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Description  |
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This invention relates generally to a method and a system for handling
consumable items, tooling and supplies, and more particularly relates to a
machine, system and method which controls the dispensing, ordering,
restocking, inventorying and recording of the end use of such consumable
items.
The typical manufacturing or other facility utilizes many consumable tools
and supplies for each operating shift. These items, which can take the
form of drugs, tool inserts, drill bits, welding rod, gloves and a host of
other items, are difficult and expensive to inventory, dispense, restock,
reorder and track to their end use. At the present time, the handling of
such consumable items is extremely labor intensive. Usually, a
manufacturing or other facility maintains one or more cribs or supply
depots or supply rooms which contain an inventory of the many items, tools
or supplies which will be needed in the facility. Such tool cribs or
supply depots are expensive to supply and maintain because of the cost of
the parts themselves; the cost of the space needed to maintain the crib or
depot and store the parts; and the labor needed to control the inventory,
reorder and restock the items, and dispense the items on a controlled
basis.
Increased competition in all forms of manufacturing operations and other
facilities has created a strong need and desire to provide a system or
method which would substantially reduce the costs associated with the
inventorying, dispensing, restocking, reordering and tracking the end use
of such consumable items in a manufacturing or other facility. The method
and apparatus for handling tooling and supplies in accordance with the
present invention meets this need by eliminating a tool crib or other
central location for storing and dispensing the items, tools and supplies.
The labor and overhead costs associated with these prior tool crib or
supply depots are thereby substantially reduced or eliminated. By
utilizing the system, apparatus and method of this invention, items,
tooling, supplies and other consumable items are dispensed throughout a
manufacturing facility on a much more rapid and efficient basis than
possible with prior systems. This invention also provides for controlled
access to the item, tool or supply dispensing operation, so that
unauthorized personnel cannot utilize the system. The invention provides
an automatic inventory control and creates a record of the use of the
items dispensed and used. The present system also allows the use of
consignment methods of handling the items, tooling and supplies, so that
major reductions in inventory costs can be realized.
SUMMARY OF THE INVENTION
The system and method in accordance with this invention places a uniquely
designed dispensing machine at one or more selected locations in the
manufacturing or other facility. The machine is located in close proximity
to the work area where the consumable items, tools and supplies are needed
to perform the daily manufacturing operations. The expensive time lost in
transporting workers, items, tools and supplies between work stations and
tool cribs or supply depots is thereby substantially reduced. The items,
tools and supplies contained in each machine are selected to meet the
needs of the particular work station. Each machine can be stocked with a
single item, or can be supplied with a plurality of different items,
depending on the needs of the users.
In one embodiment of the machine, a pneumatic system including matrix
switching is used to control the dispensing of the selected items. The
matrix switching system substantially reduces the number of component
parts needed for the dispensing system, and thereby substantially reduces
the size of the machine and the costs related to both the initial machine
construction and maintenance.
In accordance with this invention, each unique dispensing machine can
operate as a stand-alone machine, or can function as a component of an
integrated network which controls the item, tool and supply inventory and
dispensing operation for the entire factory or other facility. In large
manufacturing facilities this networked system could include a main frame
computer or other central processing unit which would be programmed with
the up-to-date inventory data for the parts and supplies to be utilized.
One embodiment of the system in accordance with this invention also
includes a program and a data base which can be programmed and utilized to
identify all authorized personnel who have access to the dispensing
machine, whether the machine is a stand-alone or networked machine. Each
machine in this embodiment includes a user identification device, such as
card reader, which is coupled to the processing unit provided in the
system. This card reader can receive a card with encoded data, and will
transmit the coded identification of the user into the machine program.
The system then functions to automatically record this information in the
memory of the central processing unit associated with the system.
Each dispensing machine further includes an input device such as a keyboard
which allows the user to enter the necessary data to identify and order
the item, tooling or supplies needed from the machine. A special
application computer, preferably of the single board type, is provided in
each machine so that the operation of the keyboard identifies the
components in the machine, responds to commands to order a particular
component, and can automatically adjust the inventory of the dispensed
component in the machine memory.
The machines are easily converted into a networked system which can collect
data from a plurality of machines and adjust the inventory for all or part
of the operations of the manufacturing or other facility. The program
provided in the special application computer in each machine is variable,
so that the machine can be set up and programmed to dispense different
types of items in the same or a different manufacturing facility.
