System and method for automated preparation of smoking articles

Abstract

A device and method for automated cigarette preparation featuring a single- station design that maintains a rolled cigarette paper stationary throughout processing. The device includes a compartment connected to a conduit, a holding arrangement for the cigarette paper, a pushing rod, vibrators, and sensors integrated with a controller implementing real-time feedback control. The holding arrangement positions the rolled paper below a conduit opening and around a pushing axis. Motors actuate vertical movement of the pushing rod and holding arrangement along the pushing axis. The controller dynamically adjusts processing parameters based on sensor feedback monitoring content amount and density. The device implements multi-cycle filling and packing protocols through coordinated control of material processing, vibration, and compression operations. A precision linear rail system enables controlled vertical positioning of both the pushing rod and holding arrangement. The single-station design eliminates transfer between stations while maintaining consistent quality and precise control.

Description

[0001] SYSTEM AND METHOD FOR AUTOMATED PREPARATION OF SMOKING ARTICLES

[0002] RELATED APPLICATIONS

[0003] This application claims the benefit of priority of US Provisional Patent Application No.

[0004] 63 / 741,904 filed on 5 January 2025, the contents of which are incorporated herein by reference in their entirety.

[0005] FIELD AND BACKGROUND OF THE INVENTION

[0006] The present invention relates generally to automated preparation devices for smoking articles, and more particularly to an automated system and method for preparing cigarettes with precise control over content weight, density, and packing uniformity.

[0007] The preparation of cigarettes such as cannabis cigarettes has traditionally been a manual process requiring significant skill and dexterity. With the increasing legalization of cannabis for medical and recreational use across various jurisdictions, there is a growing need for consistent, precise, and efficient methods of preparing cannabis cigarettes both for personal use and small-scale production operations.

[0008] Traditional manual joint preparation typically involves several discrete steps: grinding or breaking down the cannabis material to an appropriate consistency, preparing and positioning a rolling paper, filling the paper with the ground material, and carefully compacting the material to achieve proper density and distribution. This process is time-consuming and yields inconsistent results even when performed by experienced individuals. Common problems include uneven distribution of material, improper density leading to poor burning characteristics, and inconsistent weight between cigarettes. Existing automated solutions have attempted to address these challenges.

[0009] SUMMARY OF THE INVENTION

[0010] According to a first aspect of some embodiments of the present invention there is provided a device for automated cigarette preparation, comprising: a compartment connected to a conduit having a bottom conduit opening; a holding arrangement configured for holding a cigarette paper rolled to form a rolled cigarette paper top opening and a rolled cigarette paper bottom opening, both below the bottom conduit opening and around a pushing axis; a pushing rod; one or more vibrators mounted to vibrate the cigarette paper and the content confined by the cigarette paper; one or more motors mechanically connected to actuate at least one of the pushing rod and the holding arrangement along the pushing axis; a sensor adapted for sensing at least one of an amountand a density uniformity of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement; and a controller adapted to control the one or more motors and the one or more vibrators according to outputs of the sensor.

[0011] Optionally, the device is a single-station device for automated cigarette preparation, wherein the rolled cigarette paper remains stationary during preparation operations.

[0012] Optionally, the holding arrangement is configured for maintaining the cigarette paper in a fixed position throughout preparation operations.

[0013] Optionally, the pushing axis maintains a vertical alignment within 0.5 degrees throughout operation.

[0014] Optionally, the compartment having a processing surface with a compartment opening; wherein the device further comprising a rotating shaft having a top end threaded via the compartment opening and mechanically connected to a processing element.

[0015] More optionally, the conduit is adapted to be mounted around at least some of the rotating shaft and an outer surface of the processing surface.

[0016] More optionally, the processing element is an impeller.

[0017] Optionally, the compartment comprises: a processing surface with a compartment opening; a bidirectional rotating shaft extending through the compartment opening; a processing element mechanically connected to the rotating shaft; wherein the controller is adapted to alternate the rotating shaft between clockwise and counterclockwise rotations based on sensor feedback.

[0018] More optionally, the device further comprises one or more pushing elements mounted to sweep ground material into the conduit.

[0019] More optionally, the one or more pushing elements comprise a dispensing rotor mounted to sweep the content into the bottom conduit opening.

[0020] More optionally, the dispensing rotor is mounted on a rotating shaft mechanically connected to a processing element mounted to process the content in the compartment.

[0021] Optionally, the holding arrangement comprises at least one holding element which is tiltable for facilitating loading and unloading of the cigarette paper in a rolled configuration.

[0022] Optionally, the holding arrangement comprises at least one holding element which is vertically adjustable along a motorized linear rail.

[0023] Optionally, the holding arrangement is configured to move along the pushing axis to adjust a vertical position of the rolled cigarette paper for different stages of preparation.

[0024] Optionally, the holding arrangement is configured to press the rolled cigarette paper against the bottom conduit opening during a stage of content packing.Optionally, the sensor is a weight sensor integrated into the holding arrangement for sensing at least one of the amounts and the density of the content confined within the rolled cigarette paper.

[0025] More optionally, the weight sensor is a load cell.

[0026] Optionally, the controller is further adapted to implement multi-cycle filling and packing protocols, dynamically adjusting filling rate, vibration intensity, and pushing rod pressure based on real-time feedback from the sensor.

[0027] Optionally, the controller is further adapted to implement customizable protocols for different types of content to be confined within the rolled cigarette paper.

[0028] Optionally, the controller is further adapted to implement two or more of: multi-cycle filling and packing protocols, dynamically adjusting filling rate, vibration intensity, milling intensity, and pushing rod pressure based on real-time feedback from the sensor.

[0029] Optionally, the controller is further adapted to instruct the one or more motors to implement a multi-cycle protocol comprising: a first cycle of dispensing a portion of the content and applying high-intensity vibrations; a second cycle of dispensing additional content and applying gentle pressure with the pushing rod; and a third cycle of dispensing remaining content to reach a target weight and applying firm pressure with the pushing rod.

[0030] Optionally, the one or more vibrators comprise at least one of: an electromagnetic vibrator, an eccentric rotating mass (ERM) vibrator, a piezoelectric vibrator, a linear actuator vibrator, a multi-axis vibration generator, a variable frequency vibrator, or a pulsed vibration generator. According to a second aspect of some embodiments of the present invention there is provided a method for automated cigarette preparation, comprising: providing a device comprising: a compartment connected to a conduit having a bottom conduit opening, a holding arrangement configured for holding a cigarette paper rolled to form a rolled cigarette paper top opening and a rolled cigarette paper bottom opening both below the bottom conduit opening and around a pushing axis, a pushing rod, one or more vibrators mounted to vibrate the cigarette paper and content confined by the cigarette paper, one or more motors mechanically connected to actuate at least one of the pushing rod and the holding arrangement along the pushing axis, a sensor adapted for sensing at least one of an amount and a density of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement, and a controller adapted to control the one or more motors and the one or more vibrators according to outputs of the sensor; executing on the controller a code for: controlling transfer of content through the conduit into the rolled cigarette paper; sensing, using the sensor, at least one of an amount and a density of content confined withinthe rolled cigarette paper; controlling the one or more motors for adjusting the position of at least one of the holding arrangement and the pushing rod along the pushing axis for packing the content; controlling the one or more vibrators to vibrate the cigarette paper and the confined content; dynamically adjusting at least one of the content transfer, vibration, and packing based on realtime feedback from the sensor for producing a cigarette filled and packed with the content without removing the cigarette paper from the holding arrangement.

[0031] According to an aspect of some embodiments of the present invention, significant advancement is achieved through direct sensing of fill height during preparation operations. Unlike conventional approaches that rely on weight measurement as a proxy for fill completeness, at least some embodiments employ a sensing system that directly detects the height of content within the rolled cigarette paper during filling. This direct measurement approach is substantially independent of material properties such as moisture content and density, which can vary significantly between different materials and even between batches of the same material. The fillheight sensing system enables the controller to monitor filling progress in real-time and to make precise determinations about when to cease dispensing, when to apply compression, and how to adjust subsequent processing steps. By measuring the actual parameter of interest rather than an indirect indicator, the system achieves improved consistency across varying material types without requiring frequent recalibration or manual adjustment of processing parameters.

[0032] Optionally, the fill-height sensing system comprises a plurality of sensors arranged at different height positions along the rolled cigarette paper, enabling the controller to build a height profile during filling operations. This multi-position sensing capability provides several advantages beyond simple fill-level detection. The pattern of sensor outputs can reveal characteristics of the rolled cigarette paper itself, such as its length, enabling automatic adaptation to different cone sizes without manual selection. Unusual patterns in sensor outputs can indicate damaged or improperly formed cigarette paper, allowing the system to abort processing before material is wasted. Detection of content already present in the cigarette paper before processing begins enables the system to adjust its filling protocol to account for pre-existing material. These capabilities emerge from the same sensor array used for basic fill-height control, providing multiple functions from a single sensing system without requiring additional sensors or complexity.

[0033] According to an aspect of some embodiments of the present invention, substantial improvements are achieved through a positioning system that moves the holding arrangement between distinct positions optimized for different processing operations. Unlike systems where the cigarette paper remains in a fixed orientation throughout processing, at least someembodiments move the cigarette paper between a first position configured for receiving content and a second position configured for compression. This multi-position approach enables separation of the content delivery path from the compression path, addressing practical challenges that arise when both functions must occur through shared passages. When content is delivered directly from the processing compartment to the cigarette paper in the first position, and compression is applied along a different axis when the cigarette paper is moved to the second position, the system eliminates interference between these operations. Material buildup and clogging that occur in shared conduits are avoided, sealing requirements are simplified, and the risk of material infiltrating internal mechanisms is substantially reduced.

