U.S. patent application number 15/126048 was filed with the patent office on 2017-04-27 for a smoking article assembly machine.
The applicant listed for this patent is British American Tobacco (Investments) Limited. Invention is credited to William England, Gary FALLON, Kie Seon PARK.
Application Number | 20170112185 15/126048 |
Document ID | / |
Family ID | 50634820 |
Filed Date | 2017-04-27 |
United States Patent
Application |
20170112185 |
Kind Code |
A1 |
FALLON; Gary ; et
al. |
April 27, 2017 |
A smoking article assembly machine
Abstract
The present application relates to a smoking article assembly
machine. The smoking article assembly machine has a filter rod
receiving section configured to receive filter rods (9) containing
an inserted object (36, 36') and an assembled smoking article
discharge section. The smoking article assembly machine also has a
smoking article assembly path between the filter rod receiving
section and the assembled smoking article discharge section along
which filter rods (9) pass in a transverse direction to the
longitudinal axis of filter rods, and a microwave sensor unit (51)
through which filter rods (9) pass in a transverse direction, the
microwave sensor unit (51) being disposed along the assembly path.
The microwave sensor unit (51) is configured to provide an
indication of one or more properties of an inserted object (36,
36') in each filter rod (9) passing transversely along the smoking
article assembly path. The present application also relates to a
method of assembling a smoking article on a smoking article
assembly machine.
Inventors: |
FALLON; Gary; (London,
GB) ; England; William; (London, GB) ; PARK;
Kie Seon; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
British American Tobacco (Investments) Limited |
London |
|
GB |
|
|
Family ID: |
50634820 |
Appl. No.: |
15/126048 |
Filed: |
December 18, 2014 |
PCT Filed: |
December 18, 2014 |
PCT NO: |
PCT/EP2014/078416 |
371 Date: |
September 14, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
A24C 5/472 20130101;
A24D 3/061 20130101; A24C 5/478 20130101; A24C 5/3412 20130101;
A24C 5/12 20130101 |
International
Class: |
A24C 5/34 20060101
A24C005/34; A24D 3/06 20060101 A24D003/06; A24C 5/47 20060101
A24C005/47; A24C 5/12 20060101 A24C005/12 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 14, 2014 |
GB |
1404629.6 |
Claims
1. A smoking article assembly machine comprising: a filter rod
receiving section configured to receive filter rods containing an
inserted object, an assembled smoking article discharge section, a
smoking article assembly path between the filter rod receiving
section and the assembled smoking article discharge section along
which filter rods pass in a transverse direction to the
longitudinal axis of filter rods, and a microwave sensor unit
through which filter rods pass in a transverse direction, the
microwave sensor unit being disposed along the assembly path and
configured to provide an indication of one or more properties of an
inserted object in each filter rod passing transversely along the
smoking article assembly path through the microwave sensor
unit.
2. The smoking article assembly machine according to claim 1,
further comprising a conveyor drum arrangement including a
rotatable drum configured to receive the filter rods, or at least
partially assembled smoking articles including the filter rods,
around its periphery and thereby to transport the filter rods along
an arced path during its rotation, the microwave sensor unit being
configured to provide an indication of one or more properties of an
inserted object in each filter rod received by the rotatable
drum.
3. The smoking article assembly machine according to claim 2,
wherein the microwave sensor unit comprises a first detector unit
and a second detector unit configured to provide an indication of
one or more properties of an inserted object in each filter rod
when each filter rod is interposed between the first detector unit
and the second detector unit.
4. The smoking article assembly machine according to claim 3,
wherein the first detector unit is outside the diameter of the
arced path of the filter rods, and the second detector unit is
within the diameter of the arced path of the filter rods.
5. The smoking article assembly machine according to claim 3,
wherein the first detector unit is a microwave transmitter and the
second detector unit is a microwave receiver.
6. The smoking article assembly machine according to claim 3,
wherein the first detector unit is a microwave receiver and the
second detector unit is a microwave transmitter.
7. The smoking article assembly machine according to claim 3,
further comprising a base about which the rotatable drum is
rotatable, wherein at least one of the first and second detector
units is on the base.
8. The smoking article assembly machine according to claim 1,
wherein the microwave sensor unit comprises a planar resonator on
the smoking article assembly path.
9. The smoking article assembly machine according to claim 2,
wherein the rotatable drum is an intermediate drum.
10. The smoking article assembly machine according to claim 1,
further comprising a linear conveyor arrangement configured to
receive said filter rods, or at least partially assembled smoking
articles including said filter rods, and thereby to transport said
filter rods along a linear path, the microwave sensor unit being
configured to provide an indication of one or more properties of an
inserted object in each filter rod received by the linear conveyor
arrangement.
11. The smoking article assembly machine according to claim 10,
wherein the microwave sensor unit comprises a fork resonator on the
smoking article assembly path.
12. The smoking article assembly machine according to claim 1,
comprising at least two microwave sensor units configured to
provide an indication of one or more properties of an inserted
object in each filter rod at two or more points along or adjacent
to the path of each filter rod.
13. The smoking article assembly machine according to claim 12,
wherein each of the at least two microwave sensor units are
selectively operational, so that the number of operational
microwave sensor units can be set to correspond to the number of
inserted objects in each filter rod.
14. The smoking article assembly machine according to claim 1,
wherein the filter rod receiving section configured to receive
filter rods containing an inserted object is a filter rod receiving
section configured to receive filter rods containing a capsule.
15. The smoking article assembly machine according to claim 1,
wherein the microwave sensor unit is configured to be stationary
during operation.
16. A method of assembling a smoking article on a smoking article
assembly machine comprising receiving a filter rod containing an
inserted object, assembling the smoking articles including the
filter rod containing the inserted object, and discharging the
assembled smoking article, the method further including passing
filter rods in a transverse direction to the longitudinal axis of
the filter rod through a microwave sensor unit to provide an
indication of one or more properties of the inserted object in the
filter rod passing in a transverse direction between receiving the
filter rod and discharging the assembled smoking article.
