

(39) Assembly or joining over an assembling path can allow continuous and uninterrupted joining or assembly of coin components in view of the reciprocating or repetitive motion of the assembly system.

(40) The assembling path distance may be calculated such that the path distance is greater than 0.

(41) Merging Forces

(42) Merging forces, such as camming forces may be applied to assemble components together along the assembling path. The application of a camming force or forces may be resultant from a structural cam or wedge feature housed within or formed by a keyway such that components moving in receiving cavities along the keyway will abut the cam and be forced into a mating component. See, for example, FIG. 6B.

(43) Alternatively, an actuator such as a pneumatic, electronic, or mechanical actuator may apply the merging force where the merging force is a contact force. Where the merging force is a non-contact force, a magnetic actuator may be used, for example.

(44) As such, the merging force may not require physical engagement with the components or receiving cavities, but may instead be touchless, such as but not limited to a blast of gas, or magnetic force.

(45) Assembly Station with Cam-Based Assembling and Angled Insertion Over an Assembling Path

(46) In this embodiment, two components may be assembled at an assembly station. For illustrative purposes, the assembly of a separator 1 and insert 2 is described, though the two components may be any two of a multi-component coin blank or coin that may be assembled.

(47) FIG. 6A-C is a plan view of a dynamic assembly with cam-based merging forces and axial tilt over an assembling. In this embodiment, two components may be assembled into a coin assembly. For example, separator 1 and insert 2 may be assembled together to form a subassembly. In this embodiment, an assembly system is shown having a first assembling member 7 and a second assembling member 16.

(48) In FIG. 6A, the separator 1 is shown loaded into a first receiving cavity 9 defined by assembling member 7 comprising contact datum point C1. In this embodiment, the first receiving cavity 9 is open to the guide rail 8. Contact datum point B1 (not shown) is located on guide rail 8. In this embodiment, insert 2 is shown loaded into a second receiving cavity 10 defined by assembling member 16 having contact datum points B2 (not shown) and C2. Assembling member 7 may be, for example, a moveable piston. Assembling member 7 may be movable relative to assembling member 16 in an assembly reciprocation stroke.

(49) Contact datum points B1, C1 and B2, C2 may be arranged in the respective receiving cavities 9,10 to have offset horizontal centers and have offset contact datum reference planes (A1, A2). Contact datum references B1,B2 may define the bottom contact datum points of the respective receiving cavities 9,10. These contact datum points may be defined as in, for example, FIG. 5.

(50) In certain embodiments, components may be loaded into receiving cavities about a central axis as aligned by contact datum points B1, B2, C1, C2.

(51) In FIG. 6B, the insert 2 may be loaded into a stationary elongated tapered receiving cavity 10 (not shown) which may have two horizontal keyways 12 that may accept two linear cams 11 on the assembling member 7. The tapered receiving cavity 10 and the keyways 12 may be contained within a back plate 16.

(52) The assembling member 7 may move the separator and linear cams 11 towards the insert 2 until the two linear cams 11 contact the insert 2 in the stationary elongated tapered cavity 10. The linear cams 11 may become a contact point C2 for initiating merging of the insert 2 into the separator 1. As the assembling member 7 moves along the assembling path, the linear cam 11 may cause the insert 2 to experience axial tilt such that the insert's 2 trailing edge may tilt and locate into the separator 1 as shown in FIG. 6B. The insert 2 may move with the linear cam 11 on the assembling member 7 until it reaches the tapered section of the cavity 10 further called the wedge 13.

(53) Linear cam 11 and wedge 13 may each comprise an angled guiding face.

(54) As shown in FIG. 6C, as the assembling member 7 continues, the wedge 13 exerts a camming force on the subassembly (1+2) comprising separator 1 and insert 2. The merging force may be exerted such that it may merge the leading edge of the insert 2 into separator 1 and complete the merging of the insert 2 from A2 plane into the first separator 1 plane A1.

(55) The heights of receiving cavity 9,10 may allow the two different diameter components to have coincident vertical centers where the centers are at the same height.

(56) For example, FIG. 7 is a cross-sectional perspective view of the dynamic assembly with cam-based merging forces. In this embodiment, separator 1 may be loaded into receiving cavity 9 (not shown) defined by movable piston 7 that may reciprocate horizontally on a guide rail 8. A motor 14 may drive a linkage 15 connected to assembling member 7. As the assembling member 7 moves through the assembly reciprocation stroke, separator 1 may be dispensed from the corresponding array from guide channel 5 by contact datum point C1 (not shown), which may be defined by a vertical face of the receiving cavity 9 (not shown). Gravity causes separator 1 to ride on the datum reference B1 (not shown) as the assembling member 7 extends during the assembly reciprocation stoke.

(57) Inertia may cause separator 1 to seat against C1 (not shown) as the reciprocating assembly moves through the assembly stroke. Assembling member 7 may comprise two linear cams 11 that may extend into keyways 12 on planes parallel to insert 2.

(58) FIG. 8 is a further a cross-sectional perspective view of the dynamic assembly with cam-based merging forces. The cavity 9 may be open to the guide rail 8 below such that the guide rail 8 may be discontinued at the end of the assembling member 7 assembly stroke to form an ejection slot 17. In this embodiment, when the assembling member 7 reaches the end of the assembly stroke the assembled subassembly (1+2) may be ejected from the receiving cavity 9. This ejection may be facilitated by, for example, gravity, a mechanical ejector, an air blast or a combination thereof. The subassembly (1+2) may be ejected into the ejection slot 17.

(59) The ejection slot 17 may extend to become a guide channel for subsequent assembly stations or may become a guide channel to feed assembled blanks into a horizontal coining press 25. The reciprocating assembly reciprocates back to receive two more components to repeat the cycle.

