Rod analysis system

Abstract

A rod analysis system is described comprising an imaging device (configured to capture images of the end faces of rods of aerosol-generating material within a rod handling device) and a controller (configured to process the captured images and analyze the roundness of the rods). The rod handling device comprises a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive rods of aerosol-generating material transported by the drum.

Description

Technical Field

[0005] ,

[0001] The present invention relates to a rod analysis system. The rod analysis system may be part of an apparatus for handling a rod of aerosol-generating material and may form components of such an apparatus. The present invention also relates to a method of handling a rod of aerosol-generating material.

Background Art

[0002] Certain tobacco industry products generate an aerosol that is inhaled by a user during use. Such tobacco industry products generally include an aerosol-generating material in the form of a cylindrical rod surrounded by an outer wrapper.

[0003] Apparatuses for manufacturing, manipulating, transporting and otherwise handling rods of aerosol-generating material during the manufacture of consumables for use in aerosol-generating systems are known. The aerosol-generating material may include tobacco, tobacco derivatives or other types of aerosol-generating material. Such an apparatus may comprise at least one rotatable drum, around the circumferential surface of which elongated flutes are provided for receiving the rod. Such a drum may be provided with suction holes communicating with the flutes for holding the rod within the flutes when the drum rotates.

[0004] A wide variety of compositions and types of aerosol-generating material may be provided to the rods intended to be transported through such an apparatus. Thus, such rods may have various hardnesses, elasticities and deformabilities. This may cause some types of rods to present problems when handled by known apparatuses. For example, some rods may be more easily damaged by physical contact with the rod guides of known rod handling apparatuses.

Summary of the Invention

[0005] The scope of protection required for various embodiments of the present invention is presented by the independent claims. Embodiments and features described herein that are not included in the scope of the independent claims should be interpreted as useful examples for understanding various embodiments of the present invention, if any.

[0006] According to a first aspect, the apparatus is described comprising a drum (e.g., a hopper drum or grading drum) having a rotation axis and a plurality of rod seats provided around its outer surface, wherein each rod seat is configured to receive rods of aerosol-generating material conveyed by the drum, and a rod analysis system configured to analyze the roundness of rods of aerosol-generating material handled by the apparatus. The rod analysis system comprises an imaging device (e.g., a camera) configured to capture images of the end faces of rods of aerosol-generating material in the apparatus, and a controller for analyzing the captured images of the rod end faces.

[0007] Each rod seat on the drum may be configured to receive a rod of aerosol-generating material being transported by the drum.

[0008] The apparatus may include a rod forming machine, and the imaging device is configured to image the rods using the rod forming machine.

[0009] The imaging device may be oriented such that the end face of the rod passes through the field of view of the imaging device. The imaging device may have a focal point that is broadly parallel to the axial direction (for example, within 45 degrees from parallel), and other angular ranges are also possible.

[0010] The imaging device may be configured to image the rods on the drum. Alternatively or additionally, the imaging device may be configured to image the rods between the hopper and the drum.

[0011] The apparatus may further include a rejection controller for identifying non-standard rods.

[0012] The apparatus may further include a rejection device configured to discharge non-standard rods from the apparatus. For example, the rejection device may include a flute with an air jet or a controllable vacuum pressure. Alternatively or additionally, the rejection device may include a rigid member having a movable position.

[0013] A second embodiment describes a rod analysis system comprising an imaging device (e.g., a camera) configured to capture images of the end faces of rods of aerosol-generating material in a rod handling device, and a controller configured to process the captured images to analyze the roundness of the rods. The rod handling device comprises a drum (e.g., a hopper drum or a grading drum) having a rotation axis, and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive rods of aerosol-generating material being transported by the drum.

[0014] The imaging device may be configured to image the rods on the drum. Alternatively or additionally, the imaging device may be configured to image the rods between the hopper and the drum.

[0015] The imaging device may be configured to image the rods using the rod forming machine of the device.

[0016] The imaging device may be oriented so that the end face of the rod passes through the field of view of the imaging device during use. The imaging device may have a focal point that is broadly parallel to the axial direction (e.g., within 45 degrees from parallel), and other angular ranges are also possible.

[0017] The rod analysis system may further include a rejection controller for identifying non-standard rods.

[0018] A third aspect of the invention describes a method, namely, a method comprising the steps of: capturing an image of the end face of a rod of aerosol-generating material in a rod handling device, wherein the rod handling device comprises a drum having a rotation axis (e.g., a hopper drum or a grading drum) and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive a rod of aerosol-generating material being transported by the drum; and processing the captured image to analyze the roundness of the rod.

[0019] The step of capturing the aforementioned image may include imaging the rods on the drum, the rods between the hopper and the drum, and / or the rods in the rod forming machine of the apparatus.

[0020] The method may further include the step of oriented an imaging device configured to capture an image such that the end face of the rod passes through the field of view of the imaging device when in use.

[0021] The method may further include the step of identifying non-standard rods. The method may further include the step of rejecting the identified non-standard rods.

