Coin Sorter For Indian Coins

CHAPTER 1
INTRODUCTION
Counting of coins is a tedious task when coin collections are large. Say for example, in
Banks, Temples, bus depots, shops, etc., they are spending a lot of time and strain for counting
their collections. Usually the method they are adopting is first to separate the coins in each
denomination and then count the total in each denomination. Finally the totals of each
denomination are added to get the grand total. From this we can understand that separating into
denominations is a tedious work. So it will be very much helpful to them if a device can be used
to separate the coins in denominations. It will be relatively easier to attach provisions for
automatic counting once the coins are separated.
A typical counter of presorted coins uses a bowl with flat spinning disc at the bottom to
distribute coins around the bowl perimeter. An opening in the edge of the bowl is only wide
enough to accept one coin at a time. Coins either pass through a light-beam counter, or are
pushed through a spring-loaded cam that only accepts one coin at a time.
Coin sorter is invented by Berwster in 1909,he was a very rich man and to count his coins
he developed this machine.

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CHAPTER 2
STATISTICAL STUDY OF COIN PARAMETERS
For a systematic approach, the coin parameters which may help to sort out the coins into
different denominations are to be identified and their values to be measured.

2.1 COINS AND THEIR PARAMETERS

The following four parameters were considered for sorting of the coins:
Diameter/distance
Thickness
Weight
Magnetic property

2.1.1 Diameter/distance
If the shape of the coin is circular then its diameter itself is the parameter. But all the
coins are not circular in shape so in case of coins which are not circular in shape, distance is
considered as the parameter. The term distance refers to either corner to corner distance or flat to
flat distance. For example as shown in figure1 for a 5 paisa coin which is square in shape, d1 is
the corner to corner to distance while d is the flat to flat distance. The distance parameter for 10
paisa, 20 paisa and 100 paisa coins are as shown in the figure 1. The value of diameter/distance
of each of the coins is noted in table 1.
2.1.2 Thickness
For most of the edge has more thickness than the inside surface. The maximum thicknesses of
the coins were measured using a vernier caliper with a least count of 0.01 mm and the values
noted in table 1.
2.1.3 Weight
Weight of the coin is also an important parameter in sorting out the coins. Hence the
weight of each coin has been determined using an electronic weighing machine having
readability up to 0.01gmf. The coins were put one by one on the pan and the corresponding
weights are obtained on an optical read-out and values noted in table 1.

Table 1: The Values of the different parameters of the coins

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Sl. Coin Denomination Diameter Distance Thickness Weight Magnetic/

No and Size in mm In mm in mm in gmf Non-magnetic

1 05 Paisa 22.20 19.00 1.90 1.51 Non-magnetic

2 10 Paisa [small] 16.00 16.00 1.50 1.96 Non-magnetic

3 10 Paisa [medium] 23.00 20.14 2.14 1.78 Non-magnetic
4 10 Paisa [big] 25.80 24.64 1.84 2.27 Non-magnetic
5 20 Paisa 25.80 24.70 1.84 2.20 Non-magnetic
6 25 Paisa 19.00 19.00 1.38 2.40 Low-magnetic
7 50 Paisa [small] 22.20 22.20 1.40 4.00 Low-magnetic
8 50 Paisa [big] 24.00 24.00 1.54 4.98 Non-magnetic
9 1 Rs. [small] 24.90 24.90 1.50 4.86 Non-magnetic
10 1 Rs. [medium] 26.00 26.00 1.80 5.94 Non-magnetic
11 1 Rs. [big] 28.10 28.18 2.00 7.88 Non-magnetic
12 2 Rs [small] 26.20 26.20 1.60 6.14 Non-magnetic
13 2 Rs [big] 28.00 28.00 1.80 7.54 Non-magnetic
14 5 Rs 31.10 31.00 2.20 12.54 Non-magnetic
2.1.4 Magnetic property
If the coins of one denomination are magnetic while the coins of another denomination
are non-magnetic, these two denominations can easily be separated by using this parameter.
In each denomination 10 coins were taken at random and on each coin measurement of
their magnetic property made at more than one place and it was noted in table 1, whether the
coins were magnetic or non-magnetic.
A critical study of the parameters reveals the following information.
No single parameter will sort all the coins.
The diameter/distance should be used in the first stage of separation for there is a
considerable difference in the diameter/distance of each of the coins.
Once the coins are separated using the diameter/distance parameter they can be further
separated using the thickness parameter in the second stage and the weight parameter in
the third stage.
From the study of magnetic property it is found that some of 25 and 50 paisa are magnetic while
some other coins of the same denominations were non-magnetic. So it does not seem to be a
good parameter for separation

2.2. Application of coin parameters for separating the coins.

Coin sorting is done by considering different parameters which are mainly

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2.2.1 Solution using Diameter/Distance