[0034] Optionally, the positioning system moves the holding arrangement by rotating it about a pivot axis, creating angular separation between the different processing positions. This rotational approach enables compact implementation while maintaining clear separation between functional zones. The content delivery position may be oriented such that material can drop by gravity from the processing compartment directly into the cigarette paper, minimizing adhesion surfaces and transfer losses. The compression position may be oriented to align the cigarette paper axis closely with the pushing rod axis, ensuring efficient force transmission during packing. An insertion and ejection position may be oriented toward an operator access side, providing ergonomic access for loading paper and removing completed products. The mechanical simplicity of rotational positioning, combined with the functional advantages of separated processing zones, provides substantial operational benefits while maintaining a compact form factor suitable for both personal and commercial applications.

[0035] According to an aspect of some embodiments of the present invention, mechanical coordination of ancillary functions with the positioning system substantially reduces system complexity while ensuring proper sequencing of operations. When a flow control element that governs material release from the compartment is mechanically linked to the position of the holding arrangement, material can only be dispensed when the cigarette paper is properly positioned to receive it. This mechanical coordination, which may be implemented through cam mechanisms or linkage systems, eliminates the need for separate sensors and control signals to verify that conditions are correct for each operation. The same mechanical system that positions the cigarette paper can simultaneously open flow paths when positioning is complete and close them when positioning changes, providing inherent fail-safe behavior. In some embodiments, a single actuator drives multiple coordinated functions including positioning of the cigarette paper, actuation of flow control elements, and ejection of completed products, substantially reducing the number of motors and control channels required compared to systems where each functionoperates independently.

[0036] According to an aspect of some embodiments of the present invention, adaptive control methods that learn from observed behavior during processing provide substantial improvements in consistency across varying material properties. Rather than executing fixed processing protocols with predetermined parameters, at least some embodiments implement multi-cycle preparation sequences where the controller monitors process parameters during each cycle, analyzes the behavior exhibited by the material, and adjusts targets for subsequent cycles based on this analysis. This adaptive approach enables the system to automatically compensate for variations in material density, moisture content, particle size distribution, and other properties that affect packing behavior. When material settles significantly during initial filling cycles, the controller increases fill targets for subsequent cycles. This cycle-by-cycle adaptation, which occurs automatically without operator intervention, ensures that the final product meets target specifications despite material variations that would cause inconsistent results in systems using fixed processing protocols.

[0037] The controller (180) may implement adaptive control algorithms that modify processing targets across multiple fill-and-pack cycles based on observed material behavior. This adaptive capability enables the system to automatically compensate for material property variations without operator intervention or manual parameter adjustment. The adaptive control method comprises several functional stages that execute sequentially during the preparation process.

[0038] During an initialization phase, the controller (180) may utilize the fill-height sensing system to characterize the rolled cigarette paper before content dispensing begins. If an optical fill-height sensing system is employed, the controller analyzes the pattern of sensor outputs across all detectors to determine the cone length. For example, if detectors at positions 1 through 3 indicate a fully obstructed state, and detectors at positions 4 through 12 indicate the partially obstructed state (empty cone present) while detectors at positions 13 through 16 indicate the unobstructed state (no cone present), the controller determines the cone extends through 12 sensor positions, with a filter or pre-fill that extends through 3 sensor positions. Based on this detected cone length, filter length and user- specified or default fill parameters, the controller calculates an appropriate total number of fill-and-pack cycles to execute.

[0039] As used herein, the term 'unobstructed state' refers to a detector signal level indicating that no obstruction exists along the optical path between a light emitter and its corresponding light detector, typically occurring when no cigarette paper is present at the detector height position. The term 'partially obstructed state' refers to a detector signal level indicating partial obstruction of the optical path, typically occurring when empty cigarette paper without content ispresent at the detector height position, reducing received signal strength to a first intermediate level. The term 'fully obstructed state' refers to a detector signal level indicating substantial obstruction of the optical path, typically occurring when a filter tip or cigarette paper containing material is present at the detector height position, reducing received signal strength to a second intermediate level lower than the first intermediate level.

[0040] The cycle count determination may be based on a target fill height per cycle and the total height to be filled. For example, if each cycle is targeted to add material corresponding to 3 sensor positions, and the cone extends through 12 positions, then 4 cycles would be calculated as appropriate. The controller may store this calculated cycle count as a variable that can be adjusted during execution if material behavior indicates more or fewer cycles are needed. The cycle count determination accommodates varying cone sizes automatically, with shorter cones requiring as few as 2 cycles and longer cones requiring as many as 10 cycles, all determined without operator input.

[0041] During execution of each fill-and-pack cycle, the controller (180) monitors multiple process parameters and records their values for subsequent analysis. These monitored parameters may include the rate at which fill height increases during dispensing, the grinding resistance of the material, the final fill height achieved before compression begins, the rate at which compression force builds up as the pushing rod advances, the final compression force achieved, the displacement of the pushing rod required to achieve the target compression force and environmental factors such as humidity and temperature. The controller may sample these parameters at regular intervals, for example every 50 milliseconds, building a profile of material behavior throughout the cycle.

[0042] After each cycle completes, the controller executes an analysis routine that characterizes material behavior based on the monitored parameters. The analysis may calculate a settling rate by comparing fill height measured immediately after dispensing ceases to fill height measured after a settling period. The analysis may also calculate a compression response by evaluating how rapidly force increased as the pushing rod advanced. A rapid force buildup rate indicates dry material that compacts easily during vibration, while a slow force buildup rate suggests sticky or humid material that resists compaction.

[0043] Based on this behavioral analysis, the controller determines adjustments to apply for subsequent cycles. If the compression response indicates easy hard compaction, demonstrated by force building up slowly over a large displacement, the controller may increase the fill quantity for subsequent cycles or reduce the target compression force, as less force is needed to achieve adequate density. If the compaction ratio exceeds a threshold value, for example if materialheight decreased by more than 10 millimeters after compaction, the controller may decrease the fill height target for the next cycle to compensate for the anticipated additional settling. The magnitude of the adjustment may be proportional to the observed settling amount. If the compression response indicates hard compaction, demonstrated by force building up slowly over a large displacement, the controller may increase the fill quantity for subsequent cycles or reduce the target compression force, as less force is needed to achieve adequate density. Conversely, if the compression response indicates resistant material, the controller may reduce fill quantities or increase target force.

[0044] These adjustments are applied cumulatively across cycles. Early cycles provide information that influences mid-cycle parameters, and mid-cycle observations further refine parameters for final cycles. By the final cycle, the controller has accumulated sufficient behavioral data to precisely target the remaining material addition needed to achieve overall specifications. This progressive refinement through feedback enables consistent final products despite material variations including moisture content ranging from approximately 6 percent to 15 percent by weight, bulk density variations from approximately 0.1 to 0.8 grams per cubic centimeter, and particle size distribution differences resulting from different grinding settings or when mixing materials with different properties like cannabis and tobacco.

[0045] The adaptive control may also implement bounds checking to prevent adjustments from exceeding safe or practical limits. For example, the controller may enforce maximum and minimum values for fill height targets, compression force targets, and cycle counts, preventing the adaptive algorithm from commanding parameters that could cause equipment damage or product defects. If calculated adjustments would exceed these bounds, the controller may limit the adjustment to the boundary value and optionally alert the operator that material properties are outside the normal range.

[0046] Optionally, the adaptive control method incorporates detection of cigarette paper characteristics to determine an appropriate number of processing cycles before execution begins. Rather than using a fixed number of fill-and-pack cycles regardless of cone size, the system may detect the length of the inserted cigarette paper and calculate how many cycles are needed to achieve target fill height and density. Shorter cones may require only two or three cycles, while longer cones may require eight or ten cycles. This automatic adaptation to cone geometry prevents underfilling of large cones and overfilling of small cones, accommodating a range of product sizes without manual adjustment of settings. The combination of pre-process characterization to determine cycle count and in-process adaptation to adjust cycle parameters provides comprehensive optimization that spans the entire preparation sequence.According to an aspect of some embodiments of the present invention, integration of multiple sensing modalities provides comprehensive process monitoring that enables sophisticated control strategies. When fill-height sensing provides direct measurement of content quantity and compression force sensing provides direct measurement of packing resistance, the controller receives complementary information about different aspects of product quality. Fillheight data indicates whether sufficient material has been added, while force data indicates whether that material has been adequately compressed. The combination of these measurements enables cross-validation, where the controller can detect inconsistencies that might indicate process problems. Simultaneous monitoring of multiple parameters also enables more nuanced control decisions than would be possible with single-parameter feedback. The system can distinguish between material that reaches target height with low force, indicating loose packing that requires additional compression, and material that reaches target height with high force, indicating adequate density has been achieved. This multi-parameter approach, combined with adaptive adjustment based on observed behavior, represents a substantial advance over conventional single-parameter control systems.

[0047] According to an aspect of some embodiments of the present invention, operational timing of vibration during the filling phase rather than during the compression phase provides multiple advantages. When vibration is applied concurrently with content dispensing as material enters the cigarette paper, settling occurs in real-time rather than requiring a separate settling step after filling is complete. This concurrent operation reduces total cycle time while improving material distribution. Material that settles as it is added tends to distribute more uniformly than material that is added in loose form and then settled afterward. The continuous settling action during filling also reduces the amount of compression force required to achieve target density, as material is already partially compacted before the pushing rod contacts it. Additionally, vibration during filling helps prevent spillage that can occur when loose material overflows the cigarette paper opening, as settling creates space for additional material to be added.