[0022] According to a fourth aspect, a computer program is provided which, when executed by the apparatus, causes the apparatus to capture an image of the end face of a rod of aerosol-generating material in a rod handling device, the rod handling device comprising a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive a rod of aerosol-generating material being transported by the drum, and the command, when executed by the apparatus, causes the apparatus to process the captured image to analyze the roundness of the rod. The apparatus may perform (at least) any of the methods described herein, including the method of the third aspect described above.

[0023] According to a fifth aspect, there is provided a computer-readable medium (such as a non-transitory computer-readable medium) storing program instructions for performing (at least) any of the methods described herein (including the method of the third aspect described above).

[0024] According to a sixth aspect, there is provided an apparatus comprising at least one processor and at least one memory including computer program code which, when executed by the at least one processor, causes the apparatus to perform (at least) any of the methods described herein (including the method of the third aspect described above).

[0025] Next, embodiments of the present invention will be described by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0026] [Figure 1] It is a schematic block diagram of a system according to an exemplary embodiment. [Figure 2] It is a schematic block diagram showing details of a rod analysis system according to an exemplary embodiment. [Figure 3] It is a flowchart showing an algorithm according to an exemplary embodiment. [Figure 4] It is a side view of a part of a known manufacturing apparatus for tobacco industry products. [Figure 5] It is a perspective view of a part of the apparatus shown in FIG. 4. [Figure 6] It is an enlarged schematic side view of an area of the apparatus of FIG. 4. [Figure 7] It is a perspective view of a rod guide of the apparatus of FIG. 4. [Figure 8] It is a schematic block diagram of a system according to an exemplary embodiment. [Figure 9] It is a flowchart showing an algorithm according to an exemplary embodiment. [Figure 10] It is a perspective view of a part of an apparatus according to an exemplary embodiment. [Figure 11] It is a schematic block diagram of a rod rejection system according to an exemplary embodiment. [Figure 12] This is a flowchart showing an algorithm according to an exemplary embodiment. [Figure 13] This is a schematic block diagram of a processing system according to an exemplary embodiment. [Figure 14] This is an image of a rod made of aerosol-generating material. [Figure 15] This is a flowchart showing an algorithm according to an exemplary embodiment. [Figure 16] Figure 15 is a plot showing an example output of the algorithm. [Figure 17] This is an image of a rod made of aerosol-generating material. [Figure 18] Figure 15 is a plot showing an example output of the algorithm. [Modes for carrying out the invention]

[0027] As used herein, the term “delivery mechanism” is intended to encompass a system for delivering a substance to a user. Combustion-type aerosol supply system for cigarettes, cigarillos and cigars, Non-combustion aerosol supply systems that release compounds from aerosolizable materials without burning the materials, such as hybrid systems that generate aerosols using a combination of e-cigarettes, tobacco heating products, and aerosolizable materials, Articles comprising aerosolizable material and configured for use in one of these non-combustible aerosol supply systems, Includes.

[0028] According to this disclosure, a “combustion-type” aerosol supply system is a system in which the aerosol-generating material (or its components) that make up the aerosol supply system is burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0029] In some embodiments, the present disclosure relates to components such as tobacco rods for use in combustion aerosol supply systems.

[0030] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0031] Aerosol-generating material (sometimes referred to herein as an aerosolizable material) is a material that can generate an aerosol when heated, irradiated, or electrically energized, for example, in any other manner. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0032] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0033] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0034] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0035] The material may be present on or within a support to form a substrate. The support may be, for example, paper, cardboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise these. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some other embodiments, the susceptor is on one or both sides of the material.

[0036] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material so as to release one or more volatile substances from the material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the aerosol-generating material to vibration, pressure increase, or electrostatic energy.

[0037] In the figures described herein, similar reference numerals are used to indicate equivalent features, articles, or components.

[0038] Figure 1 is a schematic block diagram of a system, generally referred to as reference numeral 100, according to one exemplary embodiment. System 100 comprises a drum 102 and a rod analysis system 104. System 100 forms part of an apparatus for handling rods of aerosol-generating material, as will be described in detail below.

[0039] The drum 102 has a rotation axis and may have a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive a rod of aerosol-generating material conveyed by the drum (further described below). A rod analysis system 104 may be used to analyze the roundness of a rod of aerosol-generating material handled by the apparatus including the drum 102.

[0040] Figure 2 is a schematic block diagram showing details of a rod analysis system 104 according to an exemplary embodiment.

[0041] The rod analysis system 104 comprises an imaging device 112 (e.g., a camera) and a controller 114. The imaging device 112 may be used to capture images of one or more end faces of rods of aerosol-generating material within a rod handling device (such as system 100). The controller 114 may be used to analyze the captured images of the rod end faces.

[0042] As will be further described below, the controller 114 may be configured to determine one or more rod metrics based on the acquired image. The rod metrics may include the roundness / circularity of the rod end and / or the periphery length of the rod end of the rod being processed, as will be described in detail below. The metrics may be used (offline or on the fly) to determine whether the roundness of the rod is within an acceptable range.