In this method a circular template with a number of holes, in ascending order of diameter
in anti-clockwise direction, is held stationary. A thin circular plate which is referred to as rotating
arm has holes to accommodate a coin having maximum diameter.
This plate is mounted just above the template as shown in the [figure 2] and driven by a
hand wheel.
The rotating arm dimensions should be so designed that only one coin is carried in each
of the arm holes. When the coin comes over the corresponding hole it falls through that hole.
It may not be possible to separate all coins using this method alone as diameter/distance
of certain coins are very near. While designing the holes on the templates the different
orientation of coins have to be taken into consideration. For example 5 paisa coin can come
either in the corner to corner position or flat to flat position perpendicular to the pitch circles
diameter of the holes. If the template hole is designed for the flat to flat position of the 5 paisa
coin then the coin will not fall into the hole if it is coming in the corner to corner position.
This is the main difficulty of this method. All coins except round coins will have more
orientations. So some coins will have to be collected together & then separated using other
parameter.
2.2.2. Solution using thickness
On a thin plate number of slots of varying width are cut along a line in increasing order
[Fig. 4], (each slot has slightly greater width than the min. thickness of the corresponding coin)
i.e. this second slot is greater in width than the 1 st slot .This plate is bent into an L shape along
the line & held inclined at an angle to both vertical & horizontal planes such that when a coin
falls on it, it rolls down along the slots. The coin falls down in a slot which is just greater than its
thickness.
This method alone cannot be used for separating all coins, as many coins have the same
thickness. So due to these difficulties, sometimes more than one coin has to be collected in one
slot & other parameter should be used for further separation.

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Fig:2.1
solution using thickness
2.2.3 Solution using weight of coins
A leaf spring is hinged [Figure 5] at one end and the other end is kept free as a cantilever
system. When the coins are allowed to fall on the spring, the free end of the spring deflects, the
deflection being proportional to the weight of the coin. A mechanism can be designed to sort out
coins using the difference in their deflection.
If the weights of two coins are very near it may be difficult to sense the difference in the
deflection so such coins will have to be collected together and further separation should be done
using other parameters.

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Fig:2.2 solution using weight in a leaf spring

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CHAPTER 3
COMBINATIONS
From the previous study of each parameter it can be found that it is difficult to separate
the coins using only one parameter.
Study about magnetic property showed that it cannot be used since the coins are magnetic
and non-magnetic in same denomination. So the remaining three parameters i.e. diameter,
thickness and weight are to be used for separating the coins.
All the different combinations of the above 3 parameters are
3.1 combinations I
(a) Diameter/Distance (First Parameter)
(b) Thickness (Second Parameter)
(c) Weight (Third Parameter)
By the combination the sorting of the coins is done in the followed way. First the coins
will be separated using the parameter diameter/distance. The coins whose diameter/ distance are
very close to each other may fall together. Hence those coins which fall together are separated
using the thickness parameter in the second stage and further the coins having the same
diameter / distance and thickness are separated by using the weight parameter in the third stage.
3.1.1 Diameter/Distance as the First Parameter
From the value in [Table 1] we see that the 50 paisa [small] and the 5 paisa are collected
together in the third hole of the template. While 20 paisa and 100 paisa [small and medium] is
collected together in the seventh hole of the template.
It is assumed that the 10 paisa [medium] and 10paise [big] are removed before feeding
the coins into the chute. The remaining coins are easily separated in this stage of separation.
3.1.2 Thickness as the second parameter
In third hole and seventh hole two different coins are collected. From [Table 1] it is clear
that the 20 paisa and 100 paisa [small and medium] coins collected in the seventh hole can be
separated using this parameter. The 5 paisa and 50 paisa [small] can not be separated using this
parameter, for the 5 paisa coins does not roll freely over the angle plate.
3.1.3 Weight as the third parameter

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The 5 paisa and 50 paisa [small] coins collected together in the third hole of the template
can be separated using this parameter. As there is considerable difference in their weight. The
coins flow diagram for this combination is shown in fig.6.
3.2 Combination II
(a) Diameter/Distance
(b) Weight
(c) Thickness
3.3 Combination III
(a) Thickness
(b) Diameter/Distance
(c) Weight
3.4 Combination IV
(a) Thickness
(b) Weight
(c) Diameter/Distance
3.5 Combination V
(a) Weight
(b) Thickness
(c) Diameter/Distance
3.6 Combination VI
(a) Weight
(b) Diameter/Distance
(c) Thickness
3.7 Selection of one solution
Among the combination (I) to (VI), combination one is selected as trial solution, as
the coin sorting takes place more speedily and easily than the other five combinations. The
design of a possible prototype is made; to sort coins using the first combination.
CHAPTER 4
COINS FEEDING

