Crane Payment Innovations is a global automated payment technology company. During my time at CPI, I implemented mechanical improvements to existing products and worked as part of the R&D team to design next generation banknote handling systems.
Modular Universal Bezel
One of my core projects at CPI was the creation of a new banknote interface for the SCR (Secure Cashbox Recycler). The SCR works by accepting banknotes through the acceptor head and transferring them to the recycler module for short term storage. This product handles a variety of currency sizes in different applications (e.g. retail, vending, gaming), with the "bezel" interface that guides notes from the user to the device internals.
This project originated from growing jam issues in international markets. A jam state would cause the unit to shut down until serviced by a technician, causing product downtime and lost money for the customer.
Root Cause: The opening width of the existing universal bezel allowed users to insert notes at unfavorable angles, causing bills to skew inside the SCR drive system and eventually jam. This was exacerbated by heavily worn notes smaller than average in width.
Bezel width dictates note start position & angle
SCR with legacy universal bezel
Approach: Design, develop, and verify a new bezel that eliminates jams due to misalignment, handles a variety of currency sizes, and retrofits to all existing devices. Utilize modular design for cost effective method to control opening width for different markets / currencies. Simulate plastic injection molding performance with Moldflow software. Continuously test and validate bezel performance throughout development with design assurance team.
CAD assembly - exploded view
CAD assembly - front and lower section views
Considerations: Provide new bezel on accelerated timeline to alleviate customer issues and secure new business. Minimize new product cost to end customer. Maintain familiar design language and user experience of existing bezel. Collaborate with software team to characterize failure modes and customer jam data. Coordinate with field / sales engineering team members, providing high-fidelity prototypes for testing before production release.
Urethane cast prototype iteration
Outcome: Internal testing with new bezel yielded zero jams and significantly decreased jam rates throughout international markets. Successful T1 molded samples inspection, validation, and handoff to Mexico manufacturing team. New modular universal bezel enabled > $1M in sales to new SCR customers.
Moldflow simulation snapshots
Drawing surface finish callouts for left insert
Final injection molded assembly for modular universal bezel
Sustaining Products
As part of the sustaining team, I implemented mechanical design improvements across the entire note handling product portfolio. I regularly utilized root cause analysis, DFMEA, and simulation techniques to resolve product issues and implement solutions to manufacturing. Pictured below is a selection of products I worked on in this role.
SC Advance
GX
BNF
SCR