(60) FIG. 9 is a partial cutaway perspective view of a two-component assembly device. Such an embodiment may be used to assemble bi-metal two-piece coins to feed into a horizontal coining press.

(61) Series of Dynamic Assembly Systems/Stations with Cam-Based Cascade

(62) In an embodiment, a plurality of dynamic assembly stations as described above may be arranged where subassemblies may cascade to one or more subsequent assembly stations for further assembly with additional components.

(63) In this embodiment, four components may be assembled stepwise at consecutive dynamic assembly stations in series as described below. For illustrative purposes, the assembling of a separator 1, insert 2, insert 3 and outer ring 4 is described, though any number of components of a multi-component coin blank or coin may be assembled in series.

(64) FIG. 10 is a schematic edgewise plan view of subassembly outputs of four consecutive assembly stations. In this an embodiment, a four-component coin blank or coin comprising a separator 1, two inserts 2,3, and an outer ring 4 is shown as an example.

(65) FIG. 11 is a partial cross-sectional elevation view of the cascading assembly of FIG. 10. In this embodiment, station I 18 may assemble the separator 1 and insert 2 to form subassembly 1+2, by a mechanism described in the above. Similarly, station II 19 may merge insert 3 with the subassembly 1+2 to form subassembly 1+2+3. Insert 3 may be merged with the subassembly 1+2 from the side opposite of the separator 1. Station III 20 may merge the outer ring 4 with subassembly 1+2+3 to form complete coin blank 1+2+3+4. The loosely assembled coin blank 1+2+3+4 may be fed into horizontal coining press 25 to coin the final assembly, as shown in FIG. 12. The coining operation may be a finished coin or an assembled blank with no design details.

(66) Method of Dynamic Assembly with Cam-Based Merging Forces and Straight Insertion Over an Assembling Path

(67) FIG. 13-FIG. 19 show dynamic assembly with cam-based merging forces and straight insertion of components over an assembling path. In FIG. 13, a coin blank assembly system 47 is shown. In one embodiment, the assembly system 47 may assemble a four-component coin blank or coin over an assembling path and may feed the assembly into a coining press 25.

(68) In an embodiment shown in FIG. 14, insert 2 may be merged into separator 1 to form subassembly 1+2 (FIG. 14A). Subassembly 1+2 may subsequently be merged into outer ring 4 to form subassembly 1+2+4 (FIG. 14B). Insert 3 may then be merged into subassembly 1+2+4 to form final assembly 1+2+3+4 (FIG. 14C) over non-zero distance Y along the assembly path.

(69) To achieve a multi-component assembly over an assembling path, the respective components (for example, the separator 1, insert 2, insert 3 and outer ring 4) may be aligned in coin blank arrays within guide channels 5,6,26,27 as shown in FIG. 15. The guide channels 5,6,26,27 may be contained within guide plates 39, 40, 41, 42. While verticality of the guide channels 5,6,26,27 is preferred, horizontal, angled or a combination thereof may also be acceptable.

(70) Retainer plates 36,37,38 may be disposed between guide plates 39,40,41,42 to prevent components them from prematurely merging into a mating coin blank.

(71) Guide channels 5,6,26,27 may terminate in permanently aligned receiving cavities 9,10,28,29 containing contact datum points to align coin components deposited therein about coincident centers along a central axis. The receiving cavities 9,10,28,29 may be contained within a receiving cavity assembly 45 for horizontally reciprocating along guide rail 35.

(72) The receiving cavity 29 of the largest component, for example the outer ring 4, may be an open cavity for allowing the component to ride on datum rail 43. Smaller components, for example separator 1, and inserts 2,3, may be deposited from their respective guide channels into closed bottom cavities 5,6,28 containing contact datum points that may precisely locate the blanks concentrically along a common axis. At the end of a stroke, the datum rail 43 may be discontinued at a discharge point 44.

(73) As seen in FIG. 16, receiving cavities 9b,10b,28b,29b may carry a set of components from the respective arrays. In FIG. 17, a set of linear cams 32b,33b and cam followers 30b,31b may exert a merging force or two opposing merging forces about the components to merge the components together into the plane of the largest component, for example, outer ring 4.

(74) At the end of the reciprocation stroke, linear cams 32b,33b and cam followers 30b,31b may cease exerting the camming force(s) to allow the 1+2+3+4 assembly to drop out of a slot at the end of the stroke at discharge point 44.

(75) A second set of cavities 9a,10a,28a,29a in the receiving cavity assembly 45 may repeat the assembly operation on the return stroke. Discharge points 44a, 44b may then feed respective guide channels that guide the final assembly into, for example, subsequent stations of coin press (FIG. 18-FIG. 19).

(76) In the embodiment shown in FIGS. 20-21, the reciprocation stroke may be non-linear. For example, a stroke may follow a circular assembling path to further reduce the footprint of the assembly, improved throughput for the same speed of operation and a longer assembling path.

(77) In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to one skilled in the art that these specific details are not required.

(78) The structure, features, accessories, and alternatives of specific embodiments described herein and shown in the Figures are intended to apply generally to all of the teachings of the present disclosure, including to all of the embodiments described and illustrated herein, insofar as they are compatible. In other words, the structure, features, accessories, and alternatives of a specific embodiment are not intended to be limited to only that specific embodiment unless so indicated.

(79) In addition, the steps and the ordering of the steps of methods described herein are not meant to be limiting. Methods comprising different steps, different number of steps, and/or different ordering of steps are also contemplated.

(80) The above-described embodiments are intended to be examples only. Alterations, modifications and variations can be effected to the particular embodiments by those of skill in the art without departing from the scope, which is defined solely by the claims appended hereto.