[0043] The rod imaged by the imaging device 112 may be located, for example, on the drum 102 (e.g., within the rod seat of the drum). However, this is not essential to all exemplary embodiments. For example, as will be further described below, the imaging device may image the rod between the hopper and the drum. Alternatively or additionally, the imaging device may image the rod in the rod forming machine of the associated apparatus.

[0044] Figure 3 is a flowchart showing the algorithm, generally referred to as reference number 120, according to an exemplary embodiment.

[0045] Algorithm 120 begins in step 122, when images of the end faces of the rods of aerosol-generating material are captured using, for example, a high-speed camera or some similar imaging device 112 as they are handled within a rod handling device (such as system 100).

[0046] As described above, the rod handling device may include a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive a rod of aerosol-generating material conveyed by the drum. The imaging device may capture images of, for example, the rods on the drum, the rods between the hopper and the drum, and / or the rods in the rod forming machine of the rod forming device.

[0047] In step 124, the image acquired in step 122 is processed, for example, to analyze the roundness of the rod. Specifically, the roundness of the end face of the rod may be determined. As will be described in detail below, step 124 may include the controller 114 determining a plurality of points around the periphery of the rod face image to determine the rod end periphery, determining the center point of the rod end, measuring the distance from the determined center point to the determined rod end periphery along a plurality of angular positions of the rod end around the center point, and determining whether the measured distance at any angular position is outside all predetermined tolerance thresholds of the measured distance.

[0048] In step 126, a decision may be made as to whether a rod should be accepted or rejected (for example, by determining whether a particular rod is substandard according to some evaluation criteria). For example, step 126 may include rejecting rods having roundness below a defined threshold (or substandard in some other embodiment). Step 126 may be provided as part of a separate algorithm and is therefore shown as a dotted line (for example, the output of algorithm 120 may be the roundness determined in step 124).

[0049] Step 126 may be performed by the controller 114 described above, or by some other rejection controller for identifying non-standard rods (e.g., some other controller of system 100).

[0050] The data generated in step 124 may be stored for later analysis, in addition to, or instead of, whether the rods are accepted or rejected. Therefore, in some exemplary embodiments, step 126 may be omitted.

[0051] Figure 4 is a schematic side view showing a portion of a known manufacturing apparatus for tobacco industry products, generally referred to as reference numeral 10 (hereinafter referred to as the "apparatus" for brevity). Apparatus 10 comprises a hopper 11 configured to receive multi-length rods (hereinafter generally referred to as "rods") of aerosol-generating material Rm. That is, the rods Rm are aerosol-generating consumables (hereinafter referred to as "consumables") manufactured and finally assembled by the manufacturing apparatus, and may have lengths that are multiples of the rod length present in the consumables for use in the aerosol-generating system. Thus, the rods Rm generally require cutting and positioning as part of the process steps in the consumable manufacturing process.

[0052] Figure 5 is a perspective view of a portion of the apparatus shown in Figure 4, with the hopper omitted for clarity, showing the hopper drum, grading drum, and rod guide.

[0053] In the section of the apparatus 10 shown in Figure 4, the rod Rm is transported from the hopper 11 by the hopper drum 12 and, while held on the hopper drum, is cut into a plurality of smaller rods Rc by the first and second cutting wheels 13, 14. The cut rods Rc are then transferred to the grading drum 15. The grading drum 15 receives the cut rods Rc from the hopper drum 12 in an alternating manner, allowing for spaced placement, shuffling, and rearrangement of the cut rods Rc into finished consumables in subsequent manufacturing steps (not shown). In use, in the configuration shown in Figure 4, the hopper drum 12 may rotate clockwise and the grading drum 15 may rotate counterclockwise.

[0054] The hopper drum 12 is positioned adjacent to the hopper 11 and is configured to receive rods Rm from within the hopper 11 and transport them away from the hopper 11 for processing into consumables in a subsequent processing step of the apparatus 10 (not shown in detail herein).

[0055] The hopper drum 12, shown in detail in Figure 5, is a cylindrical component having a central axis and a bore 18 extending axially through the drum 12. The hopper drum 12 is rotatable within the apparatus 10 by being mounted on a rotatable shaft 19 of the apparatus 10, the rotatable shaft 19 extending through the bore 18. The hopper drum 12 has first and second end faces 20, 21 and a circumferential outer surface extending around the hopper drum 12 between the end faces 20, 21. The outer surface includes a plurality of flutes 23. The flutes 23 are curved recesses or depressions configured to receive a rod Rm from the hopper 11 and hold the rod Rm within the flutes 23 as the hopper drum 12 rotates, transporting the rod Rm forward within the apparatus 10 for processing into consumables so that it leaves the hopper 11. The flutes 23 are elongated and extend axially along the hopper drum 12. In other words, the flutes 23 are arranged such that their elongated lengths extend in a direction parallel to the central axis of the hopper drum 12.

[0056] Figure 6 is an enlarged schematic side view of a region of the apparatus in Figure 4, showing the interaction between the hopper drum and the rod guide, and also showing the grading drum.