Description
TECHNICAL FIELD
[0001] The present invention relates to a smoking article assembly
machine. The present invention also relates to a method of
assembling a smoking article on a smoking article assembly
machine.
BACKGROUND
[0002] Smoking articles are known in which a capsule is disposed.
Such a capsule generally contains a fluid, such as a flavourant.
The capsule may be frangible such that the frangible capsule is
broken, and the fluid released, when a user applies pressure to the
filter rod in the proximity of a frangible capsule.
[0003] Such a smoking article is manufactured by manufacturing
filter rods containing capsules on a filter making machine and
tobacco rods on a tobacco rod making machine. The manufactured
filter rods and tobacco rods may then be used in the assembly of
smoking articles on a smoking article assembly machine. An example
of such a smoking article assembly machine is the Hauni Max
manufactured by Hauni Maschinenbau AG of Hamburg Germany.
SUMMARY
[0004] According to one aspect of the invention, there is provided
a smoking article assembly machine comprising a filter rod
receiving section configured to receive filter rods containing an
inserted object, an assembled smoking article discharge section, a
smoking article assembly path between the filter rod receiving
section and the assembled smoking article discharge section along
which filter rods pass in a transverse direction to the
longitudinal axis of filter rods, and a microwave sensor unit
through which filter rods pass in a transverse direction, the
microwave sensor unit being disposed along the assembly path
configured to provide an indication of one or more properties of an
inserted object in each filter rod passing transversely along the
smoking article assembly path through the microwave sensor
unit.
[0005] The microwave sensor unit may comprise stationary first and
second detector units between which filter rods pass in a
transverse direction.
[0006] The smoking article assembly machine may further comprise a
conveyor drum arrangement including a rotatable drum configured to
receive said filter rods, or at least partially assembled smoking
articles including said filter rods, around its periphery and
thereby to transport said filter rods along an arced path during
its rotation, the microwave sensor unit being configured to provide
an indication of one or more properties of an inserted object in
each filter rod received by the rotatable drum.
[0007] The microwave sensor unit may comprise a first detector unit
and a second detector unit configured to provide an indication of
one or more properties of an inserted object in each filter rod
when each filter rod is interposed between the first detector unit
and the second detector unit.
[0008] The first detector unit may be outside the diameter of the
arced path of said filter rods. The second detector unit may be
within the diameter of the arced path of said filter rods.
[0009] The first detector unit may be within the diameter of the
arced path of said filter rods. The second detector unit may be
outside the diameter of the arced path of said filter rods.
[0010] The rotatable drum may be configured to move relative to the
microwave sensor unit. The first detector unit may be a microwave
transmitter and the second detector unit may be a microwave
receiver.
[0011] The first detector unit may be a microwave receiver and the
second detector unit may be a microwave transmitter.
[0012] The microwave sensor unit may comprise a planar resonator on
the smoking article assembly path.
[0013] The smoking article assembly machine may further comprise a
base about which the rotatable drum is rotatable. At least one of
the first and second detector units may be on the base.
[0014] The base may extend around the rotatable drum.
[0015] The rotatable drum may further comprise a first drum section
and a second drum section extending on either side of the base.
[0016] The rotatable drum may be an intermediate drum.
[0017] The smoking article assembly machine may further comprise a
linear conveyor arrangement configured to receive said filter rods,
or at least partially assembled smoking articles including said
filter rods, and thereby to transport said filter rods along a
linear path, the microwave sensor unit being configured to provide
an indication of one or more properties of an inserted object in
each filter rod received by the linear conveyor arrangement.
[0018] The microwave sensor unit may comprise a fork resonator on
the smoking article assembly path.
[0019] The smoking article assembly machine may comprise at least
two microwave sensor units configured to provide an indication of
one or more properties of an inserted object in each filter rod at
two or more points along or adjacent to the path of each filter
rod.
[0020] The microwave sensor unit may comprise at least two first
and/or two second detector units configured to provide an
indication of one or more properties of an inserted object in each
filter rod at two or more points along or adjacent to the path of
each filter rod.
[0021] The microwave sensor may comprise at least two first
detector units and at least two corresponding second detector
units. The microwave sensor unit may comprise at least two first
detector units and one corresponding second detector unit. The
microwave sensor unit may comprise one first detector unit and at
least two corresponding second detector units.
[0022] The filter rod receiving section configured to receive
filter rods containing an inserted object may be a filter rod
receiving section configured to receive filter rods containing a
capsule.
[0023] The microwave sensor unit may be configured to be stationary
during operation.
[0024] According to another aspect of the invention, there is
provided a method of assembling a smoking article on a smoking
article assembly machine comprising receiving a filter rod
containing an inserted object, assembling the smoking articles
including the filter rod containing the inserted object, and
discharging the assembled smoking article, the method further
including passing filter rods in a transverse direction to the
longitudinal axis of the filter rod through a microwave sensor unit
to provide an indication of one or more properties of the inserted
object in the filter rod between receiving the filter rod and
discharging the assembled smoking article.
BRIEF DESCRIPTION OF DRAWINGS
[0025] Embodiments of the invention will now be described, by way
of example only, with reference to the accompanying drawings, in
which:
[0026] FIG. 1 is a schematic side view of a cigarette making
machine;
[0027] FIGS. 2A to 2J illustrate successive stages during the
manufacture of filter cigarettes with the machine shown in FIG.