[0048] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of embodiments of the invention, exemplary methods and / or materials are described below. In case of conflict, the patent specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.Implementation of the method and / or system of embodiments of the invention can involve performing or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of embodiments of the method and / or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware or by a combination thereof using an operating system.

[0049] For example, hardware for performing selected tasks according to embodiments of the invention could be implemented as a chip or a circuit. As software, selected tasks according to embodiments of the invention could be implemented as a plurality of software instructions being executed by a computer using any suitable operating system. In an exemplary embodiment of the invention, one or more tasks according to exemplary embodiments of method and / or system as described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes a volatile memory for storing instructions and / or data and / or a non-volatile storage, for example, a magnetic hard-disk and / or removable media, for storing instructions and / or data. Optionally, a network connection is provided as well. A display and / or a user input device such as a keyboard or mouse are optionally provided as well.

[0050] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0051] Some embodiments of the invention are herein described, by way of example only, with reference to the accompanying drawings. With specific reference now to the drawings in detail, it is stressed that the particulars shown are by way of example and for purposes of illustrative discussion of embodiments of the invention. In this regard, the description taken with the drawings makes apparent to those skilled in the art how embodiments of the invention may be practiced.

[0052] In the drawings:

[0053] FIG. 1A is a perspective schematic illustration of an exemplary automated cigarette preparation device, according to some embodiments of the invention;

[0054] FIG. 1B is a lateral sectional view of the device of FIG. 1A, according to some embodiments of the invention;

[0055] FIG. 1C is a perspective cut schematic illustration of the device of FIG. 1A, according to some embodiments of the invention;

[0056] FIGs. 2A-2D are exploded views of a processing unit, showing respectively a top cover, a processing element, a processing surface, and a material sweeping element, according to some embodiments of the invention;FIGs. 2E-2G are plan views showing respectively the processing element, processing surface, and material sweeping element from above, according to some embodiments of the invention;

[0057] FIG. 3A is a lateral view of the device showing a tiltable holding arrangement in a loading position, according to some embodiments of the invention;

[0058] FIGs. 3B-3C are perspective views of the tiltable holding arrangement isolated from the device, according to some embodiments of the invention;

[0059] FIGs. 4A-4B are perspective and lateral sectional views of the device showing the rail system configuration, according to some embodiments of the invention;

[0060] FIGs. 4C-4D are schematic illustrations of a precision linear rail system for the pushing rod, according to some embodiments of the invention;

[0061] FIGs. 4E-4F are schematic illustrations of a precision linear rail system for the holding arrangement, according to some embodiments of the invention; and

[0062] FIG. 5 is a flowchart illustrating a process for automated cigarette preparation, according to some embodiments of the invention;

[0063] FIGs. 6A-6C are views of an optical fill-height detection array integrated with the holding arrangement, showing respectively a perspective schematic illustration, a lateral view with optical axes between sensor pairs, and a lateral view without the axes, according to some embodiments of the invention;

[0064] FIGs. 6D-6G are views of the optical fill-height detection array without the holding arrangement, showing respectively a perspective schematic illustration, a lateral view with optical axes where the cigarette paper is empty, a lateral view with optical axes where the cigarette paper is filled, and a lateral view without the axes, according to some embodiments of the invention;

[0065] FIGs. 7A-7B are schematic illustrations of the optical fill-height detection array positioned relative to the rolled cigarette paper when in an ejection position, according to some embodiments of the invention;

[0066] FIGs. 7C-7E are schematic illustrations of the device incorporating a tilting mechanism from different viewing angles with an external housing shown, according to some embodiments of the invention;

[0067] FIGs. 7F-7G are schematic illustrations of the device incorporating the tilting mechanism from different viewing angles with the housing removed, according to some embodiments of the invention;

[0068] FIGs. 8A-8C are lateral views showing the holding arrangement in a fill position,depicting respectively the configuration with the optical array, without the optical array, and with the holding arrangement removed, according to some embodiments of the invention;

[0069] FIGs. 8D-8F are lateral views showing the holding arrangement in a tamping position, depicting respectively the configuration with the optical array, without the optical array, and with the holding arrangement removed, according to some embodiments of the invention;

[0070] FIGs. 8G-8H are lateral views showing the holding arrangement in an insert / eject position, depicting respectively the configuration with the optical array, without the optical array, and with the holding arrangement removed, according to some embodiments of the invention.

[0071] DESCRIPTION OF SPECIFIC EMBODIMENTS OF THE INVENTION

[0072] The present invention relates generally to automated preparation devices for smoking articles, and more particularly to an automated system and method for preparing cigarettes with precise control over content fill height, weight, density, and packing uniformity.

[0073] As indicated above, existing automated solutions have attempted to address challenges of a manual process for preparation of smoking articles but have limitations. Many current systems employ a multi-station approach, requiring the cigarette or pre-rolled cone to be physically transferred between different stations for grinding, filling, and packing operations. This approach increases mechanical complexity, raises the risk of material loss during transfers, and often results in inconsistent final products.

[0074] Moreover, existing automated systems typically lack real-time feedback mechanisms for monitoring and adjusting the preparation process. Without such feedback, these systems cannot adapt to variations in material properties or environmental conditions, leading to inconsistencies in the final product. Current systems often employ fixed protocols that fail to account for differences in material density, moisture content, or desired end-product specifications.

[0075] Some automated systems utilize high-speed grinding mechanisms that can generate excessive heat, potentially degrading the quality of temperature- sensitive materials. These systems may also create inconsistent particle sizes, affecting the burning characteristics and overall quality of the final product. Additionally, existing grinding mechanisms often suffer from material buildup and cleaning difficulties, requiring frequent maintenance and reducing operational efficiency.

[0076] The filling and packing process in current automated systems is commonly performed as a single-step operation, which can result in uneven density distribution throughout the cigarette. This can lead to burning issues, such as canoeing (uneven burning along one side) or plugging (overly tight packing preventing proper airflow) or under-packing the lower end (packing not tight enoughat the base of the cigarette)

[0077] Furthermore, existing automated solutions often lack precision in weight measurement, fill level and density control, leading to variations in the final product that can be particularly problematic in medical applications where precise dosing is crucial. Many systems also fail to provide adequate customization options to accommodate different material types and user preferences.

[0078] There remains a need in the art for an integrated, compact single-station solution that can precisely control all aspects of cigarette preparation while maintaining consistent quality and allowing for customization based on material properties and user preferences. Such a solution should ideally incorporate real-time feedback mechanisms, precise weight, fill level and density control, and adaptive processing protocols while minimizing material waste and maintenance requirements.

[0079] At least some embodiments of the present invention provide a significant advancement in the field of automated cigarette preparation by introducing a single- station system that eliminates the need to transfer partially prepared cigarettes between different processing stations. Unlike conventional systems that require movement between separate grinding, filling, and packing stations - a process that often results in material loss and inconsistent results - the present invention maintains the rolled cigarette paper on the same mounting throughout the entire preparation process.

[0080] At least some embodiments of the present invention have ability to perform all necessary operations - including filling, weighing, vibrating, and packing - while keeping the rolled cigarette paper within a single holding arrangement. This is achieved through a sophisticated vertical positioning system that vertically adjusts the position of the rolled cigarette paper in a single station, rather than moving the cigarette itself between stations. This approach significantly reduces the risk of material loss, maintains structural integrity of the rolled paper throughout the process, and ensures consistent, high-quality results.

[0081] At least some embodiments of the present invention integrate real-time feedback control through a sensor system that continuously monitors the amount and density of content within the rolled cigarette paper. This sensor-driven approach enables dynamic adjustments to processing parameters, including filling rate, vibration intensity or duration, and packing pressure, ensuring optimal results regardless of variations in material properties, environmental conditions or variations in cone sizes or filling weights. Unlike existing solutions that rely on predetermined settings, the present invention adapts its operation in real-time to reliably achieve precise weight and density targets.At least some embodiments of the present invention implement multi-cycle filling and packing protocols that gradually build up the desired cigarette density through carefully controlled stages. This staged approach, combined with coordinated vibration and packing operations, ensures uniform density distribution throughout the cigarette - a significant improvement over conventional single-pass filling methods that often result in uneven packing and inconsistent burning characteristics. This staged approach also minimizes material spillage.

[0082] At least some embodiments of the present invention have an integrated design, incorporating a compartment connected to a conduit feeding directly to the rolled cigarette paper, minimizing the distance material must travel during processing. This reduced travel path, combined with precise control over material flow, significantly improves efficiency while reducing waste compared to traditional multi-station systems.

[0083] At least some embodiments of the present invention have a compact footprint. By consolidating all operations into a single station while maintaining the rolled cigarette paper stationary, the system requires minimal space while delivering professional-grade results. This makes it particularly suitable for both personal use and small-scale production environments where space efficiency is crucial.

[0084] At least some embodiments of the present invention enable customization of processing parameters to accommodate different materials and user preferences while maintaining consistent quality. This flexibility, combined with the system's ability to produce precisely weighted and uniformly packed cigarettes, makes it particularly valuable for medical applications where dosing accuracy is crucial.

[0085] According to an aspect of some embodiments of the present invention, a significant advancement is achieved through a single- station design that fundamentally transforms the cigarette preparation process. Unlike conventional multi-station systems that move partially prepared cigarettes between separate grinding, filling, and packing stations, the present invention maintains the rolled cigarette paper in a single holding arrangement throughout the entire preparation process, for example such that it is filled in and vibrated in the same station without relocating from one station to another which is located in a different plane or axis. This stationary approach eliminates the need for physical transfers between stations, substantially reducing the risk of material loss and inconsistencies that typically occur during movement. This leverages a sophisticated vertical positioning system that inverts the traditional paradigm - instead of moving the cigarette between stations, the system adjusts the relative positions of processing components around the stationary rolled cigarette paper and / or changes the elevation of the rolled cigarette paper from filling in position or a vibration position to a pressure applying position and vice versa.This is accomplished through precision-controlled movements of the pushing rod and holding arrangement along carefully aligned vertical axes. The system's components, including the processing unit, material transfer mechanisms, and compression elements, are all orchestrated to operate in relation to the fixed position of the cigarette paper.