[0057] Multiple circumferential grooves 24 are formed on the outer surface of the hopper drum 12. The grooves 24 extend radially inward so that they extend into the flutes 23 and intersect with the flutes. Multiple vacuum ducts 25 (see Figure 6) extend through the body of the hopper drum 12 in a direction parallel to the central axis of the hopper drum 12. The vacuum ducts 25 are arranged circumferentially around the hopper drum 12 and radially inward in the flutes 23. Each vacuum duct 25 opens at the first end face 20 of the hopper drum 12 at its respective vacuum port 26. Thus, the vacuum ports 26 are arranged in a circular arrangement on the first end face 20 of the hopper drum 12, at a radial distance rv measured from the central axis of the hopper drum 12 / rotatable shaft 19 (see Figure 6). Each flute 23 is provided with multiple suction holes 27 that are in fluid communication with their respective associated vacuum ducts 25. In one embodiment, each vacuum duct 25 may communicate with suction holes 27 in two adjacent rows of flutes 23, as shown in Figure 6. In other embodiments, each vacuum duct 25 may communicate with suction holes 27 in only one row of flutes 23, or in three or more rows of flutes 23. This allows vacuum to be applied to the suction holes 27 of one or more flutes 23 by applying vacuum to the vacuum port 26 of the associated vacuum duct 25.

[0058] The apparatus 10 includes a side retaining plate 28 that extends around a portion of the circumference of the end faces 20, 21 of the hopper drum 12 (as shown in Figure 4). The lower transfer surface 29 is located beneath the hopper drum 12 along its entire axial length and extends around a portion of the circumference of the hopper drum 12 within the bottom region of the hopper drum 12. When in use, the lower transfer surface 29 assists in the transfer of the cut rod Rc from the hopper drum 12 to the grading drum 15, as will be described in more detail below.

[0059] The rod guide 35 is positioned in the bottom region of the hopper drum 12 and comprises an elongated arm positioned substantially horizontally and extending substantially tangentially to the hopper drum 12 (see Figures 4 and 6). Possible configurations of the rod guide 35 are shown in Figure 7. Each rod guide 35 comprises an elongated arm having a longitudinal axis DD. When in use, the longitudinal axis DD is positioned substantially horizontally. The rod guide 35 includes a mounting opening 36 for securing the rod guide 35 to the device 10 by mounting bolts 37, as shown in Figure 4. The rod guide 35 includes a guide surface 38 that is inclined at the end opposite the mounting opening 36. The rod guide 35 is secured to the device 10 such that the guide surface 38 is at least partially positioned within the grooves 24 and flutes 23 of the hopper drum 12.

[0060] The cutting wheels 13 and 14 are mounted adjacent to the hopper drum 12 and are staggered in the axial and circumferential directions of the hopper drum 12. The outer cutting edge 39 of each cutting wheel 13 and 14 intersects with the outer surface of the hopper drum 12 and extends into the respective cutting grooves 40 that are formed circumferentially around the outer surface of the hopper drum 12 and extend through each flute 23. Thus, the rod Rm received in the flute 23 can be cut into individual smaller cut rods Rc as it passes through the cutting wheels 13 and 14 when the hopper drum 12 rotates.

[0061] The grading drum 15, shown in a perspective view in Figure 5, comprises a cylindrical component having a central axis and a bore 44 extending axially through the drum 15. The grading drum 15 is rotatably mounted below the hopper drum 12, as shown in Figure 4. The grading drum 15 has a circumferential outer surface 45 extending around the grading drum. The outer surface 45 includes a plurality of rod seats 46 configured to receive rods Rc cut from the hopper drum 12 / lower transfer surface 29 as the hopper drum 12 rotates, and to transport the cut rods Rc forward within the apparatus 10 for processing into consumables, away from the hopper drum 12. The lower transfer surface 29 includes a slot 47, and the rod seats 46 of the grading drum 15 rotate through the slot 47 as they pass closer to the hopper drum 12, allowing the rod seats 46 to collect rods Rc cut from the hopper drum 12. The rod seat portions 46 are staggered circumferentially when viewed in the axial direction of the grading drum 15. This allows rods Rc cut from one axial row on the hopper drum 12 (i.e., a row aligned axially within one flute 23 on the hopper drum 12) to be picked up by the grading drum 15 at staggered intervals, thereby temporarily offsetting the cut rods axially on the grading drum 15.

[0062] Next, the operation of a known apparatus shown in Figure 4 will be described. A multi-length rod Rm is supplied to the hopper 11. The rods Rm are held within the hopper 11 with their axes parallel to each other and parallel to the axis of the hopper drum 12. The hopper drum 12 rotates clockwise, and as one region of the hopper drum 12 passes through the transfer region of the hopper 11, each flute 23 picks up an individual rod Rm and transports it around and out of the hopper 11. The control flange 30 remains fixed within the apparatus 10 as the hopper drum 12 rotates.

[0063] As the rod Rm passes through the cutting wheels 13 and 14, the cutting wheels 13 and 14 cut the rod Rm into smaller individual cut rods Rc, which are held within the flute 23.