1;
[0028] FIG. 3 is a view of an intermediate drum of the cigarette
making machine shown in FIG. 1 showing one embodiment of a
microwave detector station;
[0029] FIG. 4 is an exploded view of the intermediate drum shown in
FIG. 3 with the microwave detector station;
[0030] FIG. 5 is a schematic view of the intermediate drum shown in
FIG. 3 with the microwave detector station;
[0031] FIG. 6 is a schematic view of the intermediate drum shown in
FIG. 3 with another embodiment of a microwave detector station;
[0032] FIG. 7 is a schematic view of the intermediate drum shown in
FIG. 3 with another embodiment of a microwave detector station;
and
[0033] FIG. 8 is a schematic view of a discharge section of the
cigarette making machine shown in FIG. 1 with another embodiment of
a microwave detector station.
DETAILED DESCRIPTION
[0034] Referring to FIG. 1, a cigarette making machine is
illustrated. The cigarette making machine acts as a smoking article
making machine. Although the following description describes a
cigarette making machine, it will be understood that alternative
arrangements are possible in which the smoking article making
machine makes other types of smoking article. Any reference to a
cigarette can be replaced by a reference to a smoking article.
[0035] As used herein, the term "smoking article" includes
smokeable products such as cigarettes, cigars and cigarillos
whether based on tobacco, tobacco derivatives, expanded tobacco,
reconstituted tobacco or tobacco substitutes and also heat-not-burn
products. The smoking article may be provided with a filter for the
gaseous flow drawn by the smoker.
[0036] In FIG. 1 a cigarette making machine is illustrated in which
smoking articles in the form of filter cigarettes are manufactured
in a series of fabrication steps performed at fabrication stations
along a production line. The fabrication steps include attaching
rods of tobacco to opposite ends of a filter rod, cutting the
filter rod to produce two cigarettes back-to-back, re-aligning the
cigarettes carrying out a quality control inspection, rejecting
unacceptable cigarettes and passing accepted cigarettes for
packaging.
[0037] The cigarette making machine defines a smoking article
assembly path between a filter rod receiving section and an
assembled smoking article discharge section. The cigarette making
machine comprises a conveyer drum arrangement 40. The conveyer drum
arrangement 40 transports the tobacco rods and filter rods along
the smoking article assembly path. The conveyer drum arrangement 40
also enables assembly of the cigarettes along the smoking article
assembly path. The conveyer drum arrangement comprises a plurality
of rotatable drums, also known as rollers, which are configured to
transport filter rods or at least partially assembled cigarettes
along the smoking article assembly path. As the filter rods or at
least partially assembled cigarettes are transported along the
smoking article assembly path by each of the rotatable drums, it
will be understood that they travel in a direction transverse to
their longitudinal axis. That is, the filter rods or at least
partially assembled cigarettes move in a direction which is
perpendicular or substantially perpendicular to their longitudinal
axis.
[0038] As shown in FIG. 1, successive lengths of tobacco rod 1
manufactured by a rod making machine are fed from a hopper to an
inlet drum 3 by means of a spider (not shown), such that they are
received in axially extending grooves 2 on the surface of the inlet
drum 3 of the conveyer drum arrangement 40. The tobacco rods 1 are
held in the grooves 2 by negative air pressure. As illustrated in
FIG. 2A, each of the tobacco rods 1 has a length corresponding to
two cigarettes. The tobacco rods 1 may comprise tobacco or like
smokeable material wrapped in a paper wrapper.
[0039] The conveyer drum arrangement 40 conveys the tobacco rods 1
from the tobacco rod receiving section. That is, the point at which
they are received from the hopper to a point at which the inlet
drum 3 of the conveyer drum arrangement 40 meets a cutter drum 4.
At this point, the rods 1 on conveyer drum arrangement 40 are fed
into corresponding grooves 2 of the cutter drum 4, where they pass
a rotary cutter blade 5 that cuts the rods 1 in half as illustrated
in FIG. 2B to form cut rods 1, 1'. The cut rods 1, 1' then pass
onto grooves 2 of a spacer drum 6 which is driven in synchronism
with the cutter drum 4. A spacer device 7 separates the cut rods 1,
1' and passes them onto a filter receiving drum 8 that also has
grooves 2. The various rods can be held in the grooves 2 of the
conveyer drums 4, 6, 8, 10, 11, 17, 19, 20, 25, 26, 27, 29, 30 of
the cigarette making machine described herein by negative air
pressure.
[0040] The cut rods 1, 1' are spaced apart by a distance sufficient
to receive a length of filter rod 9. Successive lengths of filter
rod 9 are manufactured by a filter rod making machine (not shown).
The filter rod making machine produces continuous lengths of filter
rod which are subsequently cut prior to being received by a filter
rod hopper (not shown). The filter rod making machine and cigarette
making machine are independent of each other. That is, the lengths
of filter rod are taken off-line following manufacture on the
filter rod making machine, and are subsequently fed to the
cigarette making machine. The filter rods may comprise cellulose
acetate tow wrapped in a plug wrap or may include other or
additional filter material. The lengths of filter rod 9 for use in
the present invention each include at least two inserted objects
36, 36' (refer to FIG. 3), such as frangible capsules. Each capsule
may hold a fluid, such as a flavourant, which is released when the
frangible capsule is broken by a user applying pressure to the
filter rod in the proximity of the frangible capsule. The filter
rods 9 may include additional material, such as a Dalmatian filter
segment or adsorbent such as particles of activated carbon. It will
be understood that it is necessary to check whether the inserted
objects are present, and/or, in the case of a frangible capsule for
example, intact, following manufacture of the continuous lengths of
filter rod. Such detection of the state or presence of an inserted
object has previously been performed offline on a separate machine
following manufacture of the continuous lengths of filter rod 9,
and prior to providing the continuous lengths of filter rod to the
cigarette making machine.
[0041] Following manufacture of the continuous lengths of filter
rod on the filter rod making machine and prior to the continuous
lengths of filter rod being received by the cigarette making
machine, the lengths of filter rods may be stored. The cut lengths
of filter rod 9 are received by the filter rod hopper (not shown)
of the cigarette making machine.