[0086] This single-station approach enables unprecedented control over the preparation process. By eliminating physical transfers, the system maintains the structural integrity of the rolled paper throughout processing while ensuring consistent material distribution. The single station approach allows for more precise sensor measurements and real-time adjustments, as the monitoring systems can maintain continuous observation without the complications introduced by movement between stations. The result is significantly improved consistency in weight, density, and packing uniformity compared to traditional multi-station systems.

[0087] Furthermore, the single- station design offers substantial practical advantages. The consolidated architecture reduces the overall mechanical complexity of the system, leading to improved reliability and reduced maintenance requirements. The elimination of transfer mechanisms and multiple processing stations results in a more compact footprint, making the system particularly suitable for both personal use and small-scale production environments where space efficiency is crucial. The simplified material flow path, from the processing compartment directly to the stationary rolled paper, minimizes opportunities for material loss while improving operational efficiency.

[0088] The described device also enables more process control through its multi-cycle preparation protocols. By maintaining the cigarette paper in a single vertically adjustable position, controlled filling, vibration, and compression cycles are implemented, each optimized through real-time sensor feedback. This level of control would be difficult to achieve in a multi-station system where material and position variations introduced during transfers would complicate precise adjustments.

[0089] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of the components and / or methods set forth in the following description and / or illustrated in the drawings and / or the Examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

[0090] Reference is now made to FIGs. 1A and 1B and 1C, which are respectively a perspective schematic illustration and a lateral schematic illustration and a perspective cut schematic illustration of an exemplary implementation of a device (100) for automated cigarette preparation in accordance with exemplary embodiments of the present invention. The device (100) comprises a compartment (110) connected to a conduit (120), where the conduit (120) has a conduit opening(122). While the opening (122) is depicted at the bottom of the conduit (120), it can be located at the lateral walls of the conduit (120).

[0091] The device includes a holding arrangement (130) configured for holding a cigarette paper (132) rolled to form a rolled cigarette paper top opening (134) and a rolled cigarette paper bottom opening (136). As used herein, 'holding arrangement' encompasses any mechanical system capable of maintaining a rolled paper in a fixed position while allowing controlled vertical movement and tilt operations for loading and unloading. The cigarette paper (132) may be a standard rolling paper, a pre-formed cone, or any suitable material for forming a smoking article. The cigarette paper (132) is rolled to form a rolled cigarette paper having a top opening (134) for receiving content and a bottom opening (136) that may optionally accommodate a filter. The holding arrangement (130) positions the rolled cigarette paper such that both openings (134, 136) are located below the bottom conduit opening (122) and are aligned around a pushing axis (A). As used herein, 'pushing axis' refers to the primary vertical axis along which compression forces are applied, with any deviation from true vertical not exceeding 0.5 degrees throughout the full range of motion. The holding arrangement (130) maybe motorized to allow rotating the rolled cigarette paper and optionally to vertically move the rolled cigarette paper.

[0092] The pushing axis (A) may serve as the primary reference axis for component alignment and movement. The holding arrangement (130) may be centered on axis A with a maximum permissible deviation of 0.5 degrees from vertical. The conduit (120) may be oriented at an angle between 30 and 60 degrees relative to axis A to optimize material flow. The rotating shaft (220) may be parallel to axis A within a tolerance of 0.2 degrees. All vertical movements of the pushing rod (140) and holding arrangement (130) occur parallel to axis A within a tolerance for example of 0.1mm per 100mm of travel.

[0093] The holding arrangement (130) may comprise a conical or annular holder designed for maintaining positional accuracy while accommodating the cigarette paper (132) in a rolled form.

[0094] In the illustrated embodiment, a pushing rod (140) is mounted for along pushing axis (A). One or more vibrators (150) are mounted to the device (100) to vibrate the rolled cigarette paper (132) and any content confined within the cigarette paper. The vibrators (150) may be electromagnetic, piezoelectric, or other suitable types capable of providing controlled vibration as described below.

[0095] One or more motors (e.g., 160, 164, 164’) are mechanically connected to actuate movement of at least one of the pushing rod (140) and the holding arrangement (130) along the pushing axis (A) and an operation of a processing unit (230) such as the rotation of a processing element of the processing unit (230) as described below for milling, grinding, granulating and / or shredding.As used herein, the term 'processing element' refers to any mechanical device capable of reducing, cutting, grinding, or otherwise manipulating material into smaller particles through mechanical action. This includes, but is not limited to, rotating blades, fixed blades, impellers, serrated elements, or combinations thereof capable of achieving particle size reduction.

[0096] As used herein, milling is a process of reducing content (such as flowers, buds, leaves or reconstituted tobacco) into smaller particles through mechanical action between two or more rotating surfaces, typically involving a combination of impact, shearing, and crushing forces to achieve a controlled particle size reduction while maintaining material consistency. As used herein, griding is a mechanical process of breaking down content into smaller particles through abrasive or crushing action between two surfaces, where at least one surface is in motion, typically resulting in a relatively fine particle size distribution with potential for variable consistency. As used herein, granulating is a process of forming cigarette content into particles of relatively uniform size and shape through mechanical reduction and / or agglomeration, involving controlled cutting or crushing followed by size classification to achieve specific particle size ranges suitable for cigarette manufacturing. As used herein, shredding is a mechanical process of cutting or tearing content (for example whole leaves or sheets) into elongated strips or strands of relatively uniform width using sharp blades or cutting elements, typically maintaining the fibrous structure of the material while achieving a specified cut width and length suitable for cigarette filling.

[0097] In an optional embodiment, a first motor (164’) controls the pushing rod (140) movement while a second motor (164) controls vertical positioning of the holding arrangement (130).

[0098] One or more sensors (170), referred to the sensor (170) are adapted for sensing an amount and / or a density uniformity of content confined by the cigarette paper between the rolled cigarette paper top opening (134) and bottom opening (136) when held by the holding arrangement (130). In one embodiment, the sensor (170) is a load cell integrated into the holding arrangement (130), though other sensing arrangements such as optical or capacitive sensors may be employed. While the weight may be determined based on reading from the sensor (170), the density uniformity maybe measured by estimating a distance between the bottom of the cigarette and the tip of the rod when a pressure applied by the rod is detected by the sensor (170). This distance can be deduced from an encoder controlling the location of the rod and / or the holding element, for instance using a controller, such as described below.

[0099] As used herein, the term 'density uniformity' refers to variations in material compaction measured at different points within the finished product. Density uniformity is consideredacceptable when the standard deviation of density measurements taken at five points along the product length is less than 5% of the mean density value."

[0100] Alternative sensor configurations may include combinations of different sensor types working in concert. Beyond the described weight sensor (170), the device may incorporate optical sensors for monitoring material distribution, capacitive sensors for density uniformity measurement, or infrared sensors for temperature monitoring during processing. Multiple sensor arrays may be positioned at different points along the processing path to provide comprehensive monitoring. Some embodiments may include ultrasonic sensors for density uniformity measurement or laser-based systems for precise position monitoring.

[0101] A controller (180) is operatively connected to control the one or more motors (164, 164’, 160) and the one or more vibrators (150) according to outputs received from the sensor (170). Optionally, the one or more vibrators (150) is a rotation mechanism rotating the rolled cigarette paper (132) around axis A. The controller (180) implements sophisticated control algorithms that dynamically adjust the operation of the motors and vibrators (150) based on real-time feedback from the sensor (170). As used herein, 'sensor feedback' refers to continuous or discrete measurements of physical parameters including, but not limited to, weight, position, force, or density, sampled at intervals not exceeding for example 100 milliseconds. The controller (180) may be implemented using a multi-tier control architecture. The controller may comprise a programmable logic controller (PLC) system. The controller may alternatively comprise an embedded control system. In one exemplary embodiment, the primary control unit comprises an industrial controller featuring a processor complemented by RAM and equipped with a solid-state drive for program and data storage. The real-time control layer may be implemented using automation software, providing deterministic control. This configuration enables precise coordination of multiple motion axes while processing sensor inputs and implementing control algorithms. As used herein, 'real-time control' means the ability to process sensor inputs and generate control outputs within a fixed time period not exceeding 100 milliseconds, with deterministic response to input changes.

[0102] Optionally, a control panel connected to the controller is mounted to provide user interface capabilities, allowing operators to input processing parameters and monitor system status through the controller (180). The control panel may include displays, buttons, switches, or other interface elements for controlling device operations. As used herein, 'processing parameters' refers to the controllable variables of the system including rotation speed, vibration frequency, compression force, and material feed rate, all of which may be adjusted during operation based on sensor inputs. Additionally or alternatively, an application may be executed on a mobile device to provide userinterface capabilities, allowing operators to input processing parameters and monitor system status through the controller (180).

[0103] In some embodiments, the compartment (110) may be configured with different geometries, including but not limited to cylindrical, rectangular, or conical shapes. The conduit (120) may incorporate various cross-sectional profiles such as circular, oval, or polygonal, optimized for different material flow characteristics. The pushing rod (140) may be implemented with different tip configurations including flat, concave, convex, or profiled surfaces to achieve specific compression patterns. The vibrators (150) may include electromagnetic, piezoelectric, eccentric rotating mass, or linear actuator mechanisms, operating independently or in coordinated patterns. The motors (160, 164, 164') may be implemented as stepper motors, servo motors, or direct drive systems with various torque and speed specifications.