[0064] As the hopper drum 12 rotates, the vacuum port 26 is opened to the atmosphere at several rotational angles. This removes the suction force through the suction holes 27 in the flute 23, freeing the severed rods Rc from the flute 23. The severed rods Rc are transported on the lower transport surface 29 around the lower region of the hopper drum 12 until the severed rods Rc are picked up by the grading drum 15 in its upper region. The rod seats 46 of the grading drum 15 pass near the bottom of the hopper drum 12 through slots 47 in the lower transport surface 29. Thus, as the severed rods Rc leave the flute 23, those rods are picked up by the respective rod seats 46 of the grading drum 15 and transported forward within the rod seats 46 as the flute 23 of the hopper drum 12 rotates away from the grading drum 15 and then rotates back towards the hopper 11 to collect another multi-length rod Rm.

[0065] In ideal operation, when the suction force is removed from the suction holes 27, the cut rods Rc fall consistently, quickly, and uniformly from each flute 23 of the hopper drum 12 by gravity. However, some rods Rm / Rc of certain compositions of the aerosol-generating material being processed by the apparatus 10 may have certain material properties (such as hardness, elasticity, or elastic / plastic deformability) or dimensions (such as lack of "roundness"), which can cause problems for the cut rods Rc leaving the flutes 23. In some cases, even after the suction force is removed, the cut rods may get stuck in the flutes. In particular, rods Rc containing aerosol-generating material with softer material properties may deform more easily and tend to get trapped in the flutes 23. This can lead to manufacturing defects, machine clogging, or at least waste of rod material, as the rods Rc are lost from the production line or actively removed and disposed of.

[0066] Some rods may enter the hopper drum 12 with variations in circumference and / or roundness (or perfect roundness). Alternatively or additionally, perfect roundness may be affected by the processing steps. For example, the aforementioned use of the rod guide 35 is effective in removing the cut rods Rc from the flutes 23 and / or in assisting the movement of the rods toward the grading drum 15. However, problems may arise due to forces that the rods Rc may come into contact with the guide surface 38 of the rod guide 35. Such collisions may dent or damage the cut rods Rc, which may result in the production of uneven or damaged consumables. Furthermore, the cut rods Rc may be unevenly deflected away from the flutes 23, which may result in the rods being collected inconsistently by the grading drum 15.

[0067] Variations in roundness and / or circumference can affect both product quality and machine operation reliability. Rod variations can lead to numerous problems, including hopper clogging, variations in filling rate, and / or transportation issues.

[0068] Figure 8 is a schematic block diagram of a system, generally referred to as reference number 130, according to an exemplary embodiment. System 130 comprises a hopper 134, a hopper drum 135, and a grading drum 136 (these may be the hopper 11, hopper drum 12, and grading drum 15 described above). System 130 also comprises a rod analysis system, generally referred to as reference number 131. Rod analysis system 131 is an exemplary embodiment of rod analysis system 104 described above.

[0069] The rod analysis system 131 comprises a camera 132 (for capturing images of the end faces of rods of aerosol-generating material within the device) and a controller 133. The camera is typically oriented so that the end faces of the rods pass through the camera's field of view during use. The controller 133 includes a processor configured to analyze the captured images of the rod end faces in order to analyze the roundness of the rods of aerosol-generating material handled by the device.

[0070] Camera 132 is shown in three possible positions within the system 300, indicated by reference numerals 132a, 132b, and 132c, respectively. It should be noted that in some exemplary embodiments, two or more cameras may be provided (for example, in two or more of positions 132a, 132b, and 132c). Alternatively or additionally, one or more cameras may be provided in one or more other positions (such as rod formation positions).

[0071] Camera 132 may be configured to image the rod between the hopper 134 and the hopper drum 135 (as shown by camera 132a). Camera 132a may be configured to image the rod, for example, while the rod is being pulled out of the hopper 134.

[0072] Alternatively or additionally, the camera may be configured to image the rods on the hopper drum 135 (as shown by camera 132b). Thus, camera 132b can generate an image of the rods on the first drum behind the hopper 134. This allows defective rods to be removed as quickly as possible (potentially reducing machine downtime).

[0073] Alternatively or additionally, a camera may be configured to image a rod on the grading drum 136 (as shown by camera 132c). This is the same position as camera 152, which will be discussed later.

[0074] Figure 9 is a flowchart of the algorithm, generally referred to as reference number 140, according to an exemplary embodiment. Algorithm 140 may be implemented by the system 130 described above.

[0075] Algorithm 140 begins in step 142, and the imaging device (such as the camera 132 described above) is oriented so that, when in use, the end faces of the rods passing through the system (such as the rod handling system 100) pass through the field of view of the imaging device. Step 142 may form part of the start or setup process and may be performed only once (in fact, it may be omitted from some implementations of algorithm 140).

[0076] In step 144 (same as step 122 described above), an image of the end face of the aerosol-generating material rod as it is handled in the rod handling device is captured, for example, using a high-speed camera (e.g., camera 132) or some similar imaging device 112.