[0042] The cut lengths of filter rod 9 are fed onto the filter
receiving drum 8 from filter inlet drum 10 that receives successive
filter rods 9 from a hopper (not shown) fed in the direction of
arrow B. Although in the present arrangement a single filter
receiving drum 8 is described and shown, it will be understood that
further drums may be disposed between the filter rod hopper (not
shown) and the filter inlet drum 10, such as a filter rod cutting
drum, a grading drum, a shifting drum and an accelerating drum.
Where the filter rods 9 enter the cigarette making machine is the
filter rod receiving section.
[0043] The resulting configuration of tobacco rods 1, 1' and filter
rod 9 on the filter receiving drum 8 is illustrated in FIG. 2C.
This arrangement of aligned rods is then transferred to a tipping
drum 11 that is driven in synchronism with filter receiving drum 8
and a washplate (not shown) to ensure that the rods 1, 9 and 1'
abut one another.
[0044] Then, a cut length of tipping paper 12 is applied to the
filter rod 9 so as to overlap its ends and join the rods 1, 1', 9
together as illustrated in FIG. 2D. The tipping paper 12 is fed as
a web from a supply roll (not shown) in the direction of arrow C
onto an applicator roller 14 after having been passed over a
curling plate and having adhesive applied in a manner well known
per se and not illustrated in FIG. 1 in order to simplify the
explanation. A cutter roller 15 with blades 16 cuts the continuous
web of tipping paper into individual segments of tipping paper 12
for each pair of cigarettes as illustrated in FIG. 2D. The action
of the drum 11 is to roll the tipping paper around the coaxial
arrangement of rods 1, 1', 9 shown in FIG. 2D so that they become
joined by the glued tipping paper segment 12 to provide the
combined rod arrangement illustrated in FIG. 2E.
[0045] The combined rod arrangement 1, 1', 9 is then transferred to
a ventilation forming station that comprises a synchronously driven
drum 17 with an associated laser 18 which burns ventilation holes
into the filter and/or tobacco rods 1, 9, 1'. The ventilated rods
are then passed by a feeder roller 19 to a cutting station
comprising a final cut roller 20 and rotary cutter blade 21 which
cuts the joined rods in half by the rotary cutter blade 21 to
provide a pair of cigarettes 22, 22' with tobacco rods 23, 23' and
filter rod segments 24, 24' respectively arranged back-to back, as
shown in FIG. 2F.
[0046] The cut cigarettes 22, 22' are then fed onto the periphery
of an intermediate drum 25 shown in FIG. 1. The intermediate drum
25 is disposed on the smoking article assembly path between the
final cut roller 20 and the turning drum 26. The intermediate drum
25 is driven in synchronism with final cut roller 20. The
intermediate drum 25 transports the cigarettes 22, 22'. A microwave
detector station 50 comprising the intermediate drum 25 is provided
to inspect the properties of an inserted object 36, 36' in each
filter rod segment 24, 24'. The microwave detector station 50
comprises two microwave sensor units 51 (only one shown in FIG. 1).
The microwave sensor units 51 are offset from one another. The two
microwave sensor units 51 are aligned with the path of the pair of
cigarettes 22, 22' to provide an indication of one or more
properties of an inserted object 36, 36' in each filter rod segment
24, 24', passing transversely along the smoking article assembly
path. One advantage of offsetting the microwave sensor units 51 is
to allow the microwave sensor units 51 to be received with a space
having a limited width in the axial direction, and to restrict any
interference between adjacent microwave sensor units 51. However,
it will be understood that in an alternative embodiment that the
microwave sensor units 51 are axially aligned with each other.
[0047] Although two microwave sensor units 51 are described in the
present embodiment, it will be understood that in an alternative
embodiment only one microwave sensor unit 51 may be present. For
example, in an arrangement in which the microwave detector station
50 is disposed further down the smoking article assembly path, as
will be described hereinafter, only a single microwave sensor unit
may be present as the cigarettes 22' are aligned with the
cigarettes 22.
[0048] A detailed description of the microwave detector station 50
will be given below.
[0049] The cut cigarettes 22, 22' are then fed onto the periphery
of a turning drum 26 shown in FIG. 1 that is driven in synchronism
with intermediate drum 25 at which the cigarettes 22' are flipped
over to be aligned with cigarettes 22 as illustrated in FIG.
2G.
[0050] The aligned cigarettes 22, 22' are then fed from the turning
drum 26 into grooves 2 of inspection drum 27 that rotates in
synchronism with turning drum 26. Therefore, the aligned cigarettes
are fed successively through an inspection station comprising the
inspection drum 27 at which a camera 28 or other optical detector
carries out an inspection of the quality of the thus manufactured
cigarettes received in grooves 2 of the inspection drum 27. The
camera 28 feeds data to a processor P which compares it with stored
information corresponding to quality control criteria so as to
control a diverter gate G depending on the outcome, so that the
cigarettes which meet the quality control criteria are fed in an
accept path onto outlet drum 29 driven in synchronism with
inspection drum 27 and then pass in the direction of arrow D onto
an output conveyor (not shown) for packaging. The diverter gate G
diverts rejected cigarettes so that they continue on a reject path
around the inspection drum 27 and transfer onto a reject drum 30.
The diverting action of the gate G may be implemented or assisted
by controlling or releasing a negative pressure that retains the
cigarettes 22 in the grooves 2 on the inspection drum 27.
[0051] The processor P may also or alternatively receive quality
control data from other tests performed on the cigarettes whilst
they pass along the smoking article assembly path, which can used
to control the diverter gate G. For example, the cigarettes may be
subject to a pressure test as they pass around the inspection drum
27, in which air is pumped into one end and the pressure drop
through the rod is measured. If the pressure drop is too high or
too low, this indicates a bad join between the tobacco rod and
filter of the cigarettes 22, 22' such that the cigarette should be
rejected. Also an optical detector (not shown) may be provided to
detect loose ends where not enough tobacco fills the rod, or
strands of tobacco that are protruding from the rod ends.