The system thereby provides controlled access to the machines, efficient
tool and supply dispensing and restocking, and accurate inventory control
and updating. The system in accordance with this invention permits the
elimination of a central tool crib or supply depot, and is adapted to
allow the inventory in each machine to be provided by a tool or parts
supplier on a consignment basis.
The system and method of this invention provides the above-described
machine having a supply of consumable items with a memory and a program to
select the items to be dispensed. Means are provided to enter data to
select the item and to transmit the data to the machine memory. The
machine then dispenses the selected item. The data stored in the machine
memory can then be used to control the ordering, inventorying and tracking
of the use of the consumable items dispensed from the machine. The system
can also be programmed to identify and record the authorization of the
machine user. The system allows each machine to be periodically restocked
with replacement items in a manner which does not interfere with the basic
operation of the manufacturing facility. No pneumatic control system
including matrix switching allows the machine to be expanded to handle a
large number of items efficiently and economically.
BRIEF DESCRIPTION OF THE DRAWINGS
Further objects and features of this invention will become more apparent
from the following description of illustrative embodiments of the
invention, taken in conjunction with the accompanying drawings in which:
FIG. 1 is a front perspective view of a machine for dispensing consumable
tools and supplies in accordance with the present invention;
FIG. 2 is a top view of a user identification card which can be utilized
with the dispensing machine shown in FIG. 1;
FIG. 3 is a removed perspective view of a card reader incorporated into the
machine shown in FIG. 1 for use in reading the data presented on the user
card illustrated in FIG. 2;
FIG. 4 is an enlarged view of the keyboard incorporated in the machine
shown in FIG. 1 for use in identifying and selecting the items to be
dispersed;
FIG. 5 is a front view of the machine in FIG. 1 shown in an opened
condition to illustrate the internal components of the machine;
FIG. 6 is an enlarged and removed partial sectional view of one of the
magazines positioned within the machine to store and dispense selected
tooling or supply items;
FIG. 7 is an enlarged and removed view in partial section of the ejection
mechanism incorporated in the machine to eject a selected item from each
of the storage magazines as shown in FIG. 6:
FIG. 8 is an enlarged sectional side view taken along the line 8--8 in FIG.
5 showing the relationship between the magazines and ejection mechanisms
incorporated into the machine near the final stage of the dispensing
operation;
FIG. 8a is an enlarged sectional side view of the magazine and ejection
mechanism shown in a return and charging stage of the dispensing
operation;
FIG. 9 is a front sectional view of the magazine and ejection mechanism as
viewed along the line 9--9 in FIG. 8;
FIG. 10 is a top view in partial section of the dispensing machine
illustrating the arrangement for movably mounting a monitor within the
machine;
FIG. 11 is a front view of a modified dispensing machine in accordance with
this invention;
FIG. 12 is a flow chart representing the operation of the program
incorporated into the machine shown in FIG. 1 to control the dispensing,
ordering, restocking and reordering of the end use of the items stored and
dispensed by the machine in accordance with this invention;
FIG. 13 is a front view of a third embodiment of the machine in accordance
with this invention which incorporates a pneumatic control system with
matrix switching which adapts the machine for dispensing a large number of
items;
FIG. 14 is a schematic side view of the machine illustrated in FIG. 13;
FIG. 15A is a removed partial sectional view of the pneumatic dispensing
cylinder included in the machine illustrated in FIGS. 13 and 14 showing
the cylinder in the at-rest position before the dispensing operation is
begun;
FIG. 15B is a removed partial sectional view of the pneumatic dispensing
cylinder of FIG. 15A shown in the actuated position for dispensing a
selected item from the machine; and
FIG. 16 is a schematic representation of the control system included in the
pneumatic dispensing machine shown in FIGS. 13 and 14 and illustrating the
configuration and operation of the matrix switching system in accordance
with this invention.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
A dispensing machine for use in the system and method for handling
consumable items such as tooling and supplies in accordance with this
invention is indicated by the reference numeral 20 in FIG. 1. The machine
20 comprises an enclosed cabinet made from sheet steel or other suitable
material which can be positioned at a selected station within a
manufacturing facility. In accordance with this invention, one or more of
these machines 20 are located in stations which are in the proximity of
the end user of the items, tools or supplies to be dispensed by the
machine. Adjustable support legs 22 allow the machine 20 to be supported
in a level position. A movable front panel 24 is pivotally attached to the
machine 20 by a piano hinge 26 to provide for easy access into the
interior of the machine. A locking handle 28 is mounted on the panel 24 on
the side opposite the hinge 26 so that access to the interior of the
machine can be controlled.