[0077] As described above, the rod handling device may include a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, each rod seat configured to receive a rod of aerosol-generating material conveyed by the drum. The imaging device may capture images of the rods, for example, on the drum, between the hopper and the drum, and / or in the rod forming machine of the rod forming device. Imaging on the drum can offer several advantages. For example, since the rods reach a consistent position in a predictable manner, the measurements and the determination of the differences between the measurements tend to be more reliable.

[0078] In step 146 (similar to step 124 described above), the image acquired in step 144 is processed, for example, to analyze the roundness of the rod. Specifically, the roundness of the end face of the rod may be determined. Step 146 may include the controller 133 determining a plurality of points around the rod surface image to determine the rod end periphery, determining the center point of the rod end, measuring the distance from the determined center point to the determined rod end periphery along a plurality of angular positions of the rod end around the center point, and determining whether the measured distance at any given angular position is outside a predetermined tolerance threshold of all measured distances.

[0079] In step 148, off-spec rods are identified. All identified off-spec rods may be rejected. For example, as described above with reference to step 126, step 148 may include identifying rods with roundness below a defined threshold (or being off-spec in some other way). It should be noted that step 148 may be performed on the fly (for example, to identify off-spec rods during processing). Alternatively, step 148 may be performed later based on historical data. For example, step 148 may be performed after the execution is complete or after a malfunction occurs (for example, if it is necessary to shut down a manufacturing device such as apparatus 10).

[0080] Figure 10 is a perspective view of a portion of the apparatus, generally referred to as reference numeral 150, according to an exemplary embodiment. The apparatus 150 includes the hopper drum 12 and grading drum 15 (or hopper drum 135 and grading drum 136) described above, and further comprises a camera 152 and a camera frame 154. The camera 152 may be used to capture the image described in step 144 of algorithm 140. The camera 152 may be, for example, camera 132c of system 130. Of course, as described above, the camera 152 may be located in a different position. Furthermore, the apparatus 150 may be provided with additional cameras.

[0081] The camera 152 is oriented in a focal direction parallel to the axial direction of the hopper drum 12 and the grading drum 15.

[0082] Camera 152 is typically a high-speed camera, thereby enabling analysis of objects rapidly passing through the apparatus 150. Commercially available cameras have been found to be suitable for this purpose.

[0083] Figure 11 is a schematic block diagram of a rod rejection system, generally referred to as reference number 160, according to an exemplary embodiment. The rod rejection system 160 comprises a rejection controller 162 and a rod rejection device 164. The controller 162 identifies non-standard rods and may be implemented as part of the controller 133 or controller 114 described above.

[0084] The rod rejection device 164 is configured in some manner to eject non-standard rods from the associated device. The rod rejection device can take many forms. These include reducing the flute vacuum pressure / pressurized air injection at the rejection position and / or providing pressurized air injection at the rejection position. Alternatively or additionally, a rigid member having a movable position for ejecting the rod (such as a simple arm for "pulling out" or for ejecting the rejected rod in any other way) may be provided. Those skilled in the art will recognize that there are other options for implementing the rod rejection device 164.

[0085] Figure 12 is a flowchart showing the algorithm, generally referred to as reference number 200, according to an exemplary embodiment.

[0086] Algorithm 200 is initiated in step 202, in which one or more images of the end faces of the rod of aerosol-generating material as it is handled in the apparatus are captured.

[0087] In step 203, rod data is determined based on the image captured in step 202. The rod data may include information such as which pixels in the image are occupied by the rods and where the edges of the rods are located. The rod data determined in step 203 is sometimes called raw data.

[0088] In step 204, one or more rod evaluation criteria are determined from the rod data. These evaluation criteria may relate to the roundness of the rod end faces (i.e., rod circularity), as will be further described below. Other evaluation criteria that may be determined (in addition to or instead of roundness) include indices of the rod end periphery and / or rod end circumference based on the captured images.

[0089] In step 206, some or all of the rod data determined in step 203 and / or some or all of the rod evaluation criteria determined in step 204 are stored. Data for individual rods (e.g., including rod data measurements) may be stored. Alternatively or additionally, rod data or evaluation criteria for multiple rods (e.g., rod statistical data for multiple imaged rods) may be stored. Alternatively or additionally, data relating to the rod material input to the device (rather than a specific rod) may be generated and stored.

[0090] For future analysis, at least some data or evaluation criteria may be stored in process 206. As described above, such future analysis may be performed after defective products have been detected.

[0091] In step 208, a decision may be made (based on the evaluation criteria determined in step 204) regarding whether to accept or reject the rod. For example, if the determined evaluation criteria fall below a threshold level, a rejection signal may be generated.

[0092] Step 208 may be initiated in response to a decision to reject a particular rod. Alternatively or additionally, step 208 may include an action taken when the percentage of rods with evaluation criteria below a threshold level exceeds a global threshold (such as stopping the drive or transmitting a warning signal).

[0093] It should be noted that in some exemplary embodiments, one or both of steps 206 and 208 may be omitted. For example, algorithm 200 may be used to collect data for future analysis (in which case step 208 may be optional). Alternatively, the algorithm may be used to accept or reject rods on the fly (in which case step 206 may be optional). Furthermore, depending on the determined evaluation criteria, any other action may be taken (in addition to or instead of steps 206 and / or 208).