[0052] The processor P may also or alternatively receive data on
the properties of an inserted object 36, 36' in each filter rod
segment 24, 24' determined as they pass through the microwave
detector station 50. This data may be used to control the diverter
gate G. For example, the microwave detector station 50 may be used
to measure the moisture level. If the determined moisture level is
too high or too low, this may indicate a damaged capsule in the
filter rod segment 24, 24' such that the cigarette should be
rejected. Alternatively, a different control means and/or discharge
means may be used together with the microwave detector station
50.
[0053] Referring to FIG. 2H, it can be seen that rejected cigarette
22'' has a filter 24'' that includes a fault 32 at its mouth end
which will be unacceptable to the user. The rejected cigarettes
that pass cutter 31 abut against a transverse guide 33 and so are
accurately aligned axially. As a result, the cutter blade 31 can
accurately cut the filter 24'' from the tobacco rod 23'' as shown
in FIG. 2J through the tobacco rod whilst in situ on the reject
drum 30. The cut filter 24'' falls along a first reject path 34
whereas the tobacco rod 23'' falls along a second reject path 35 as
shown in FIG. 2J.
[0054] Many modifications and variations to the described cigarette
making machine will be evident to those skilled in the art. For
example the described process may be used for smoking articles
other than cigarettes.
[0055] Also, further quality control measures may be included. For
example, the combination of rods shown in FIG. 2C may be rejected
either after optical detection or in terms of their combined weight
e.g. at drum 8, so as to detect whether a filter rod 9 was
successfully placed between the tobacco rods 1, 1'.
[0056] It will also be appreciated that the various steps of
production described with reference to FIG. 2 can be altered and
modified. For example additional conveyer drums may be included
along the smoking article assembly path to allow additional
manufacturing steps to be performed, and/or particular conveyer
drums may be reordered or omitted.
[0057] With reference to FIGS. 3 to 5, one embodiment of the
microwave detector station 50 is shown. In the present embodiment,
the microwave detector station 50 is arranged to analyze the
condition of filter rod segments 24, 24' at the intermediate drum
25 of the smoking article machine. An advantage of providing the
microwave detector station 50 at the position of the intermediate
drum 25 is that it is proximate to the end of the smoking article
assembly path, and also prior to the inspection drum 27. Therefore,
it is possible to detect any damage caused to the objects 36, 36'
inserted in the filter rod segments during assembly of the smoking
articles 22, 22'. Furthermore, it is possible to utilize the
inspection station to discard any smoking articles having faulty
filter rod sections 22, 22' determined by the microwave detector
station 50. However, it will be understood that the microwave
detector station 50 may be disposed at a different location within
the smoking article machine.
[0058] An intermediate drum arrangement 60 includes the
intermediate drum 25 and a stationary collar 61. The drum sections
52, 53 are configured to rotate about the stationary collar 61. The
microwave detector station 50 includes the intermediate drum
arrangement 60 and first and second microwave sensor units 51, 51'.
It will be understood that the microwave detector station 50 may
alternatively include another conveyer drum instead of the
intermediate drum 25.
[0059] The intermediate drum 25 forms a hollow cylinder. The
intermediate drum 25 comprises a first drum section 52 and a second
drum section 53. The first and second drum sections 52, 53 are
fixedly mounted to each other by a hollow shaft 54. The first and
second drum sections 52, 53 are configured to rotate in
synchronization. The first and second drum sections 52, 53 may be
integrally formed.
[0060] The intermediate drum 25 has a cylindrical wall 55, end
walls 56, 57, and a circumferentially extending channel 58. The
channel 58 is configured to receive the stationary collar 61. The
stationary collar 61 is configured to be slidably mounted in the
channel 58 of the intermediate drum 25 so that the intermediate
drum 25 is rotatable thereabout. Moreover, the drum is configured
to be rotatable about its cylindrical axis. The channel 58 is
formed between the first and second drum sections 52, 53.
[0061] The stationary collar 61 is recessed below the outer surface
of the cylindrical wall 55. That is, the outer diameter of the
stationary collar 61 is less than the diameter of the outer surface
of the cylindrical wall 55. Therefore, the stationary collar 61
does not interact with combined rod arrangement 1, 1', 9 as it
moves along its path. A support 62 extends from the collar 61 away
from the path of the combined rod arrangement 1, 1', 9. A recess 63
is formed in the collar 61. The recess 63 is formed by a base 64
and side walls 65, 66 of the stationary collar 61. The recess 63 is
formed in the outer side of the stationary collar 61.
[0062] The intermediate drum 25 has axially extending grooves 59,
as already described with reference to FIG. 1. The grooves 59 act
as smoking article conveying points. The intermediate drum 25 also
has a pump (not shown) and pressure delivery apparatus (not shown)
which is operable to deliver a pressure differential from the pump
to the grooves 59. The outer surface of the cylindrical wall 55 of
the intermediate drum 25 comprises grooves 59 running parallel to
the cylindrical axis of the intermediate drum 25 and spaced around
the circumference of the intermediate drum 25. Each groove 59 is
configured to receive a smoking article 1. A first part 59a of each
groove is formed on the first drum section 52. A second part 59b of
each groove 59 is formed on the second drum section 53. The first
and second parts 59a, 59b of each groove 59 are aligned with each
other. For illustrative purposes cigarettes are shown held in a
number of the grooves 59 in FIG. 3.
[0063] The intermediate drum 25 comprises air ports 67 aligned with
the grooves 59. Each air port 67 comprises a hole through the
cylindrical wall 55 of the intermediate drum 25.
[0064] The pump (not shown) is configured such that, when operated,
it will generate a first air pressure which is lower than the
ambient air pressure at the outer surface of the intermediate drum
25 and a second air pressure which is higher than the ambient air
pressure at the at the outer surface of the intermediate drum
25.
