This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2009-190308, filed Aug. 19, 2009, the entire contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to a valve device for circulating and interrupting a fluid, and more particularly, to a paper sheet pickup apparatus for picking up sheets of paper one by one by attaching each sheet to a belt using a suction force.
2. Description of the Related Art
There is a conventional standard paper sheet pickup apparatus, in which a belt with holes runs along mail matters to attach thereon each mail matter by drawing each mail matter through the holes of the belt using a suction nozzle provided near the reverse side of the belt, thereby picking up the mail matters one by one (see, for example, U.S. Pat. No. 5,391,051). This apparatus comprises a solenoid valve interposed between the suction nozzle and a vacuum tank.
When operating the apparatus to pick up mail matters, the belt runs, and each mail matter is attached to the belt by the suction force of the suction nozzle that is generated when the solenoid valve is open. To sequentially pick up mail matters, the solenoid valve is periodically closed in accordance with the pickup timing of each mail matter, thereby forming a gap between a currently picked up mail matter and a mail matter to be subsequently picked up.
In general, the solenoid valve 100 comprises a coil 104 for axially moving a substantially cylindrical plunger 102, a chamber 106 (shown only in
When opening the solenoid valve 100, the coil 104 is excited to pull the plunger 102 out of the chamber 106 to make the two holes 108a and 109a communicate with each other via the chamber 106. In contrast, when closing the solenoid valve 100, the excitation of the coil 104 is interrupted to thereby push the plunger 102 into the chamber 106 and block the two holes 108a and 109a, thereby blocking a fluid path 110 that connects the pipes 108 and 109.
The solenoid valve 100 is opened and closed by axially moving the plunger 102. Therefore, great inertia occurs when opening/closing the solenoid valve 100. In particular, when the diameter of the pipes 108 and 109 connected to the solenoid valve 100 is increased to increase the flow of air, it is necessary to also increase the diameter of the plunger 102 for blocking the holes 108a and 109a. In this case, greater inertia will occur accordingly.
Further, when opening the solenoid valve 100, much time is required until the pressure in the chamber 106 reaches a preset value after the coil 104 is excited to move the plunger 102 and introduce air into the chamber 106. Thus, the response rate of the solenoid valve 100, i.e., the rate of starting the circulation of air after the excitation of the coil 104, is low. Similarly, when closing the solenoid valve 100, the moving rate of the plunger 102 is low since the plunger 102 is pushed into the chamber 106 against air of the preset pressure. Namely, the response rate of the conventional solenoid valve 100 is low both when the coil 104 is excited, and when the excitation of the coil 104 is stopped.
This being so, if the solenoid valve 100 is used between the suction nozzle and the vacuum tank employed in the sheet (mail matter) pickup apparatus disclosed in the above-mentioned US patent, the mail matter pickup rate will inevitably be low because of the low response rate of the solenoid valve 100 itself.
Further, if the solenoid valve 100 is used in the sheet (mail matter) pickup apparatus disclosed in the above-mentioned US patent, it will be difficult to attach, by suction force, a relatively large and heavy mail matter on the belt with holes. Namely, when the solenoid valve 100 assumes the open state shown in
It is an object of the present invention to provide a valve device capable of circulating a relatively large amount of fluid and interrupting the circulation at high response rate.
It is another object of the present invention to provide a paper sheet pickup apparatus capable of easily picking up a relatively heavy paper sheet and picking up sheets of paper at high pickup rate.
In accordance with an aspect of the invention, there is provided a valve device comprising: a first shielding plate movable across a fluid passage for passing a fluid therethrough, the first shielding plate including a first fluid passing hole which overlaps with the fluid passage when the first shielding plate is moving; a second shielding plate adjacent to the first shielding plate, movable across the fluid passage and including a second fluid passing hole which overlaps with the fluid passage when the second shielding plate is moving; and a driving unit configured to make the first and second shielding plates cooperate with each other to close and open the fluid passage.
In the above structure, the fluid passage can instantly be opened simply by angularly moving the first and second shielding plates, and hence circulation of a relatively large amount of fluid can be started immediately after the fluid passage is opened. Thus, the valve device of the invention is excellent in response rate, and hence can instantly circulate and block a relatively large amount of fluid.
In accordance with another aspect of the invention, there is provided a valve device comprising: a first shielding plate rotatable across a first fluid passage for passing a fluid therethrough, and across a second fluid passage separate from the first fluid passage, the first shielding plate including a plurality of first fluid passing holes which overlap with the first and second fluid passages when the first shielding plate is rotating; a second shielding plate adjacent to the first shielding plate, rotatable across the first and second fluid passages and including a plurality of second fluid passing holes which overlap with the first and second fluid passages when the second shielding plate is rotating; and a driving unit configured to make the first and second shielding plates cooperate with each other to close and open the first and second fluid passages.