[0104] During operation, content such as ground plant material is dispensed through the conduit (120) and bottom conduit opening (122) into the rolled cigarette paper (132). The sensor (170) continuously monitors the amount and / or density uniformity of content being deposited. Based on these sensor readings, the controller (180) adjusts the position of the holding arrangement (130) and / or pushing rod (140) via motors (160) while also controlling the vibration parameters of vibrators (150) to achieve optimal filling and packing of the content.

[0105] The pushing rod (140) may apply variable pressure to pack the content, with the pressure level being dynamically controlled by the controller (180) based on sensor feedback, for instance by controlling one or more of motors (164,164’) to change the distance between the tip of the rod (140) and the holding arrangement (130). Similarly, the vibrators (150) can operate at different frequencies and amplitudes as determined by the controller (180) to achieve optimal content distribution and density uniformity.

[0106] Similarly, when a rotation mechanism is used it may operate at different rotation speeds or periods as determined by the controller (180) to achieve optimal content distribution and density uniformity.

[0107] The holding arrangement (130) is designed to securely hold the rolled cigarette paper (132) while allowing for precise vertical positioning along pushing axis (A). This enables the device to optimize the filling and packing process by adjusting the relative positions of the cigarette paper openings (134, 136) relative to the bottom conduit opening (122) and pushing rod (140).

[0108] The compartment (110) and conduit (120) are configured to maintain a controlled environment for the content prior to and during dispensing. The conduit (120) is shaped and sized to facilitate smooth flow of the content while preventing clogging or uneven distribution. Thecompartment (110) maybe detachably connected to a mount so as to allow easy cleanup and maintenance by washing.

[0109] In some embodiments, the controller (180) implements multi-cycle filling and packing protocols, where the content is dispensed and packed in multiple stages with different vibration and pressure parameters at each stage. This staged approach, combined with real-time sensor feedback, enables precise control over the final density uniformity of the packed content.

[0110] Reference is now also made to FIGs. 2A-2D which are a blowup of an exemplary processing unit 230, according to some embodiments of the present invention. When such processing unit 230 is used, the compartment (110) includes a processing unit with a processing surface (212) having a compartment opening (214), optionally adapted to limit the movement of a processing element 233 which may be covered with a rounded top (229). A rotating shaft (220) extends through the compartment opening (214), with its top end being threaded to enable precise vertical adjustment. The rotating shaft (220) is mechanically connected to a processing element (233) positioned within the compartment (110).

[0111] The processing element (233) may be implemented with various blade configurations beyond the described embodiment. Alternative designs include interchangeable processing heads with different cutting patterns, adjustable blade angles, or multiple blade arrangements for specialized material processing. Some embodiments may incorporate serrated edges, cross-cutting patterns, or helical blade designs. The processing element may also be implemented as a multistage system with primary and secondary processing zones, or as a modular system allowing quick replacement of different processing configurations.

[0112] The processing element (233) may accommodate materials with sizes ranging from 0.5mm to 30mm in their initial state. For optimal processing, materials should exhibit moisture content between 6% and 15% by weight, with bulk density ranging from 0.1 g / cm3to 0.8 g / cm3. Processing rates are maintained between 0.05 and 2.0 grams per second, automatically adjusted based on material characteristics sensed during operation

[0113] A processing surface (212) is configured to define a controlled processing zone within the compartment (110), with its geometry optimized to direct processed material toward the conduit (120). The compartment opening (214) is shaped to accommodate the threaded portion of the rotating shaft (220) while maintaining proper alignment during operation.

[0114] The rotating shaft (220) may be supported by precision bearings that maintain shaft stability while allowing smooth rotation.

[0115] The mechanical connection between the rotating shaft (220) and the processing element may be accomplished through various means, such as keyed interfaces, set screws, or other suitablemechanical fastening methods that ensure reliable power transmission while allowing for easy disassembly when needed for maintenance or cleaning.

[0116] The interface between the conduit (120) and processing unit (230) is implemented through a precision-machined connection that maintains material containment while allowing for component removal for cleaning and maintenance. The interface may include sealing elements that prevent material escape while accommodating thermal expansion. The transition zone between the processing unit and conduit may maintain a constant cross-sectional area to prevent material accumulation.

[0117] When referenced together, the "processing unit (230)” may include part or all of the rotating shaft (220), and associated drive components.

[0118] In the embodiment depicted in FIG. 1C, the motor (160) is a shaft drive motor (160) is mechanically connected to drive rotation of the rotating shaft (220). This drive system includes several specialized components to ensure precise control over the shaft's rotational movement.

[0119] The shaft drive motor (160) may be mounted to a motor support bracket that maintains proper alignment with the rotating shaft (220).

[0120] Optionally, the controller (180) enables and manages alternating rotational directions of the rotating shaft (220). This system works in conjunction with the shaft drive motor (510) and controller (180) to implement bi-directional processing sequences where clockwise rotation periods (T1) alternate with counterclockwise periods (T2), with both duration and speed may independently be optimized based on real-time feedback from the sensor (170). The implementation of real-time sensor feedback enables dynamic process control with unprecedented precision. The weight sensor (170) provides continuous monitoring with accuracy for example to within 0.01 grams, while position control systems maintain spatial precision for example to within 0.05mm. This level of control ensures consistent product quality with density variations for example less than 2% across production runs, representing a significant improvement over conventional systems that may experience variations of 10% or more.

[0121] The device (100) may incorporate sealing to ensure material containment. The compartment (110) may use a dual-seal configuration with a primary elastomeric seal and secondary mechanical seal around all access points. The conduit (120) interfaces may include seals to prevent material escape while allowing necessary movement. The processing unit (230) may incorporate maintenance-free sealed bearings and shaft seals rated for continuous operation. All sealing elements may be designed for easy inspection and replacement, with visual wear indicators where applicable.As depicted in FIGs. 2A-2D, the device (100) may include a material sweeping element (225) comprising one or more pushing elements (912) specifically designed to efficiently direct processed material into the conduit (120). This sweeping system is integrated with the processing chamber to ensure consistent material flow while preventing accumulation. This sweeping system may work in coordination with the rotation, optionally the bi-directional rotation, of the shaft (220) to ensure efficient material transfer while preventing accumulation or clogging in any processing zone. As used herein, 'material transfer' refers to the controlled movement of processed material from the processing unit through the conduit into the rolled paper, maintaining consistent flow characteristics throughout the transfer path. The pushing elements may be part of a dispensing rotor designed for gentle and controlled material transfer into the bottom conduit opening (122). The dispensing rotor is engineered to maintain material integrity while ensuring consistent flow rates. FIGs. 2E-2G are plan drawings depicting respectively exemplary elements (233), (214) and (225) from above (horizontal plan).

[0122] Optionally, the processing element (233) comprises a blade (310) specifically shaped to fit against the inner side of the processing surface (212). The blade assembly (310) includes precision-engineered cutting edges (314) that maintain optimal clearance with respect to the inner surface (312) throughout their range of motion.

[0123] The blade assembly (310) may be fabricated from hardened stainless steel or other suitable materials that maintain a sharp edge while resisting wear and corrosion. The cutting edges (314) may be treated with various surface hardening processes or coatings to extend their operational life. This blade configuration works in concert with the threaded rotating shaft (220) described previously, enabling optimal material processing before delivery to the conduit (120) for dispensing into the stationary rolled cigarette paper (132).

[0124] Optionally, as shown in FIG. IB, the conduit (120) is specially adapted with a mounting configuration that encompasses both the rotating shaft (220) and the outer surface of the processing surface (212). The conduit assembly includes a shaft-surrounding portion and a surface-engaging portion that work together to create an efficient material flow path while maintaining proper alignment of system components.

[0125] Reference is now made to FIG. 3 A which depicts an exemplary holding arrangement (130) having a tiltable holding element (1210) specifically designed to facilitate easy loading and unloading of the rolled cigarette paper (132) and to FIG. 3B-3C depicting this exemplary holding arrangement (130) separately from the device (100). The tiltable mechanism enables smooth transition between operating and loading positions while maintaining precise alignment during processing.The tiltable holding element (130) includes a primary pivot assembly (1211) formed for continuous operation. The pivot assembly (1211) provides smooth rotational movement around a defined pivot axis while maintaining positional accuracy for example within ±0.02 degrees throughout its range of motion. In one embodiment, the pivot assembly utilizes paired roller bearings preloaded to eliminate mechanical play.

[0126] A counterbalance mechanism may be incorporated into the tiltable assembly (1211), comprising a gas spring calibrated to provide optimal assistance force throughout the tilting range. The counterbalance force is selected to require minimal operator effort during tilting operations while preventing uncontrolled movement under any operating condition.

[0127] The tiltable assembly, separately exemplified by FIGs. 3B and 3C, may incorporate multiple defined positions corresponding to specific operational states. A vertical processing position, depicted for example in FIGs. 1A-1C, provides precise alignment for material processing operations. An angled loading position, depicted in g. 3A-3C, optionally oriented at 45 degrees from vertical, facilitates ergonomic loading of rolled paper materials. An unloading position, which may be identical to the angled loading position or different therefrom, for instance oriented at 60 degrees from vertical, enables convenient removal of completed products.