Referring to FIG. 1 in more detail, the top portion of the front panel 24
includes a transparent viewing window 30 for viewing the monitor or video
display play terminal 32 incorporated in the machine 20. The central
portion of the panel 24 includes a keyboard 34 interconnected with the
monitor 32. The keyboard 34 is thereby positioned for easy access by the
user of the machine. The types of keys typically provided on the keyboard
34 are illustrated by the enlarged view of the keyboard shown in FIG. 4.
Function keys 36 are provided to perform the various functions of the
program incorporated into the system of this invention. Cursor arrow keys
38 are also provided to allow the user of the machine to move the cursor
to the desired position on the monitor 32 during the operation of the
system. A numerical key pad 40 similarly allows the entry of numerical
data into the computer during system operation.
A full view of the computer monitor 32 is shown in FIG. 5. The provision
and location of the central processing unit (CPU) 42 of the computer is
also illustrated in FIG. 5. The CPU 42 can be an IBM PC or other suitable
standard computer unit, or can be a unit that is scaled down and custom
made to perform only the computer functions needed in the dispensing
system in accordance with this invention. A power source 44 is
incorporated in the machine to drive the computer system including the CPU
42, the monitor 32 and the keyboard 34.
The embodiment of the machine 20 illustrated in FIGS. 5 and 10 includes a
rotatably shelf 46 for supporting the computer monitor 32. As shown in
FIGS. 5 and 20, a mounting bracket 48 and pivot pin 50 support the shelf
46 so that the monitor 32 can be pivoted between an inner and an outer
location. In the inner location, as shown in FIG. 5 and shown in solid
lines in FIG. 10, the monitor 32 is aligned with the viewing window 30. In
the outer position, as shown in dotted lines in FIG. 10, the shelf 46
supports the monitor 32 in an outward position so that access can be
gained to other internal components of the machine 20.
A modified embodiment of the machine 20A is shown in FIG. 11. The parts of
the machine 20A are the same as in the machine 20 except for the computer
system components. In the machine 20A the monitor 32A is reduced in size
and mounted on the front panel 24. Also the CPU 42A is illustrated as a
custom-designed unit which is substantially reduced in size and cost
compared to the standard CPU 42. This embodiment of the machine 20A
further includes a printer 52, positioned in the lower portion of the
machine. The printer 52 is interfaced with the CPU 42A and other
components of the computer system to provide for a hard copy printout of
the data generated by the use of the machine 20A.
As shown in FIG. 3, each embodiment of the machine 20 and 20A in accordance
with this invention is adopted to be provided with an identification card
reader 60. The reader 60 is mounted on the front panel 24 and defines a
reading slot 62. The slot 62 includes a magnetic head 64 which is capable
of reading the encoded data carried on the magnetic strip 66 of a user
identification card C. As shown in FIGS. 2 and 3, the card C is designed
to be provided to each authorized user of the machines 20 or 20A, and is
very similar to identification cards currently in use in many
manufacturing facilities. The reader 60 is interfaced with the keyboard
34, the CPU 42 or 42A and the other components of the computer system to
identify the machine user and allow access to the machine only to
authorized personnel. A suitable reader 60 for performing these functions
is a fixed head type reader available from TPS Electronics, Inc., 4047
Transport St., Palo Alto, Calif. 94303.
As shown in FIGS. 5 and 11, each machine 20 or 20A includes twelve storage
and dispensing magazines 70. In the illustrated embodiments each of the
magazines 70 is identical in construction and is designed to store and
dispense generally rectangular boxes of inserts 72, as seen in FIG. 8. If
desired, a single machine 20 can be adapted to dispense a plurality of
different items by substituting magazines of different size for one or
more of the common magazines 70. Such a machine which is adapted to
dispense a large number of items which can differ in size and shape is
illustrated in FIGS. 13-16 by the machine 20B, as further described
hereinbelow.