In accordance with yet another aspect of the invention, there is provided a paper sheet pickup apparatus comprising: an input unit configured to receive a plurality of paper sheets accumulated; a pickup member including a suction hole and configured to run along one of accumulated paper sheets, the one paper sheet being positioned at a most downstream side with respect to a direction of accumulation; a negative-pressure generating unit configured to draw air through the suction hole from a reverse side of the pickup member, thereby generating negative pressure on a surface of the pickup member to attach thereon the one paper sheet; a suction unit connected to the negative-pressure generating unit via a fluid passage; and a valve device provided across the fluid passage, wherein the valve device comprises: a first shielding plate movable across the fluid passage, and including a first fluid passing hole which overlaps with the fluid passage when the first shielding plate is moving; a second shielding plate adjacent to the first shielding plate, movable across the fluid passage, and including a second fluid passing hole which overlaps with the fluid passage when the second shielding plate is moving; and a driving unit configured to make the first and second shielding plates cooperate with each other to close and open the fluid passage.
In the invention constructed as above, a large amount of air can instantly be drawn from the negative-pressure chamber when picking up a paper sheet, thereby instantly reducing the internal pressure of the negative-pressure chamber. Accordingly, a relatively heavy paper sheet can easily be picked up, which enables high rate pickup of paper sheets.
In accordance with yet further aspect of the invention, there is provided a paper sheet pickup apparatus comprising: an input unit configured to receive a plurality of paper sheets accumulated; a pickup member including a suction hole and configured to run along one of accumulated paper sheets, the one paper sheet being positioned at a most downstream side with respect to a direction of accumulation; a negative-pressure generating unit configured to draw air through the suction hole from a reverse side of the pickup member, thereby generating negative pressure on a surface of the pickup member to attach thereon the one paper sheet; a suction unit connected to the negative-pressure generating unit via a first fluid passage; and a valve device provided across the first fluid passage and across a second fluid passage, wherein the valve device comprises: a first shielding plate rotatable across the first and second fluid passages, and including a plurality of first fluid passing holes which overlap with the first and second fluid passages when the first shielding plate is rotating; a second shielding plate adjacent to the first shielding plate, rotatable across the first and second fluid passages and including a plurality of second fluid passing holes which overlap with the first and second fluid passages when the second shielding plate is rotating; and a driving unit configured to make the first and second shielding plates cooperate with each other to close and open the first and second fluid passages.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
Embodiments of the invention will be described in detail with reference to the accompanying drawings.
The pickup apparatus 1 comprises an input unit 2, a supply mechanism 3, a pickup belt 4 (pickup member), a negative-pressure chamber 5 (negative-pressure generator), a suction chamber 6, a separation roller 7, conveyor belts 8a and 8b, a plurality of sensors S1 to S6, and a control unit 10 for controlling the operation of the entire apparatus.
The control unit 10 is connected to the sensors S1 to S6, a motor 11 for operating a floor belt or a backup plate (not shown) incorporated in the supply mechanism 3, a motor 12 for running the pickup belt 4 in the direction indicated by arrow T, a pump 13 (suction unit) for drawing air from the negative-pressure chamber 5, a blower 14 for drawing air from the suction camber 6, a motor 15 for imparting separation torque to the separation roller 7, a pump 16 for generating negative pressure around the periphery of the separation roller 7, and a motor 17 for running the conveyor belts 8a and 8b.
In the input unit 2, a plurality of paper sheets P are input in an accumulated and upright state. The paper sheets P accumulated in the input unit 2 are moved to one side (the left side in
The pickup belt 4 runs endlessly around a plurality of pulleys. Part of the pickup belt 4 is brought into contact with the paper sheet P at the pickup position S, and runs at a constant rate in a direction parallel to the surface of the paper sheet P, i.e., in the pickup direction T. The negative-pressure chamber 5 faces the inside (reverse side) of the belt 4, and faces the pickup position S with the pickup belt 4 interposed therebetween.
As shown in
The paper sheet P picked up from the pickup position S is conveyed by a conveyor path 9 upward in
The suction chamber 6 is provided upstream (at the lower position in
The separation roller 7 is provided downstream of the pickup position S with respect to the paper sheet pickup direction (i.e., at the upper side in
Namely, by applying, to the sleeve 7c, separation torque that exerts in a direction opposite to the paper sheet pickup direction, using the motor 15, and producing negative pressure around the outer periphery of the sleeve 7c, using the pump 16, a few paper sheets P picked up unintentionally simultaneously with a leading paper sheet P when the leading paper sheet is picked up from the pickup position S can be separated from the leading paper sheet.