[0128] Beyond the tiltable version described, the holding arrangement (130) may be implemented with various mechanisms including a sliding drawer configuration that moves horizontally for loading / unloading, a rotating carousel system supporting multiple cigarette papers for batch processing, or a pneumatic gripping mechanism. In some embodiments, the holding arrangement may incorporate adjustable diameter mechanisms to accommodate different cigarette paper sizes. Alternative implementations may include spring-loaded retention systems, magnetic holding mechanisms, or vacuum-assisted gripping systems. Each variation maintains precise alignment with the pushing axis while offering different advantages for specific applications. In some embodiments it can have a replicable cone holder to accommodate for different cone sizes.

[0129] With reference to FIGs. 4A-4F, the device may include a linear rail system enabling controlled vertical adjustment of the holding element (130) and / or the pushing rod (140) according to some embodiments of the present invention. Optionally, as shown separately from the other components of the device at FIGs. 4E-4F, the linear rail system comprises an elongated rail member (1312) having a precision-ground surface extending parallel to the pushing axis A. A carriage assembly (1314) is mounted on the rail member (1312) and supports the holding element, wherein the carriage assembly (1314) may include recirculating ball bearings providing smooth, low-friction movement along the rail member (1312).The precision linear rail system may be mechanically connected to actuate the holding arrangement (130) along the pushing axis towards the pushing rod (140) for adapting the density uniformity of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement.

[0130] The motor (164), used for positioning, may be operatively connected to the carriage assembly (1314) through a precision drive mechanism. The positioning motor (164) may be a servomotor providing precise position control with encoder feedback.

[0131] Position control could also be achieved by the use of a precision stepper motor.

[0132] Optionally, a linear position encoder is mounted to provide continuous position feedback to the controller (180), enabling closed-loop position control optionally with micron-level precision. In one example implementation, the linear position encoder comprises a glass scale with 1 -micron resolution.

[0133] In operation, the controller (180) commands the positioning motor (164) to move the holding element to specific vertical positions required for different processing operations. For example, during initial loading, the holding element may be moved to a height of 70mm from a reference position. During processing, the height may be adjusted to 60mm for optimal material reception, and during final packing, the height may be reduced to 30mm for proper compaction.

[0134] The holding element position may be dynamically adjusted during processing based on feedback from other system sensors.

[0135] Additionally, or alternatively, with reference to FIGs. 4C and 4D, the precision linear rail system may be mechanically connected to actuate the pushing rod (140) along the pushing axis towards the holding arrangement (130) for adapting the density uniformity of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement. The pushing rod (140) may be mechanically connected to a linear rail (1352) enabling controlled vertical adjustment of the pushing rod (140). The linear rail (1352) may have a precision-ground surface extending parallel to the pushing axis A. A carriage assembly 1354, optionally with elongated connector (1356) having a structure that may be divided to L shaped segment and L shaped segment in inverted orientation is mounted on the rail member 1312 and supports the pushing rod (140). Such a precision linear rail system is mechanically connected to actuate the pushing rod (140) along the pushing axis towards the holding arrangement (130) for adapting the density uniformity of content confined by the cigarette paper between the rolled cigarette paper topopening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement.

[0136] As used herein, the term 'content' refers to the material to be processed and packaged within the cigarette paper, which may include but is not limited to cannabis, tobacco, herbal blends, or other plant materials intended for smoking. The content may be provided in various initial forms including whole leaves, coarse pieces, or pre-ground material, and is processed to an appropriate particle size by the processing element before being dispensed into the cigarette paper.

[0137] Optionally, a linear position encoder is mounted to provide continuous position feedback to the controller (180), enabling closed-loop position control optionally with micron-level precision. In one example implementation, the linear position encoder comprises a glass scale with 1 -micron resolution.

[0138] In operation, the controller (180) commands the positioning motor to move the pushing rod (140) to specific vertical positions required for different processing operations. For example, during initial loading, the pushing rod (140) may be moved to a height of 10mm from a reference position. During processing, the height may be adjusted to 50mm for optimal material compression.

[0139] The rail member (1352) maybe shared for carrying both the carriage assembly 1354 of the rod and the carriage assembly (1314) of the holding arrangement (130) (not shown).

[0140] FIGs. 4A and 4B depict how rail member (1352) and rail member (1312) are placed to allow vertically moving both the pushing rod (140) and the holding arrangement (130) as described above, optionally in a synchronized manner.

[0141] The linear rail system provides superior mechanical advantage through its innovative design. The dual-rail configuration, incorporating both holding arrangement (130) and pushing rod (140) movement, enables precise force application while maintaining perfect alignment. This design eliminates the lateral forces and misalignments common in single-rail systems, resulting in reduced wear and extended component life expectancy by approximately 300% compared to conventional designs.

[0142] In certain embodiments, operational parameters are established within experimentally verified ranges ensuring optimal performance. The processing speed may be controlled from 5 RPM to 800 RPM, with optimal operation typically achieved between 100 RPM and 300 RPM. The vibration system operates effectively across frequencies from 2Hz to 350Hz, with preferred operational ranges between 100Hz and 220Hz for most applications. Material feed rates may be regulated between 0.01 grams per second to 1.0 grams per second, with optimal results typically achieved between 0.05 and 0.1 grams per second.According to some embodiment, operation commences with sensor calibration and a cigarette paper detection and verification phase requiring approximately 2 to 5 seconds to complete. Following verification, the initial filling and packing cycle occurs with a processing duration of 3 to 10 seconds. Material is continuously transferred to the cigarette paper. The vibration packing sequence initiates with the pushing rod descending into the cone, followed by intense vibration applied for 2 to 6 seconds. Quality verification incorporates weight measurement completed within 0.2 seconds, followed by density calculations performed in 0.1 seconds, concluding with final verification requiring approximately 1 second.

[0143] The processing element may be implemented in various configurations according to specific application requirements. One embodiment incorporates single-edge linear blades optimized for particular material types. Another embodiment utilizes multi-edge rotating assemblies providing enhanced processing efficiency. Serrated edge variants offer improved processing characteristics for certain materials, while helical cutting patterns may be employed for specialized applications. Material transport may be accomplished through gravity-fed designs, mechanical assist mechanisms, or pneumatic transfer systems depending on material properties and processing requirements. Compression may be achieved through direct linear actuators, compound lever systems, or hydraulic compression units according to force and control requirements.

[0144] In accordance with certain embodiments, the system may be implemented in various configurations offering different levels of automation and control capability. A foundational implementation incorporates essential processing elements with basic control interfaces suitable for simplified operations. Advanced implementations may incorporate multiple processing stages with automated material handling and comprehensive sensor integration providing enhanced process control. Premium configurations extend functionality through adaptive control systems, multiple product capability, and network connectivity for remote monitoring and control. Each implementation maintains fundamental processing capabilities while offering enhanced features appropriate to specific application requirements.

[0145] For example, reference is now to FIG. 5, a flowchart illustrating a process (3000) for automated cigarette preparation according to some embodiments of the present invention. The process implements initialization, calibration, and multi-cycle processing sequences through coordinated control of system components. As used herein, the term 'multi-cycle processing' refers to a sequence of distinct material addition and compression steps, where each cycle includes material addition, vibration, and compression phases, with at least two such cycles required to complete product formation.The process begins at initialization step (3010) where the controller (180) activates the tiltable holding element 1210 to execute initial positioning. At step (3012), the holding arrangement 130 moves to a loading position Pl through activation of the pivot assembly 1212. The initialization sequence executed by the controller (180) comprises several sub-phases that prepare the system for processing and characterize the inserted cigarette paper. Upon activation of the device, either through a start button on a control panel, through a sensor detecting cigarette paper insertion or through a remote application, the controller begins the initialization sequence.

[0146] A first sub-phase comprises sensor calibration and verification. If a weight sensor is integrated into the holding arrangement, the controller commands a zero-offset calibration by reading the sensor output with no cigarette paper present and storing this value as the zero reference. If an optical fill-height sensing system is present, the controller samples all detectors and stores these baseline readings as the unobstructed reference values corresponding to no cigarette paper present.

[0147] A second sub-phase comprises cigarette paper detection and characterization. For systems with an optical fill-height sensing system, the controller samples all detectors after cigarette paper insertion and compares each detector output to its baseline unobstructed value. Detectors showing minimal signal strength indicate a filter tip or material blocking the signal, while detectors showing a signal strength reduced below a threshold indicate the presence of cigarette paper at the corresponding height position. The controller counts the number of consecutive detectors showing this partially obstructed state to determine fillable cigarette paper length. For example, if detectors 1 through 3 show full obstruction, and sensors 4 through 10 show partial obstruction while detectors 11 through 16 show no obstruction, the controller determines the cigarette paper extends through 10 sensor positions, corresponding to a specific length based on known sensor spacing.

[0148] The controller also analyzes the pattern of partial obstruction for anomalies. If the partially obstructed detectors are not consecutive, indicating gaps in the cigarette paper, the controller may determine the paper is damaged and abort processing with an error message. If some detectors show full obstruction (equivalent to material-filled state) before processing has begun, the controller determines the cigarette paper contains pre-existing material and adjusts processing parameters accordingly, reducing the total material to be added.

[0149] If a weight sensor is present, the controller may measure cigarette paper weight during this initialization phase by comparing the sensor reading with cigarette paper present to the previously stored zero reference. This paper weight measurement enables more accurate material addition control, as the controller can account for the paper weight when targeting total productweight.

[0150] A third sub-phase comprises processing parameter calculation based on the characterization results. Using the determined cigarette paper length, the controller calculates an appropriate number of fill-and-pack cycles. This calculation may use a stored algorithm or lookup table that relates cigarette paper length to cycle count. For example, a short cone of 40 millimeters may require 2 cycles, a medium cone of 70 millimeters may require 4 cycles, and a long cone of 100 millimeters may require 6 cycles. The controller stores this calculated cycle count and uses it to control the subsequent processing sequence.