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 Coin Sorter For Indian Coins

It is mentioned previously in 2.2.1 that the rotating arm of separating mechanism is

designed to take only one coin in one hole at a time. To prevent jamming, the coin has to be in
horizontal position before it is taken up by the rotating arm. That is, coins have to be stacked one
above the other. This cannot be achieved by merely pouring the coins into the feeding funnel
which has direct contact to the rotating arm. Hence, a mechanism was thought for feeding the
coin one by one stacking the coin one above the other.
4.1 Rotating Plate with Gravity Feeding
A plate with a number of holes, each capable of seating only one coin at a time is rotated
over a stationary plate, he coin falls down due to gravity when they come above the hole of the
stationary plate [fig 7].A guiding funnel below this hole loads the coin to the rotating arm of the
separating mechanism.

Fig:4.1 Rotating plate with gravity feeding

Chapter 5

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MECHANISM
The main parts of the coin sorter are
5.1 SEPARATING MECHANISM
(a) Template
(b) Rotating arm
(c) Angle plate
(d) Leaf spring and spring housing
(e) Connecting [vertical] shaft
(f) Coin guide
(g) Coin collectors
5.1.1 Template
Template is one of the most critical part of the setup. It is a circular aluminum plate, having eight
holes in ascending order of the diameter. The template is shown in fig 8. The first hole in the
template catches the coin having the least diameter/distance(10 paisa[small]).The last hole
catches the coin having the largest diameter/distance (200 paisa[small]).The diameter/distance of
each coin and diameter of their corresponding holes is shown in table 5.1

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Fig:5.1 template

Table 2: The Diameter of the coins and the diameter of their respective holes on the template.

Sl. Coin Diameter/Distance hole size

No. Denomination in mm in mm

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1. 10 paisa [small] 16.00 17.00

2. 25 paisa 19.00 20.00
3. 50 paisa[small] 22.20 22.60
4. 10 paisa[medium] 23.00 23.50
5. 50 paisa [big] 24.00 24.50
6. 100 paisa [small] 24.90 25.50
7. 20 paisa and
100 paisa [medium] 25.80 26.20
8. 200 paisa [small] 26.20 26.70

5.1.2 Rotating Arm

It is circular plate of aluminum alloy, having 11 equispaced holes of 28.5mm diameter on a
189mm P.C.D.[fig 9].Only one coin can be seated at a time inside a hole[for the thickness of the
plate is 1.5mm].The coins dropping into the guiding funnel are continuously picked up by the
holes on the rotating arm and carried over the holes of the template, in an anti-clockwise
direction.

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Fig:5.2.Rotating arm

5.1.3 Angle Plate

The principle of separating coins using thickness as a parameter as been discussed in
section 2.2.2 .the seventh hole of the template collects 20 paisa and the 100 paisa coins which
are guided over the angle plate , inclined at 30 degree to the horizontal, so that the coins troll
freely over it. The 100 Paisa coins fall into the slot on angle plate while the 20 Paisa coins cross
the slot and are collected at the end of angle plate.
5.1.4 Leaf Spring and Spring Housing
As discussed in section 2.2.3 a leaf spring is designed for the separation of coins having
different weights. The 5 paisa and the 50 paisa [small] coins collected together in the third hole
are separated using this method. Five paisa coin has a weight of 1.5 gmf while 50 paisa [small]

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coin has a weight 4.0 gmf. So they have a considerable difference in weight and hence, they can
be separated using weight as a parameter.

The spring is considered to be a cantilever with load at free end. A phosphor bronze sheet of 0.2
mm thick and 20 mm wide is selected for making the spring. The deflection of free end of the
spring is obtained as follows, with the help of figure shown on the page no 15.

Fig:5.3 solution using thickness

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fig:5.4
solution using weight
Mx = - W (1 x)
EI dy/ dx = - [- W (1- x)] = Wl - Wx
EI dy/dx = Wlx Wx / 2 + C1 ---------------------------- (a)
EIy = Wlx - Wx/ 6x + C1x + C2 ---------------------------- (b)
At x=0, dy/dx = 0 and y=0
Substituting in (a), C1 = 0
Substituting in (a), C2 = 0
EI dy/dx = Wlx Wx / 2 and
EIy = Wx /2- Wx/ 2
At x=1
Slope B = 1/EI (Wl - Wl/2) = Wl/EI
Deflection YB =1/EI (Wl /2 - Wl /6) = Wl /3EI
For a section of 20 mm width and 0.2 mm thickness,
I= bd / 12 = 2* 0.02 / 12 = 16 * 10-6 / 12 = 4/3 * 10-6 cm4
W= 1.5 * 10-3 kg for 5 paisa.
For YB = 2 cms