The conveyor belt 8a, an endless belt, is tensioned (at the left side in
A description will now be given of the operation of feeding, one by one onto the conveyor path 9, a plurality of paper sheets P received in the inlet unit 2.
When a plurality of paper sheets P are fed from the inlet unit 2 to the pickup apparatus 1, they are sequentially supplied by the supply mechanism 3 to the pickup position S, and are drawn by the pickup belt 4 and fed onto the conveyor path 9. The paper sheets P conveyed through the conveyor path 9 are monitored in conveyor position and state by the control unit 10 via the sensors S1 to S6.
When each paper sheet P is picked up, the pump 13 is operated to draw air from the negative pressure chamber 5, thereby generating negative pressure on the surface of the pickup belt 4. Further, an air flow directed to the pickup position S is constantly applied by the suction chamber 6 to the paper sheet P earliest accumulated in the inlet unit 2 (i.e., the leftmost one in
The paper sheet P picked up from the pickup position S is guided to the nip 8c of the conveyor belts 8a and 8b, and then guided to a further downstream position, with the front end of the paper sheet nipped by the nip 8c. The fact that the picked paper sheet P has reached the nip 8c is detected when the output of the sensor S5 is changed from the “bright level” to the “dark level.” At this time, the running rate of the conveyor belts 8a and 8b is set to a value slightly higher than that of the pickup belt 4, which means that the paper sheet P is pulled out by the conveyor belts 8a and 8b.
When one or more paper sheets P are picked up simultaneously with a paper sheet P firstly fed to the pickup position S, they are separated from the latter sheet by the separation roller 7. At this time, negative pressure is produced on the periphery of the separation roller 7, and separation torque is exerted on the sleeve 7c in a direction opposite to the pickup direction. When a single paper sheet P is normally picked up, the sleeve 7c of the separation roller 7 is rotated in the pickup direction. In contrast, when two or more paper sheets are simultaneously picked up, the sleeve 7c is rotated in a direction opposite to the above, whereby the second and later paper sheets are returned and separated from the first paper sheet.
When superposed paper sheets P are separated and fed to the conveyor path 9 one by one, as described above, a gap is formed between the adjacent paper sheets P by executing on-off control of the negative pressure in the negative-pressure chamber 5, or by intermittently running the pickup belt 4. The gap is determined in accordance with the processing rate of paper sheets P in a processing unit (which is not shown or described) connected to the conveyor path 9 and located downstream of the pickup apparatus 1. In addition to this structure, or alternatively, the gap is determined in accordance with the switching rate of a gate (not shown) provided downstream of the conveyor path 9.
For instance, to enhance the processing efficiency of the processing unit located downstream and impart a sufficient processing time, it is desirable to control the gap between adjacent paper sheets to a desired length. However, in the method of forming a gap by intermittently operating the pickup belt 4, it is difficult to highly accurately control the times required for accelerating and decelerating the belt, and hence slippage may occur between the belt and each paper sheet when the belt is accelerated or decelerated.
Further, to control the gap between adjacent paper sheets, another method is possible, in which the above-mentioned conventional solenoid valve is provided across the line connecting the pump 13 to the negative-pressure chamber 5 to open/close the solenoid valve, thereby on/off controlling the negative pressure in the negative-pressure chamber 5 and hence controlling the gap. In this method, however, since the response rate of the solenoid valve itself is low, it is difficult to accurately adjust the gap between adjacent paper sheets to a desired value.
To accurately adjust the gap, the inventors of the present invention have developed a valve device that has an extremely high response rate, can circulate a large amount of air, and can instantly circulate air and stop the circulation of the air. Various embodiments of the valve device will now be described.
The valve device 20 is provided across a suction tube 22 that connects the negative-pressure chamber 5 and the pump 13. As shown in
As shown in
The two servo motors 33 and 34 function as driving units of the present invention, and are connected to the control unit 10 of the pickup apparatus described above. The servo motors 33 and 34 are provided outside the first and second blocks 24 and 26, respectively. Although the first embodiment employs the two servo motors 33 and 34 for independently rotating the two shielding plates 31 and 32, the two shielding plates 31 and 32 may be rotated by a single driving unit (not shown).
As indicated by the broken line in
The first and second shielding plates 31 and 32 are arranged rotatable (angularly movable) on the plane extending across the air passage 23. Further, the rotary shaft of the servo motor 33 is extended through the central portions of the first and second block 24 and the first shielding plate 31, and the rotary shaft of the servo motor 34 is extended through the central portions of the second block 26 and the second shielding plate 32. The rotary shafts of the servo motors 33 and 34 are arranged coaxial.