[0151] The controller may also calculate initial target parameters for each cycle based on the total cycles and total material to be added. If 4 cycles are planned and 1.0 gram total material is desired, the controller may initially target 0.25 grams per cycle. These initial targets serve as starting values that the adaptive control algorithm will adjust based on observed behavior during actual processing. The initialization sequence concludes with the controller moving the holding arrangement to the fill position and signaling readiness to begin processing.

[0152] Following initial positioning, the process advances to calibration sequence (3020) where the controller (180) executes weighting operations based on readings from the sensor, e.g., weight sensor (170). For example, the sensor is a load cell performing zero-offset calibration, compensating for mechanical components through strain gauge arrangement. The process may continue to verification sequence comprising multiple validation steps. The holding arrangement may be elevated until detecting contact between the rolled cigarette paper 132 and bottom conduit opening 122 based on reading from the sensor (170). The controller may evaluate contact detection, proceeding upon successful verification or branching to error handling sequence if contact is not established.

[0153] Upon successful verification, cone weight measurement is performed through the weight sensor 170. At step (3052) the pushing rod 140 descends while force feedback is monitored based on reading of readings from the sensor (170). The multi-cycle processing sequence (3060) implements three distinct filling cycles. For example, a first cycle (3062) targets a certain amount, for example 0.5 grams, utilizing milling by the processing element (230) at for example 100 RPM. Monitoring point may track material accumulation through the sensor (170). Upon reaching target weight, vibration packing sequence activates utilizing the one or more vibrators (150) and the pushing rod (140). A second cycle (3070) and a third cycle (3080) may implement similar sequences with modified parameters. The second cycle may target another amount, for example 0.8 grams, while third cycle may target final weight. Each cycle may maintain independent monitoring points and vibration sequences. Process completion sequence (3090)may execute a final validation before product release for example by controlling the tilt of the holding arrangement (130). The controller (180) may implement continuous monitoring throughout all sequences through feedback paths enabling real-time adjustment of process parameters, for example based on the described above. Reference is now also made to FIGs.

[0154] 6A-6C, which illustrate an optional fill-height sensing system, referred to herein as an optical fill-height detection array (600) that may be integrated with the holding arrangement or part thereof, for instance in two opposite sides of a conical or annular holder (601) designed for maintaining positional accuracy while accommodating the cigarette paper in a rolled form. FIG.

[0155] 6A provides a perspective schematic illustration showing the spatial arrangement of the detection system. The optical fill-height detection array (600) optionally comprises a first printed circuit board (PCB) assembly (610) and a second PCB assembly (620) positioned on opposite sides of the holding arrangement (130). The first PCB assembly (610) may support a plurality of light emitters (612), while the second PCB assembly (620) may support a corresponding plurality of light detectors (614) arranged to receive optical signals from the emitters (612). The PCB assemblies (610, 620) may be oriented substantially parallel to the pushing axis (A) described previously.

[0156] The fill-height sensing system described herein may be implemented using various sensing technologies beyond optical detection. While the illustrated embodiment employs an optical fill-height sensing system utilizing light transmission measurements, alternative implementations may use capacitive sensing, ultrasonic sensing, radar- based detection, or other technologies capable of detecting material presence at different height positions. The term ‘fill¬ height sensing system’ as used in the claims encompasses all such implementations, with the optical fill-height sensing system representing a preferred embodiment offering advantages of material -independent measurement and minimal calibration requirements.

[0157] Optionally, the light emitters (612) comprise infrared light-emitting diodes operating at a wavelength of approximately 940 nanometers, though other wavelengths within the infrared spectrum may be employed. The light detectors (614) may optionally comprise phototransistors configured to detect the infrared emissions, though other detector types such as photodiodes, photoresistors, or avalanche photodiodes may alternatively be utilized depending on sensitivity and response time requirements.

[0158] FIG. 6B presents a lateral view with optical axes (616) illustrated between each corresponding pair of light emitter (612) and light detector (614). The optical axes (616) traverse the interior volume of the holding arrangement (130) where the rolled cigarette paper (132) is positioned. The spacing between adjacent optical sensor pairs may range from approximately 3millimeters to 20 millimeters, providing resolution suitable for detecting fill height progression during operation. In the illustrated embodiment, sixteen optical sensor pairs are shown, though implementations may utilize between 3 and 30 or more pairs depending on desired resolution and cone size compatibility. The number of sensor pairs may be selected based on the range of cigarette paper sizes to be accommodated and the precision required for fill height detection.

[0159] FIG. 6C shows the same lateral view without the optical axes (616) depicted, providing clear visualization of the physical component arrangement. The first and second PCB assemblies (610, 620) may be mounted to support structures (not shown) that maintain precise alignment between corresponding emitter-detector pairs throughout device operation, ensuring that angular deviation between aligned pairs does not exceed approximately 0.5 degrees.

[0160] Reference is now made to FIGs. 6D-6G, which illustrate the optical fill-height detection array (600) in isolation from the holding arrangement (not shown). FIG. 6D provides a perspective schematic illustration showing the first PCB assembly (610) with light emitters (612) and the second PCB assembly (620) with light detectors (614) in their relative spatial arrangement. The assemblies (610, 620) are positioned to define an inspection volume (630) through which the rolled cigarette paper (132) passes during operation.

[0161] FIG. 6E presents a lateral view with optical axes (616) shown between sensor pairs, depicting a condition where the rolled cigarette paper (132) is empty. In this state, each optical axis (616) experiences partial obstruction due to the paper material alone, resulting in a first signal strength level at each detector (614). The controller (180) may be configured to recognize this first signal strength level as indicating an empty cone state at the corresponding height position.

[0162] FIG. 6F shows the same lateral view with optical axes (616), but depicting a condition where the rolled cigarette paper (132) contains material. In this filled state, optical axes (616) passing through material-occupied regions experience greater obstruction, resulting in a second signal strength level at the corresponding detectors (614) that differs measurably from the first signal strength level. The controller (180) may be configured to distinguish between at least three signal states for each detector (614): an unobstructed state indicating no cigarette paper present, a partially obstructed state indicating empty paper present, and a fully obstructed state indicating paper with material present.

[0163] FIG. 6G presents the lateral view without optical axes (616) depicted, showing the physical arrangement of components and the rolled cigarette paper (132).

[0164] Optionally, the controller (180) may be adapted to analyze the pattern of signal states across the array (600) to determine various characteristics of the rolled cigarette paper (132). Thenumber of detectors (614) showing the partially obstructed state may indicate the length of the cigarette paper, enabling automatic adaptation of processing parameters. Unusual obstruction patterns may indicate damaged or crumpled paper, allowing the controller (180) to abort processing before material is wasted. Detection of fully obstructed sensors (614) before processing begins may indicate pre-filled paper, enabling the controller (180) to adjust filling protocols accordingly.

[0165] Optionally, an ability to detect cone size automatically through counting the number of sensors showing the empty state enables the device (100) to adapt its operation without manual adjustment. The controller (180) may automatically determine the appropriate number of fillpack cycles based on detected cone length, optimizing the process for different sizes without operator intervention. Detection of pre-filled or damaged cones before processing begins prevents material waste and operational errors.

[0166] Reference is now also made to FIGs. 7A-7B, which schematically illustrate the optical fill-height detection array (600) positioned relative to the rolled cigarette paper (132) when the holding arrangement (not shown) is in an ejection position. In this configuration, the holding arrangement (not shown) is tilted by a tilting mechanism (700) described below to facilitate removal of the completed cigarette. The optical axes (616) maintain their relative orientation to the holding arrangement (130) during tilting operations. Optionally, one or more of the detectors (614) positioned near the ejection end of the holding arrangement (130) may serve as an ejection confirmation sensor, verifying that the completed cigarette has been removed before the controller (180) permits initiation of a new preparation cycle.

[0167] Reference is now also made to FIGs. 7C-7E, which present schematic illustrations of the device (100) incorporating the tilting mechanism (700) from different viewing angles, with an external housing (710) shown. The housing (710) encloses the compartment (previously depicted as 110), conduit (previously depicted as 120), holding arrangement (previously depicted as 130), pushing rod (previously depicted as 140), and tilting mechanism (700) while providing access points for loading and unloading operations. The tilting mechanism (700) enables rotation of the holding arrangement (130) between distinct indexed positions as described below. Optionally, the housing (710) may incorporate ventilation features, access panels for maintenance, and transparent windows for process observation.

[0168] As used herein, the term 'indexed positions' refers to predetermined angular positions of the holding arrangement where the positioning system is configured to stop and maintain position during processing operations. Indexed positions may be mechanically defined through detents, cam dwells, or other features that provide tactile feedback and stable positioning, or maybe electronically defined through position encoder feedback and servo control. The tilting mechanism (700) enables rotation of the holding arrangement (130) between distinct indexed positions as described below.

[0169] At least some embodiments implementing the optical detection array (600) and tilting mechanism (700) achieve improved consistency in product quality. Testing has demonstrated that fill height can be controlled to within approximately plus or minus 2 millimeters across multiple cycles, and density variations are reduced to less than approximately 5 percent compared to 10 percent or more in systems relying solely on weight measurement. The direct measurement of height eliminates errors introduced by material density variations, while force-controlled compression ensures adequate packing regardless of material characteristics.