[0065] The microwave detector station 50 includes the first and
second microwave sensor units 51, 51'. The first and second
microwave sensor units 51, 51' are generally the same and so one
microwave sensor unit 51 will be described herein in detail. The
use of microwaves helps to minimize any adverse effects occurring
due to detection of the condition of the inserted object 36, 36'.
The microwave sensor unit 51 comprises a microwave transmitter 68
and a microwave receiver 69. The transmitter 68 and receiver 69 are
spaced apart from each other. The transmitter 68 acts as a first
detector unit. The receiver 69 acts as a second detector unit. A
detection space or area 70 is defined between the transmitter 68
and receiver 69. Detection space or area 70 is configured to allow
the object to be inspected to be received therein so that
properties of the object can be detected. The transmitter 68 is
disposed on one side of the arced path of the pair of cigarettes
22, 22'. The receiver 69 is disposed on the other side of the arced
path of the pair of cigarettes 22, 22'. The transmitter 68 and
receiver 69 are spaced apart to allow the passage of each of the
pair of cigarettes 22, 22' to pass therebetween.
[0066] In the present arrangement, the transmitter 68 is disposed
outside the diameter of the arced path of the pair of cigarettes
22, 22'. The transmitter 68 is mounted relative to the intermediate
drum 25 and stationary collar. The transmitter 68 is mounted
independently of the intermediate drum 25 and stationary collar 61.
Alternatively, the transmitter 68 is mounted to the support 62
extending from the stationary collar 61. It will be understood that
the stationary collar 61 is spaced from the path of the pair of
cigarettes 22, 22'. The receiver 69 is received in the recess 63 in
the stationary collar 61. That is, the receiver 69 is disposed
within the diameter of the arced path of the pair of cigarettes 22,
22'. The receiver 69 is aligned with the transmitter 68 so that the
receiver 69 receives emitted microwaves from the transmitter 68.
The transmitter 68 remains stationary. That is, the intermediate
drum 25 rotates relative to the transmitter 68. The receiver 69
remains stationary. That is, the intermediate drum 25 rotates
relative to the receiver 69.
[0067] Although in the present arrangement, as shown in FIGS. 3 to
5, the transmitter 68 is disposed outside the diameter of the arced
path of the pair of cigarettes 22, 22' and the receiver 69 is
received in the recess 63 in the stationary collar 61, it will be
understood that alternative embodiments are possible. One such
embodiment is shown in FIG. 6. In this embodiment, the positions of
the transmitter 68 and the receiver 69 of each of the microwave
sensor units 51, 51' are reversed. The receiver 69 is disposed
outside the diameter of the arced path of the pair of cigarettes
22, 22'. The transmitter 68 is mounted inside the diameter of the
arced path of the pair of cigarettes 22, 22'. In such an
arrangement, the receiver 69 acts as a first detector unit and the
transmitter 68 acts as a second detector unit. Although in the
above embodiments the transmitters 68 of the first and second
microwave sensor units 51, 51' are grouped together and the
receivers 69 of the first and second microwave sensor units 51, 51'
are grouped together, it will be understood that in alternative
embodiments the receiver 69 of the second microwave sensor unit 51'
may be grouped with the transmitter 68 of the first microwave
sensor unit 51.
[0068] The transmitter 68 and receiver 69 of the first microwave
sensor unit 51 are aligned to inspect the properties of the
inserted object 36 of filter rod segment 24. That is, the first
microwave sensor unit 51 is positioned so that the inserted object
36 of filter rod segment 24 passes through the detection space 70
of the first microwave sensor unit 51 as it is rotated by the
intermediate drum 25. It will be understood that the filter rod
segment 24 will pass through the detection space 70 in a transverse
direction to the longitudinal axis of the filter rod segment 24.
This provides for the microwave sensor unit 51 to detect across the
width of the filter rod segment 24.
[0069] The transmitter 68 and receiver 69 of the second microwave
sensor unit 51' are aligned to inspect the properties of the
inserted object 36' of filter rod segment 24'. That is, the second
microwave sensor unit 51' is positioned so that the inserted object
36' of filter rod segment 24' passes through the detection space 70
of the second microwave sensor unit 51' as it is rotated by the
intermediate drum 25. It will be understood that the filter rod
segment 24' will pass through the detection space 70 of the second
microwave sensor unit 51' in a transverse direction to the
longitudinal axis of the filter rod segment 24'. This provides for
the second microwave sensor unit 51' to detect across the width of
the filter rod segment 24'.
[0070] Although in the above described embodiment the first and
second microwave sensor units 51, 51' have separate transmitters
68, it will be understood that, in an alternative embodiment, the
transmitters 68 of the first and second microwave sensor units 51,
51' may be integrally formed with each other. Although in the above
described embodiment the receivers 69 of the first and second
microwave sensor units 51, 51' are integrally formed with each
other, it will be understood that, in an alternative embodiment,
the receivers 69 of the first and second microwave sensor units 51,
51' may be separate.
[0071] During operation of the cigarette making machine, the cut
cigarettes 22, 22' are fed onto the periphery of the intermediate
drum 25. The cigarettes 22, 22' are fed from the final cut roller
20. The intermediate drum 25 transports the cigarettes 22, 22'
along an arcuate path. The cigarettes 22, 22' are therefore
received by the microwave detector station 50. The detection space
70 of each microwave sensor unit 51, 51' is aligned with the path
of a corresponding filter rod segment 24, 24' of one of the
cigarettes 22, 22'. As the filter rod segment 24, 24' passes
through the detection space 70, the microwave sensor unit 51 is
operable to detect a property of the inserted object 36, 36'. For
example, the microwave sensor unit 51 is operable to detect one or
more of whether the inserted object 36, 36' is present, whether the
inserted object 36, 36' is intact, whether the inserted object 36,
36' is filled with fluid, and/or whether the inserted object 36,
36' is leaking, or has leaked, its contents.