The first and second shielding plates 31 and 32 are independently rotated in opposite directions by the servo motors 33 and 34 as indicated by arrows CW and CCW, respectively. More specifically, the first shielding plate 31 is rotated clockwise (in the direction indicated by the arrow CW) when seen from the left side in
A communication hole 24a is formed through the first block 24 so that it communicates with the upstream-side tube 22a, and a communication hole 26a is formed through the second block 26 so that it communicates with the downstream-side tube 22b. The communication holes 24a and 26a are formed at preset corresponding positions away from the axes of rotation of the first and second blocks 24 and 26, respectively. The communication holes 24a and 26a are formed coaxial, facing each other, to define the opposite ends of the aforementioned air passage 23.
A plurality of (three in the embodiment) air passing holes 31a (first air passing holes) and a plurality of (three in the embodiment) air passing holes 32a (second air passing holes) are formed in the first and second shielding plates 31 and 32, respectively. These air passing holes 31a and 32a rotate (angularly move) in accordance with the rotation of the first and second shielding plates 31 and 32. In the first embodiment, the air passing holes 31a and 32a are of a fan shape having diametrically extending edges. Namely, by virtue of this shape, the air passing holes 31a and 32a overlap with the communication holes 24a and 26a of the first and second blocks 24 and 26, i.e., overlap with the air passage 23 of the suction tube 22 for a relatively long time, while the shielding plates 31 and 32 are rotated.
Referring now to
In the state shown in
More specifically, in the state shown in
If in this state, an “open” instruction is issued from the control unit 10, the shielding plates 31 and 32 are rotated in the respective directions indicated by the arrows, until the state shown in
Since at this time, the control unit 10 starts to rotate the shielding plates 31 and 32 that are in the standby state shown in
Thus, by fully opening the air passage 23 during acceleration of the shielding plates 31 and 32, the air passage 23 can be extremely quickly switched from the closed state to the open state as shown in
On the other hand, if it is necessary to simultaneously open the air passage and stop the shielding plates 31 and 32, an extra time required for deceleration of the shielding plates 31 and 32 performed to stop them, after they are accelerated from their respective standby positions. This inevitably increases the time required until the air passage 23 is fully opened after an “open” instruction is issued.
Further, if the first shielding plate 31 is rotated from the position in which the front edge 311 of the air passing hole 31a does not cross the air passage 23, and the second shielding plate 32 is rotated from the position in which the front edge 321 of the air passing hole 32a does not cross the air passage 23, thereby opening the air passage 23, the angular moving distance (rotational angle) of each shielding plate 31 or 32, required to shift the air passage 23 from the open state to the closed state, becomes longer (larger). Thus, a long time will be necessary to fully open the air passage 23 after receiving the “open” instruction.
In light of the above, the first embodiment is designed such that the two shielding plates 31 and 32 start to rotate from their angular standby positions shown in
After that, the control unit 10 decelerates and stops the shielding plates 31 and 32 while the state shown in
More specifically, in the standby state shown in
When the two shielding plates 31 and 32 are rotated from the angular standby positions shown in
To block the air passage 23 in a short time, it is important to stop the shielding plates 31 and 32 at the angular standby positions shown in
Thereafter, the control unit 10 decelerates and almost stops the rotation of the shielding plates 31 and 32 while the state shown in
The operations shown in
As described above, the valve device 20 of the first embodiment can instantly open and close the air passage 23 to enable a plurality of paper sheets P to be sequentially picked up at high rate. Further, the pickup apparatus 1 of the first embodiment, which employs the above-described valve device 20, can instantly circulate and block a large amount of air, thereby enabling even relatively heavy paper sheets P to be attached to the pickup belt 4 reliably.
If the conventional solenoid valve is used for the same purpose as the above, it is difficult to simultaneously pass therethrough a large amount of air since the solenoid valve has a significant fluid passage resistance as described above, with the result that the negative-pressure chamber 5 cannot instantly be set to negative pressure. Furthermore, if the fluid passage itself is made thicker, the inertia of the plunger will inevitably be increased, and accordingly, the response rate of the solenoid valve becomes low.
In contrast, the valve device 20 of the first embodiment can instantly open and close the air passage 23 by simply rotating the motor 27, and hence the response rate of the valve device can be easily enhanced. Further, in the valve device 20 of the first embodiment, the diameter of the air passage 23 can be set to an arbitrary value, whereby a greater amount of air can be circulated and blocked. Yet further, since the valve device 20 of the first embodiment has a structure for linearly passing air, it has almost no air passing resistance and hence can smoothly circulate a large amount of air.