[0094] Figure 13 is a schematic block diagram of a processing system, generally referred to as reference numeral 210, according to an exemplary embodiment. The processing system 210 comprises a processor 212 and a memory 214 (such as RAM and / or ROM) connected to the processor. The memory 214 may store computer program code, which, when executed by the processor 212, causes the processing system 210 to implement one or more of the algorithms described herein (such as algorithm 120 or algorithm 200).

[0095] Processor 212 may be used to process the image acquired in step 202. For example, processor 212 may perform one or more of steps 203, 204, 206, and 208 of algorithm 200. Processor 212 may provide outputs, such as data for storage and / or evaluation criteria (performing step 206) and / or an output indicating whether the rod of aerosol-generating material should be rejected (performing step 208).

[0096] Figure 14 is an image of the rod 300 of the aerosol-generating material. It is clear that the rod 300 has a high degree of circularity.

[0097] Figure 15 is a flowchart of the algorithm, generally referred to as reference number 310, according to an exemplary embodiment. Algorithm 310 may be used to determine information regarding rod 300.

[0098] Algorithm 310 starts in step 312, when an image of rod 300 is captured. Step 310 is an example of step 202 of algorithm 200 described above.

[0099] In step 314, a circle that best fits the image of the rod is generated.

[0100] Circle data is determined in step 316. The circle data may include, for example, the radius and / or circumference of the circle generated in step 314.

[0101] Finally, in step 318, the rod data is determined based in part on the circle data generated in step 316.

[0102] Of course, steps 314 to 318 are shown as separate steps, but some or all of those steps may be combined.

[0103] Figure 16 is a plot diagram, generally referred to as reference number 320, showing the output of algorithm 310. Plot diagram 320 shows an image of the rod 300 produced in step 312 of algorithm 310.

[0104] The plot figure 320 has a circle 322 drawn around the image 320, as generated in step 314. Information such as the center point, radius, and circumference of the circle can be easily determined.

[0105] Circle 322 can be generated in many ways. For example, the periphery of the rod end may be determined, multiple points around the periphery of the rod surface image may be determined, and / or the center point of the rod end surface image may be determined. These points may be used to determine the best fit of the circle and the center point of the circle.

[0106] Image 320 displays data related to a circle and a rod. The rod is processed rod number 53. Circle 322 has a circumference of 22.592 mm (determined in process 316).

[0107] The generation of rod data (in step 318) may include determining the distance from the determined center point to the determined rod end periphery along multiple angular positions of the rod end around the determined center point. An estimate of roundness or circularity can be determined by determining the discrepancies between the determined periphery at multiple rod angular positions and the periphery of the perfect circle 322. In the illustrated example, a circularity of 90.318% is determined.

[0108] Plot 320 also displays the average circumference (22.618 mm) and average roundness (88.843%) of the measured rods. This plot shows that rod 300 has a slightly higher-than-average roundness.

[0109] As described above, step 312 of algorithm 300 is an example of step 202 of algorithm 200. Furthermore, steps 314-318 may be used to carry out steps 203 and 204.

[0110] Step 208 of algorithm 200 may be performed based on the data determined in steps 314-318. For example, a determination may be made as to whether the measured distance at any angular position is outside a predetermined tolerance threshold for all measured distances. This may indicate a defective product (which may be stored as information and / or used to reject each rod). Alternatively or additionally, the evaluation criterion may be determined based on the difference between the maximum and minimum determined distances from the center point of the rod to the periphery, divided by the minimum determined distance. Again, this evaluation criterion may be used to identify potentially defective products.

[0111] If the determined evaluation criterion is outside the acceptable range (which may be user-definable or set in any other manner), a rejection signal may be generated (in the exemplary embodiment of step 208).

[0112] Figure 17 is an image of rod 330 of the aerosol-generating material. Rod 330 is damaged. It is clear that rod 330 has a lower degree of roundness than rod 300 shown in Figure 14.

[0113] Figure 18 is a plot diagram, generally referred to as reference number 340, showing the output of the algorithm in Figure 15 based on the image of rod 330 (generated in step 312 of algorithm 310).

[0114] The plot figure 340 has a circle 342 drawn around the image 340, as generated in step 314. The center point, radius, and circumference of the circle 342 can be easily determined.

[0115] Image 340 displays data regarding circle 342 and rod 330. The rod is processed rod number 50. Circle 342 has a circumference of 22.028 mm (determined in process 316) and a roundness of 76.277%. This is lower than the average roundness (78.892%), indicating that rod 330 has some degree of damage.

[0116] If the determined evaluation criterion (such as roundness) is outside the acceptable range (which may be user-definable or set in some other manner), a rejection signal may be generated (in the exemplary embodiment of step 208).

