Intelligent system diagnostics for bank note processing machines

1. A method for monitoring the health of a bank note processing machine using a plurality of operating condition sensors positioned within the machine at specific points of interest, the sensors in communication with a central processing unit (CPU) connected to a memory for automatic gathering and analysis of sensor data, the method steps comprising:

obtaining baseline data of the bank note processing machine operating condition from one or more of the sensors by the CPU and storing the baseline profile data in the memory;

monitoring the sensors by the CPU during the bank note processing machine operation to obtain operating data and storing the operating data in the memory;

comparing by the CPU the baseline data with the operating data by reading the data from the memory to determine if an abnormal condition exists within the bank note processing machine; and

logging the comparison results in the memory.

2. The method of claim 1 , the method steps further comprising:

locating the approximate area within the bank note processing machine of the abnormal condition; and

notifying the operator of the abnormal condition and the location.

3. The method of claim 1 , wherein the operating condition sensors are acoustic sensors and wherein the acoustic sensors monitor the mechanical systems of the bank note processing machine for noise or vibration.

4. The method of claim 1 , wherein the operating condition sensors are temperature sensors and wherein the temperature sensors monitor localized temperatures among the mechanical systems of the bank note processing machine.

5. The method of claim 1 , wherein the operating condition sensors are electrical current sensors and wherein the electrical current sensors monitor current usage of specific electrical components within the bank note processing machine.

6. The method of claim 1 , wherein the operating condition sensor is the CPU, the method steps further comprising:

monitoring the output data of at least one bank note detector;

comparing the output data with the known normal range of the bank note detector; and

notifying the operator if the output data is outside the known range.

7. The method of claim 1 , wherein the operating condition sensor is the CPU, the method steps further comprising:

monitoring the output data of a first bank note detector;

monitoring the output data of at least a second bank note detector that is functionally similar to the first bank note detector;

comparing the first and second detector output data; and

notifying the operator if the first and second detector output data does not correlate.

8. The method of claim 1 , the method steps further comprising:

automatically scheduling maintenance or repair based upon the comparison results.

9. The method of claim 1 , wherein the sensors are monitored in real-time during bank note processing machine operation to obtain real-time operating data, the method steps further comprising:

automatically halting the machine in response to the comparison results.

10. A diagnostic system for use in a bank note processing machine, the system comprising:

a plurality of operating condition sensors, wherein the sensors are positioned throughout the bank note processing machine at points of interest;

a central processing unit in communication with the plurality of sensors, wherein the processing unit is operably configured to execute stored program instruction steps, the program steps comprising:

obtaining baseline profile data of the bank note processing machine operating condition from one or more of the sensors;

monitoring the sensors during bank note processing machine operation to obtain operating data;

comparing the baseline data with the operating data to determine if an abnormal condition exists within the bank note processing machine; and

logging the comparison results.

11. The system of claim 10 , the program steps further comprising:

locating the approximate area within the bank note processing machine of the abnormal condition; and

notifying the operator of the abnormal condition and the location.

12. The system of claim 10 , wherein the operating condition sensors are acoustic sensors and wherein the acoustic sensors monitor the mechanical systems of the bank note processing machine for noise or vibration.

13. The system of claim 10 , wherein the operating condition sensors are temperature sensors and wherein the temperature sensors monitor localized temperatures among the mechanical systems of the bank note processing machine.

14. The system of claim 10 , wherein the operating condition sensors are electrical current sensors and wherein the electrical current sensors monitor current usage of specific electrical components within thebank note processing machine.

15. The system of claim 10 , wherein the operating condition sensor is the CPU, the program steps further comprising:

monitoring the output data of at least one bank note detector;

comparing the output data with the known normal range of the bank note detector; and

notifying the operator if the output data is outside the known range.

16. The system of claim 10 , wherein the operating condition sensor is the CPU, the program steps further comprising:

monitoring the output data of a first bank note detector;

monitoring the output data of at least a second bank note detector that is functionally similar to the first bank note detector;

comparing the first and second detector output data; and

notifying the operator if the first and second detector output data does not correlate.

17. The system of claim 10 , the program steps further comprising:

automatically scheduling maintenance or repair based upon the comparison results.

18. The system of claim 10 , wherein the sensors are monitored in real-time during bank note processing machine operation to obtain real-time operating data, the program steps further comprising:

automatically halting the bank note processing machine in response to the comparison results.