[0072] It will be understood that the microwave sensor unit 51 is
operable on a periodic basis. That is, the transmitter 68 is
operated either on a timed basis to correspond to the passage of
the filter rod segment 24, 24' through the detection space 70, or
when it is determined that the filter rod segment 24, 24' will be
passing through the detection space 70. Alternatively, the
transmitter 68 is operable on a continuous basis. As the cigarettes
12, 12' are fed successively through the microwave detector station
50, the filter rod segments 24, 24' pass through the detection
space 70 in a transverse direction to their longitudinal axis. The
microwave sensor units 51, 51' carry out an inspection of the
condition of the inserted objects 36, 36' of the manufactured
cigarettes received in grooves 2 of the intermediate drum 25. The
processor P compares the data from the microwave sensor units 51,
51' with stored information corresponding to quality control
criteria. The processor P is therefore able to determine whether
each filter rod segment 24, 24' meets the quality control
criteria.
[0073] The processor P is configured to determine whether the
inserted objects 3, 36' in the filter rod segment 24, 24' are
intact or damaged. In the present embodiment, the microwave
detector station 50 is used to measure the moisture level. If the
determined moisture level is too high or too low, this may indicate
a damaged capsule in the filter rod segment 24, 24' such that the
cigarette should be rejected. The processor P then controls the
diverter gate G, acting as a diverting unit, depending on the
outcome of the inspection, so that the cigarettes which meet the
quality control criteria are fed in an accept path onto outlet drum
29 driven in synchronism with inspection drum 27 and then pass in
the direction of arrow D onto an output conveyor (not shown) for
packaging. The diverter gate G diverts rejected cigarettes so that
they continue on a reject path around the inspection drum 27 and
transfer onto the reject drum 30. The diverting action of the gate
G may be implemented or assisted by controlling or releasing a
negative pressure that retains the cigarettes 22 in the grooves 2
on the inspection drum 27. A different control means and/or
discharge means may be used together with the microwave detector
station 50. For example, in embodiments the microwave detector unit
51 includes its own diverter unit (not shown) which is operable to
divert rejected cigarettes. In such an embodiment, the processor P
is configured to control the diverter unit depending on the outcome
of the inspection performed by the microwave detector station 50 to
reject damaged capsules.
[0074] Although embodiments of a microwave detector station are
described above with reference to FIGS. 3 to 6, it will be
understood that alternative embodiments are possible. Referring now
to FIG. 7, an alternative embodiment of a microwave detector
station 100 is shown. The microwave detector station 100 shown in
FIG. 7 is generally the same as the embodiments of the microwave
detector station 50 described above and so a detailed description
will be omitted herein. Furthermore, features and components of the
microwave detector station 100 of the present embodiment
corresponding to features and components of the microwave detector
station 50 described above will retain the same terminology and
reference numerals. However, in the microwave detector station 100
shown in FIG. 7 a different type of microwave sensor unit 101 is
used.
[0075] In FIG. 7 the microwave sensor unit 101 is a planar
resonator. The planar resonator removes the need to have separate
transmitter and receiver modules. Therefore, the planar resonator
is able to be positioned on one side of the path of the pair of
cigarettes 22, 22'. Therefore, it is not necessary to ensure that
separate modules are orientated correctly relative to each other.
The planar resonator, acting as the microwave sensor unit 101 has a
detection space 102. The detection space 102 is disposed so that it
coincides with the path of the inserted object of a filter rod
segment. The corresponding filter rod segment passes through this
detection space in a transverse direction to its longitudinal axis.
In the arrangement shown in FIG. 7 the planar resonator is disposed
outside the diameter of the path of the inserted object of filter
rod segment. However, in another arrangement the planar resonator
may be disposed inside the diameter of the path of the inserted
object of filter rod segment.
[0076] Although embodiments of a microwave detector station are
described herein with the intermediate drum 25, it will be
understood that the microwave detector station may be used together
with one of the other conveyor drums within the smoking article
making machine. For example, the microwave detector station 50 may
be used with one of conveyer drums 8, 10, 11, 17, 19, 20, 26, 27,
29, 30 of the cigarette making machine. Furthermore, in an
embodiment in which the microwave detector station is provided
downstream of the turning drum 26 then only one microwave sensor
unit will be required because all of the inserted objects of the
filter rod segments will be aligned. This minimises the hardware
that is needed to inspect the inserted objects.
[0077] Although embodiments of a microwave detector station are
described above with a conveyor drum, it will be understood that
alternative embodiments are possible. The cigarettes may be
conveyed along part the smoking article assembly path by an
alternative mechanism. Referring now to FIG. 8, an alternative
embodiment of a microwave detector station 110 is shown. The
microwave detector station 110 shown in FIG. 8 comprises a conveyer
belt arrangement 111. In the present embodiment, the microwave
detector station 110 also comprises the inspection drum 27 and the
outlet drum 29. However, it will be understood that the microwave
detector station 110 may be disposed at another position along the
smoking article assembly path.
[0078] In the present embodiment as shown in FIG. 8, the conveyor
belt arrangement 111 includes a smoking article conveying section
112 on which smoking articles, in this case fully assembled smoking
articles 22 are conveyed. The smoking article conveying section 112
conveys a linear path along which smoking articles 22 pass. The
smoking articles 22, and therefore the corresponding filter rod
segment, travel in a transverse direction to its longitudinal
axis.
[0079] A fork resonator 113 acts as the microwave sensor unit. The
fork resonator 113 is disposed along the linear path. The fork
resonator 113 comprises two arms 114, 115. A detection space 116 is
defined between the two arms 114, 115. The smoking article
conveying section 112 of the conveyor belt arrangement in extends
through the detection space 116. Therefore, the linear path along
which smoking articles 22 pass extends through the detection space
116, and so the detection space 116 coincides with the path of the
inserted object of filter rod segment. The fork resonator 113
removes the need to have separate transmitter and receiver
modules.