[0117] Apparatus for handling rods of aerosol-generating material from a hopper 11 (or 134) to a grading drum 15 (or 136) has been described above. Such apparatus may form part of a larger manufacturing machine, which may include further stations for handling, processing, assembling, and arranging the rods into consumables or groups of consumables. Such machine may consist of a single machine, and apparatus 10 may comprise a section of such machine. Such machine may comprise a modular machine comprising separate modules assembled and connected to one another to perform desired functions and manufacturing steps, and apparatus may comprise individual modules of such modular machine, or a portion of such modules of such modular machine. For example, apparatus 10 may comprise a hopper, a hopper drum 12, and a grading drum 15 (and the related components described above). Alternatively, apparatus 10 may comprise only the hopper drum 12, without a grading drum 15 or other drum upstream or downstream of the hopper drum 12 in the apparatus. As described above, in such a situation, the apparatus may comprise drums other than the hopper drum 12 within the scope of the present invention.

[0118] In the illustrated embodiment, the flute 23 is formed integrally with the hopper drum 12 on the outer surface of the drum 12. However, the flute 23 may be provided as one or more separate components attached to the surface of the drum.

[0119] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. It is a device, A drum having a rotation axis and a plurality of rod seating portions provided around its outer surface, wherein each of the rod seating portions is configured to receive a rod of aerosol-generating material conveyed by the drum, A rod analysis system configured to analyze the roundness of a rod of aerosol-generating material handled by the aforementioned apparatus, Equipped with, The aforementioned rod analysis system An imaging device configured to capture an image of the end face of the rod of the aerosol generating material within the apparatus, A controller that analyzes the captured image of the end face of the rod, A device equipped with the following features.

2. The apparatus according to claim 1, wherein each of the rod seat portions of the drum is configured to receive a rod of the aerosol generating material conveyed by the drum.

3. The apparatus according to claim 1 or 2, wherein the drum is a hopper drum.

4. The apparatus according to any one of claims 1 to 3, wherein the drum is a grading drum.

5. The apparatus according to any one of claims 1 to 4, further comprising a rod forming machine, wherein the imaging device is configured to image a rod using the rod forming machine.

6. The apparatus according to any one of claims 1 to 5, wherein the imaging device is oriented such that the end face of the rod passes through the field of view of the imaging device.

7. The apparatus according to any one of claims 1 to 6, wherein the imaging device is configured to image the rod on the drum.

8. The apparatus according to any one of claims 1 to 7, wherein the imaging device is configured to image the rod between the hopper and the drum.

9. The apparatus according to any one of claims 1 to 8, further comprising a rejection controller for identifying non-standard rods.

10. The apparatus according to any one of claims 1 to 9, further comprising a rejection device configured to discharge non-standard rods from the apparatus.

11. The apparatus according to claim 10, wherein the rejection device includes a flute having air injection or a controllable vacuum pressure.

12. The apparatus according to claim 10, wherein the rejection device includes a rigid member having a movable position.

13. An imaging device configured to capture an image of the end face of a rod of aerosol-generating material inside a rod handling device, A controller configured to process the captured image and analyze the roundness of the rod, A rod analysis system comprising, A rod analysis system comprising a rod handling device having a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, wherein each of the rod seats is configured to receive a rod of aerosol-generating material conveyed by the drum.

14. The rod analysis system according to claim 13, wherein the imaging device is configured to image the rods on the drum.

15. The rod analysis system according to claim 13 or 14, wherein the imaging device is configured to image the rod between the hopper and the drum.

16. The rod analysis system according to any one of claims 13 to 15, wherein the drum is a hopper drum or a grading drum.

17. The rod analysis system according to any one of claims 13 to 16, wherein the imaging device is configured to image a rod in the rod forming machine of the apparatus.

18. The rod analysis system according to any one of claims 13 to 17, wherein the imaging device is oriented such that the end face of the rod passes through the field of view of the imaging device when in use.

19. A rod analysis system according to any one of claims 13 to 18, further comprising a rejection controller for identifying non-standard rods.

20. The apparatus according to any one of claims 1 to 12, or the rod analysis system according to any one of claims 13 to 18, wherein the imaging device comprises a camera.

21. A step of capturing an image of the end face of a rod of aerosol-generating material in a rod handling device, wherein the rod handling device comprises a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, and each of the rod seats is configured to receive a rod of aerosol-generating material being transported by the drum; The steps include processing the captured image to analyze the roundness of the rod, A method that includes this.

22. The method according to claim 21, wherein the step of acquiring the image includes imaging the rod on the drum, the rod between the hopper and the drum, and / or the rod in the rod forming machine of the apparatus.

23. The method according to claim 21 or 22, further comprising the step of oriented the imaging device, which is configured to capture the image, such that the end face of the rod passes through the field of view of the imaging device when in use.

24. The method according to any one of claims 21 to 23, further comprising the step of identifying a non-standard rod.

25. The method according to claim 24, further comprising the step of rejecting the identified non-standard rod.

26. A computer program that includes instructions, When the aforementioned instruction is executed by the device, the device will: An image of the end face of a rod of aerosol-generating material inside a rod handling device is captured, and the rod handling device comprises a drum having a rotation axis and a plurality of rod seats provided around the outer surface of the drum, each of which is configured to receive a rod of aerosol-generating material conveyed by the drum, and A computer program that processes the captured image to analyze the roundness of the rod.

Images