The exhaust tube 28 comprises an upstream-side exhaust tube 28a located upstream of the valve device 30 with respect to the flow direction (indicated by arrow Q) of air exhausted from the exhaust port 13a of the pump 13, and a downstream-side exhaust tube 28b located downstream of the valve device 30. The upstream-side exhaust tube 28a connects the exhaust port 13a of the pump 13 to the communication hole 26b of the second block 26 of the valve device 30, while the downstream-side exhaust tube 28b connects the negative-pressure chamber 5 to the communication hole 24b of the first block 24 of the valve device 30. The exhaust tube 28 defines an air passage 29 described later.
The communication hole 24a of the first block 24, and the communication hole 24b of the first block 24, which is connected to the downstream-side exhaust tube 28b, are formed symmetrical with respect to the rotation axis of the shielding plate 31. Similarly, the communication hole 26a of the second block 26, and the communication hole 26b of the second block 26, which is connected to the upstream-side exhaust tube 28a, are formed symmetrical with respect to the rotation axis of the shielding plate 32. The communication hole 26b is also formed coaxial with the communication hole 24b of the first block 24. Since the structural elements of the second embodiment other than the above-described ones are similar to those of the valve device 20 of the first embodiment, they will not be described in detail but be only denoted by corresponding reference numbers.
The operation of the valve device 30 constructed as above will be described.
For facilitating the description,
In the
More specifically, in the above state, the CW directional leading edge 311 of one of the air passing holes 31a of the first shielding plate 31 crosses the air passage 23, and the CCW directional leading edge 321 of one of the air passing holes 32a of the second shielding plate 32 crosses the air passage 23. In addition, the one air passing hole 31a does not overlap with the one air passing hole 32a within the cross section of the air passage 23.
Furthermore, in the above state, the CW directional trailing edge 312 of another air passing hole 31a of the first shielding plate 31 is adjacent to an edge portion of the air passage 29, and the CCW directional trailing edge 322 of another air passing hole 32a of the second shielding plate 32 with respect to the is adjacent to another edge portion of the air passage 29 opposite to the first-mentioned edge portion. In this state, the two air passing holes 31a and 32a completely overlap with the air passage 29.
When the two shielding plates 31 and 32 are rotated from their angular standby positions shown in
By thus simultaneously subjecting the air passages 23 and 29 to the full open state and full blocked state, respectively, during the acceleration of the shielding plates 31 and 32, the air passage 23 can be switched from the closed state to the open state within an extremely short time, and the air passage 29 can be switched from the open state to the closed state within the extremely short time. Namely, the valve device 30 can realize a very high response rate. To this end, it is important to set the
Thereafter, the control unit 10 decelerates and stops the two shielding plates 31 and 32 while the
More specifically, in the standby state shown in
At the same time, in the standby state shown in
When the two shielding plates 31 and 32 are rotated from the angular standby positions shown in
To block the air passage 23 and open the air passage 29 in a short time, it is important to stop the shielding plates 31 and 32 at the angular standby positions shown in
Thereafter, the control unit 10 decelerates and stops the shielding plates 31 and 32 while the
The operations shown in
As described above, the second embodiment can provide the same advantage as the first embodiment, and can also instantly introduce a large amount of air into the negative-pressure chamber 5 when releasing the paper sheet P from the pickup belt.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
For instance, although the above-described embodiments employ the endless pickup belt 4 as a pickup member for picking up each paper sheet p set at the pickup position S, the invention is not limited to this. Alternatively, a pickup member may be a rotor that has a plurality of suction holes and is rotatable in the sheet pickup direction.
Further, although the above-described embodiments employ the valve device 20 (30) including the two shielding plates 31 and 32 that cooperate to open/close the air passage 23 (29), the invention is limited to this. Alternatively, three or more shielding plates may be employed to make them cooperate to open/close a plurality of air passages. In this case, it is difficult to arrange all shielding plates coaxially, and hence the shielding plates may be made overlap each other so that their rotational axes are arranged parallel to each other.
Furthermore, although the valve device 20 (30) according to the above-described embodiments opens and closes a single air passage 23 or simultaneously opens and closes two air passages 23 and 29, the invention is not limited to this structure. The number of air passages controlled by a single valve device may be set arbitrarily.
In addition, although in the above-described embodiments, the two shielding plates cooperate to completely block the air passage(s) in a standby state assumed before opening the air passage, it is not always necessary to completely block the air passage, but a slight clearance may be defined between the two shielding plates.
Number | Date | Country | Kind |
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2009-190308 | Aug 2009 | JP | national |