Six of the magazines 70, numbered 1 through 6 in FIGS. 5 and 11, form an
upper bank of magazines which dispense items into a common upper
collection chute 74. Six other magazines 70, numbered 7 through 12 in FIG.
8, form a lower bank of magazines which dispense items into a common lower
collection chute 76. Support chains 78 or the like maintain the chutes 74
and 76 in the proper position below the related magazines 70. As shown in
FIG. 1, the front panel 24 of the machine 20 or 20A includes an upper
dispensing trough 80 aligned to receive the items collected and dispensed
from the upper chute 74. In the same regard, the front panel 24 also
includes a lower dispensing trough 82 aligned to receive the items
collected and dispensed from the lower chute 76.
Each of the magazines 70 is removably mounted within the machine 20 or 20A
in a manner that permits the magazines to be changed to suit the
particular needs of the machine users. To accomplish this arrangement each
magazine 20 includes a hanger bracket 84 fixed, such as by welding, to the
top of the magazine. A pair of struts 86 extend across the interior of the
machine 20 in the upper and lower portions of the machine and are adapted
to receive the hanging brackets 84. A pair of braces 88 extend in a
similar fashion across the upper and lower portions of the machine
interior in positions parallel to the struts 86. As shown in FIGS. 6 and
8, the magazines 70 abut against and are held in the proper position by
the braces 88 when the magazines are hanging from the supporting struts
86.
As shown in FIGS. 6 through g, the lower end of each dispensing magazine 70
is provided with a discharge tray 90. The tray 90 is slidably mounted
within opposed channels 92 formed in a bottom member 94. The bottom member
94 in turn is fixed to the lower end of the magazine 70. The tray 90 is
formed from a bifurcated slide 96 which is provided with an apertured
extension 98 at the front end. A support plate 100 is positioned on the
slide 96 and is firmly supported at the front end by a brace 102 extending
across the bifurcated slide. The plate 100 and the brace 102 are spaced
from the front end of the slide 96 to form a discharge opening 104 of a
predetermined size in the slide 96. As seen in FIGS. 8 and 8a, the purpose
of the opening 104 is to allow the items 72 to be discharged downwardly
into the chute 76 during the operation of the machine 20 or 20A. Thus, the
size of the opening 104 is selected to accommodate the item 72 being
dispensed. The slide 96 will be replaced with a slide having an opening of
a different dimension when the machine is adapted to dispense items of
different shapes or sizes.
Each plate 100 is designed to support the column of items 72 stored in the
magazine 70 as the lowermost item 72 is being dispensed into the adjacent
chute 74 or 76. As shown in FIG. 8, the discharge tray 90 is therefore
positioned adjacent the bottom end of the magazine 70 so that the plate
100 catches and supports the second-lowest item 72 as the lowest item is
being discharged. As also shown in FIGS. S and 8a, the bottom member 94 is
positioned at the lower end of the magazine 70 to extend below the column
of items 72 a sufficient distance to support the column. It has been found
that sufficient support for the column of items 72 is provided if the
member 94 extends below approximately one half of the column.
Each magazine 70 also includes a springloaded pusher assembly 106 which is
designed to maintain the items 72 in an aligned vertical column to
facilitate the dispensing operation. This assembly 106 comprises an
elongated pusher shoe 108 which abuts against the items 72. The shoe 108
is maintained in a vertical position within the magazine 70 by a pair of
horizontal mounting pins 110. The outer end of each pin 110 is slidably
supported in an aperture in the magazine 70, as seen in FIG. 8. The inner
end of each pin 110 is fixed to a boss 112 attached to the rear of the
shoe 108. A compression spring 114 extends between the magazine 70 and the
shoe 108 along each pin 110 in abutment with the adjacent boss 112. These
springs function to bias the shoe 108 inwardly (to the left in FIG. 8)
against the items 72 in the magazine 70. The pins 110 are adjustable so
that the force of the shoe 108 on the items 72 is sufficient to maintain
the items in a vertical column in a manner that will not interfere with
the dispensing of the items from the magazine during the operation of the
machine 20.
The actuation of the disch | | |