[0080] As cigarettes 22 are fed successively around the inspection
drum 27 and fed onto the conveyor belt arrangement iii. The
cigarettes 22 then successively pass along the smoking article
conveying section 112 through the detection space 116 defined by
the fork resonator 113. The corresponding filter rod segment pass
through this detection space 116 in a transverse direction to its
longitudinal axis. The fork resonator 113 carries out an inspection
of the inserted object of filter rod segment. The fork resonator
113 feeds data to the processor P which compares it with stored
information corresponding to predefined criteria. The processor
then controls the outlet drum 29, acting as a diverting unit,
depending on the outcome, so that the cigarettes which meet the
quality control criteria are fed in an accept path onto an output
conveyor 115 for packaging. The rejected cigarettes are not picked
up by the outlet drum 29, and so they continue on a reject path of
the conveyor belt arrangement in and transfer into a reject bin
116. The diverting action of the outlet drum 29, acting as a
diverting unit, is implemented or assisted by controlling a
negative pressure that holds and retains the cigarettes 22 in the
grooves 2 on the outlet drum 29.
[0081] It will be recognized that in embodiments of the cigarette
making machine, the or each microwave sensor unit may be disposed
at any point online on the cigarette making machine. That is, at
any point along the smoking article assembly path of the cigarette
making machine between the filter rods being received by the
cigarette making machine and the assembled smoking article being
discharged from the cigarette making machine.
[0082] In the above described embodiments, one microwave sensor
unit is disposed along the assembly path and configured to provide
an indication of one or more properties of an inserted object in
each filter rod passing transversely along the smoking article
assembly path through the microwave sensor unit. For example, in
the embodiments described with reference to FIGS. 3 to 6, the
microwave sensor unit for providing an indication of each filter
rod comprises one microwave transmitter and one corresponding
microwave receiver acting together as a sensing arrangement.
However, it will be understood that in an alternative embodiment
two or more microwave sensor units are disposed along the assembly
path, the two or more microwave sensor units being configured to
provide an indication of one or more properties of an inserted
object in each filter rod passing transversely along the smoking
article assembly path through the microwave sensor units. It should
be understood that the number of microwave receivers and microwave
transmitters may vary.
[0083] In an arrangement with two microwave sensor units arranged
to detect each filter rod passing transversely along the smoking
article assembly path through the microwave sensor units, the
microwave sensor units are disposed across the path of each filter
rod. That is, the microwave sensor units form an array arranged
transverse to the path of each filter rod. In an arrangement in
which each microwave sensor unit comprises one microwave
transmitter and one microwave receiver, the microwave receivers
form an array arranged transverse to the path of each filter rod
and the corresponding microwave transmitters are disposed across
the path of each filter rod to form an array arranged transverse to
the path of each filter rod. The array of microwave transmitters
and the array of microwave receivers are aligned with each
other.
[0084] The microwave sensor units are disposed adjacent to each
other and are configured to provide an indication of one or more
properties of an inserted object in each filter rod at two or more
points along or adjacent to the path of each filter rod. That is,
each microwave sensor unit is disposed to provide detection at a
different point along the longitudinal axis of the filter rod. This
provides redundancy in the event that one of the microwave sensor
units is restricted from providing feedback.
[0085] Furthermore, in one embodiment one or more of the microwave
sensor units are disposed adjacent to the path of each filter rod.
That is, said microwave sensor unit may be aligned with a rod, such
as a tobacco rod, disposed adjacent to the filter rod. Such a
microwave sensor unit is configured to provide an indication of the
property of an inserted object in the filter in dependence on the
effect on the adjacent rod. For example, by said microwave sensor
unit aligned with the adjacent rod determining the moisture level
of the adjacent rod it is possible to determine whether liquid has
been transferred to the adjacent rod from the inserted object. This
arrangement, helps to provide an indication of one or more
properties of an inserted object in each filter rod when a material
which obscures detection using microwave sensing means, such as
charcoal, forms part of the filter rod. Therefore, it is possible
to indirectly determine a property of an inserted object.
[0086] One or more microwave sensor units in the array may be
selectively switched off, depending on the properties being sensed.
For example, if there is only one capsule or inserted object in a
filter rod, only one sensor in the array need be activated. The
number of microwave sensors that are operable can depend on the
number of capsules or inserted objects in a filter rod, with any
redundant sensors in the array being selectively deactivated.
[0087] It should also be understood that, by providing an array of
microwave sensor unit disposed along the assembly path and
configured to provide an indication of one or more properties of an
inserted object in each filter rod passing transversely along the
smoking article assembly path through the microwave sensor units,
it is possible to allow for misalignments of the filter rods in a
longitudinal direction.
[0088] In order to address various issues and advance the art, the
entirety of this disclosure shows by way of illustration various
embodiments in which the claimed invention(s) may be practiced and
provide for a superior smoking article assembly machine and/or
method of assembling a smoking article on a smoking article
assembly machine. The advantages and features of the disclosure are
of a representative sample of embodiments only, and are not
exhaustive and/or exclusive. They are presented only to assist in
understanding and teach the claimed features. It is to be
understood that advantages, embodiments, examples, functions,
features, structures, and/or other aspects of the disclosure are
not to be considered limitations on the disclosure as defined by
the claims or limitations on equivalents to the claims, and that
other embodiments may be utilised and modifications may be made
without departing from the scope and/or spirit of the disclosure.
Various embodiments may suitably comprise, consist of, or consist
essentially of, various combinations of the disclosed elements,
components, features, parts, steps, means, etc. In addition, the
disclosure includes other inventions not presently claimed, but
which may be claimed in future.
* * * * *