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l3 = 2 * 3EI/W = 2*3*1.132.106*4*10-6 /1.5*10-3*3

l3=3018.67 cm3
l=14.45 cms
say length of spring is 15 cms
Deflection for 50 paisa [small] coin
Weight of 50 Paisa [small] coin = 4.0 /10 kgs
Y = (4 * 10 *15 * 3) / 3 * 1.132 * 106 * 4 * 10-6)
Y =2098 cms
Hence, the deflection of the spring for the 50 paisa [small] coin is 2.98 cms.
The spring housing is so designed such that the 5 paisa coin falls out through the hole
provided in to housing, while 50 Paisa coin falls in side the housing.
The spring is fixed to the housing with the help of two rivets; the housing is fixed to the
coin guide with the help of a clamp.
5.1.5 Connecting [Vertical] shaft
The shaft made of mild steel. The details of the shaft shown in the fig. 12
5.1.6 Coin Guide
The coin guides are made of sheet-metal they are hollow cylindrical pipes. Flattened at
the ends, and stuck to the template holes at the bottom using araldite. PVC tubes are inserted into
the guides to lead the coins in to their respective collectors.
5.1.7 Coin collector
These are square boxes of mild steel, inserted into their holders which are welded to the
horizontal plate fixed to the frame.

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Fig:5.5 Rotating feed plate

5.2 FEEDING MECHANISM
There are 5 types of feeding mechanism, they are
Rotating feed plate
Fixed feed plate
Feed driving shaft
Feeding Chute
Guiding Funnel

5.2.1 Rotating feed plate

It is a 1.5mm thick round plate made out of aluminum alloy, and as 10 equi-spaced holes
on a 180 mm P.C.D. The holes have diameter of 32mm in order to provide space for the
maximum coin size. A hole can contain one coin at a time. The holes carry the coin to the top
where it falls down into the guiding funnel or into the 200 paisa, 500 paisa slots depending on

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their diameter. At the center of the rotating feed plate, there is a small hole of 11.2mm diameter
through which the threaded end of the feed driving shaft inserted and fixed by means of a nut. It
also contains four holes of 5mm diameter on 30.5mm P.C.D., to fix the boss on to it.

Fig:5.6 Rotating feed plate

5.2.2 Fixed Feed Plate

It is a 4mm thick aluminum plate fixed to the frame which is supported on stand. It has
three holes 26.3mm, 28mm and 32mm on a 180mm P.C.D. as shown in the fig 14. The center of
the plate has a hole through which the feed driving shaft rotates. There are four counter sunk
holes on a 55.5mm p.c.d to fixed the boss on to it.

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Fig:5.7 Fixed feed plate

5.2.3 Feed Driving Shaft
The Feed driving shaft is made of mild steel.It is as shown in figure 4.1.It is used to vibrate the
coins so that it can stack one above the other.
5.2.4 Feeding Chute
It is one of the important parts of the coin sorter. A pipe of 35mm diameter is cut at 30
degree to the vertical and joined to from an elbow pipes. One end of the elbow pipe is flattened
and the rectangular hopper is inserted into it, and welded. The circular end of elbow rests just
above the rotating feed plate. The coins fed into the funnel get stacked one above in the elbow,
and are continuously picked-up by the rotating plate. The funnel is fixed to the inclined frame
with the help of L shaped, strip welded to it, and an adjustable mechanism, to alter the clearance
between the rotating feed plate and the funnel to the desired level.
5.2.5 Guiding Funnel

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The coins falling one by one from the feeding system have to be taken to the hole of the
rotating arm of the separating system. This is the function of the guiding funnel. Coins fall in to
the guiding funnel due to gravity from the hole of fixed plate. The coins slide down the guide
guiding funnel and reach the rotating arm. When a hole of the rotating arm comes below the coin
it picks up the coin and carries it over the template for sensing the coin denomination.

SOME EXAMPLES OF COIN SORTERS

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Speed: 2000 coins per minute

Coin off-sort bagging attachment
Easy to read LED display
Hopper capacity: 4,000 coins

Power: AC 100/120w

Weight:28lbs

Speed:3500 coins per minute

Hopper capacity: 10,000 coins
Weight:36lbs.
Power: AC 100/120w

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Speed: 1800 coins per minute

Hopper capacity: 2,000 coins
Weight: 19 lbs.
Power: AC 100/120w

CONCLUSION

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As we know that counting of coins can be a tedious job when coin collections are large in
places like temples, bus stands, shops, or even in banks. The coin sorting machine can be of great
help to these sectors.
Once coins are separated by using this coin sorting machine the different coins can be
counted and finally the totals of each coin can be added with their values to get the grand total
sum.
So, it will be very much helpful to them if a device can be used to separate the coins in
different denominations, and these sector people can save their time and labour as well.

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