[0170] Reference is now made to FIGs. 7F-7G, which illustrate the device (100) from different viewing angles with the housing (710) removed to reveal internal components. These views show the tilting mechanism (700) optionally comprising a pivot assembly (712) mechanically connected to the holding arrangement (130), a positioning motor (714) operatively connected to control angular position, and a cam-lever mechanism (720) for coordinating multiple functions. The pivot assembly (712) may include precision bearings that enable smooth rotation while maintaining positional accuracy. The positioning motor (714) may be a stepper motor, servo motor, or other actuator capable of precise angular positioning, and is operatively connected to the controller (180) to receive positioning commands.

[0171] The cam- lever mechanism (720) optionally includes a cam surface (722) that engages with follower elements during rotation to control additional operations including funnel door actuation and ejection sequences. Optionally, the cam surface (722) may incorporate multiple cam profiles corresponding to different indexed positions, with spring-loaded engagement mechanisms providing tactile feedback and fail-safe positioning. The mechanical coordination between tilting angle and ancillary functions ensures that operations occur in proper sequence without requiring separate control signals for each function.

[0172] Optionally, the positioning motor (714) receives control signals from the controller (180) based on the current stage of the preparation process. The controller (180) may command the positioning motor (714) to rotate the holding arrangement (130) to the fill position when material dispensing is required, to the tamping position when compression operations are to be performed, and to the ejection position when a completed cigarette is ready for removal. The controller (180) may receive position feedback from an encoder associated with the positioning motor (714) or from position sensors that detect when indexed positions are reached, enabling closed-loop position control.The cam- lever mechanism (720) may be implemented with a single cam drum or disc that rotates in coordination with the positioning system, with multiple cam profiles formed on the same rotating element to control different functions based on angular position. The cam surface (722) may include a first cam profile that controls the funnel door position, a second cam profile that controls ejection mechanism actuation, and optionally additional profiles for other coordinated functions. Each cam profile comprises a shaped surface that engages with a corresponding follower element, which may be a roller, slider, or other mechanical element that rides along the cam surface as the cam rotates.

[0173] For the funnel door control profile, the cam surface may be shaped such that the follower element is at a low position when the holding arrangement is away from the fill position, maintaining the funnel door in a closed state. As the holding arrangement rotates toward the fill position, the cam profile rises, lifting the follower element and thereby opening the funnel door through a mechanical linkage. The cam profile may include a dwell region at the fill position angle, maintaining the door in the fully open state throughout the period when the holding arrangement is positioned for filling. As the holding arrangement rotates away from the fill position toward the tamping position, the cam profile descends, allowing the follower element to lower and thereby closing the funnel door.

[0174] The ejection control profile may be positioned at a different angular location on the same cam element. This profile may remain at a low position throughout the fill and tamp positions, keeping the ejection mechanism retracted. When the holding arrangement reaches the insert-eject position, the ejection control profile includes a raised section that lifts its corresponding follower element, driving the pusher element through the holding arrangement to displace the completed cigarette. The ejection profile may include a sharp rise followed by a gradual fall, providing rapid initial ejection motion followed by controlled retraction.

[0175] Spring elements may be incorporated to maintain follower contact with cam surfaces and to provide return forces. For example, a compression spring may bias the funnel door toward the closed position, such that the funnel door automatically closes when the cam profile allows it, providing fail-safe door closure. Similarly, a spring may bias the ejection pusher toward the retracted position, with the cam profile working against this spring bias to extend the pusher during ejection. The spring-biased configuration ensures that functions return to safe states if power is lost or if the positioning system stops at an intermediate angle.

[0176] Reference is now also made to FIGs. 8A-8C, which present lateral views showing the holding arrangement (130) in a fill position. In this configuration, the holding arrangement (130) is positioned at a first angle, for example approximately 170 degrees from horizontal, such thatthe rolled cigarette paper top opening (134) is aligned below a funnel outlet (810) of the conduit (120). FIG. 8A shows the configuration with the optical fill-height detection array (600) in place, with the detectors (614) providing real-time feedback regarding fill height as material is dispensed. FIG. 8B presents the same view with the optical array (600) removed for clarity of other components. FIG. 8C shows the configuration with the holding arrangement (130) removed, revealing the funnel outlet (810) and a funnel door that controls material flow from the conduit (120).

[0177] Optionally, the funnel outlet (810) comprises a tapered transition section connecting the conduit (120) to a discharge opening. The funnel outlet (810) may be positioned at or constitute part of the bottom conduit opening (122) previously described, providing a shaped interface for directing material from the conduit into the rolled cigarette paper top opening (134) when properly positioned. In some embodiments, the bottom conduit opening (122) and funnel outlet (810) refer to the same structural feature viewed functionally, with the bottom conduit opening referring to the exit point from the conduit and the funnel outlet referring to the shaped discharge configuration at that location.

[0178] Optionally, the funnel outlet (810) comprises a tapered transition section connecting the conduit (120) to a discharge opening positioned to direct material into the rolled cigarette paper top opening (134) when the holding arrangement (130) is in the fill position. The funnel outlet (810) may be shaped to minimize material adhesion and facilitate complete material discharge. The conduit (120) may connect to the compartment (110) such that material processed by the processing element (233) is directed toward the funnel outlet (810).

[0179] The funnel door is optionally mechanically coordinated with the tilting mechanism (700) such that it opens when the holding arrangement (130) reaches the fill position and closes when the holding arrangement (130) rotates away from the fill position. This coordination may be achieved through the cam- lever mechanism (720), wherein a cam follower attached to the funnel door (812) rides along the cam surface (722), translating rotational motion of the tilting mechanism (700) into linear motion of the door (812). Optionally, the funnel door (812) may incorporate a sealing element such as an elastomeric gasket that forms an airtight seal when closed, preventing odor release and maintaining material freshness within the compartment (110).

[0180] As used herein, the term 'mechanically coordinated' refers to a configuration where two or more functions or components are linked through mechanical coupling such that motion or position of one component directly causes corresponding motion or position change of another component without requiring separate control signals or actuators for each component.Mechanical coordination may be achieved through cam mechanisms, linkage systems, gear trains, or other mechanical connections that translate motion of a driving element into coordinated motion of one or more driven elements.

[0181] Optionally, the compartment (110) may be configured as a removable cartridge assembly (830) that can be detached from the device (100) as a single unit including the processing element (233) and associated drive components. This cartridge assembly (830) may enable pre-loading with material, facilitating quick changeovers between different material types or strains. The cartridge assembly (830) may include mechanical alignment features that ensure proper positioning and sealing when installed in the device (100).

[0182] Reference is now made to FIGs. 8D-8F, which present lateral views showing the holding arrangement (130) in a tamping position. In this configuration, the holding arrangement (130) is positioned at a second angle, for example approximately 80 degrees from horizontal, such that the rolled cigarette paper (132) is substantially aligned with the pushing axis (A) and the pushing rod (140) can access the rolled cigarette paper top opening (134) for compression operations. The deviation from vertical alignment may be less than approximately 10 degrees to ensure effective compression force transmission. FIG. 8D shows the configuration with the pushing rod (140) above the rolled cigarette paper top opening (134), enabling tilting of the rolled cigarette paper before and after compression. FIG. 8E presents the same view with the rod pushed into the rolled cigarette paper via the rolled cigarette paper top opening (134). FIG. 8F shows the configuration with the holding arrangement (130) removed, revealing the path of the pushing rod (140) and its alignment with the tamping position.

[0183] Optionally, a force sensor (840) may be integrated into the pushing rod (140) or its support structure to measure compression force applied during tamping operations. The force sensor (840) may comprise a load cell, strain gauge, piezoelectric sensor, or other forcemeasuring device capable of providing real-time feedback to the controller (180). This force measurement provides direct indication of packing resistance, enabling the controller (180) to detect when target compression has been achieved regardless of material properties. The force sensor (840) may work in conjunction with the optical fill-height detection array (600) to provide dual validation of packing quality, with the optical array (600) confirming material height and the force sensor (840) confirming adequate compression.

[0184] Reference is now made to FIGs. 8G-8H, which present lateral views showing the holding arrangement (130) in an insert / eject position. In this configuration, also referred to as the ejection orientation, the holding arrangement (130) is positioned at a third angle, for example approximately 60 degrees from horizontal, oriented toward an operator access side of the device(100) to facilitate loading of rolled cigarette paper (132) and removal of completed cigarettes. FIG. 8G shows the configuration with the tilting mechanism parts in place, which may serve to verify complete ejection before permitting a new cycle. FIG. 8H presents the same view with the tilting

[0185] Optionally, the ejection mechanism (820) may comprise a pusher element that travels along the interior of the holding arrangement (130) to displace the completed cigarette toward the open end. The ejection mechanism (820) may be actuated by various means. In one embodiment, the cam-lever mechanism (720) may include a cam profile that drives a lever arm connected to the pusher element, translating rotational motion of the tilting mechanism (700) into linear ejection motion. In another embodiment, a separate linear actuator such as a solenoid, pneumatic cylinder, or motor-driven lead screw may drive the pusher element. In yet another embodiment, a spring-loaded pusher may be cocked during loading and released during ejection. The ejection force may be calibrated to reliably displace completed cigarettes without causing damage, typically in the range of approximately 0.5 to 5 Newtons depending on cigarette size and packing density.

[0186] Optionally, the one or more vibrators (150) described previously may be mounted to vibrate the holding arrangement (130) rather than operating as separate elements. The vibrators (150) may be active during material dispensing operations when the holding arrangement (130) is in the fill position, causing material to settle as it enters the rolled cigarette paper (132). This concurrent vibration during filling may reduce spillage and improve packing efficiency. The vibrators (150) may operate at frequencies between approximately 100 and 300 Hertz during filling operations. Optionally, the vibrators (150) may be inactive or operate at reduced intensity during compression operations to prevent material displacement by the pushing rod (140).

[0187] The integration of the optical fill-height detection array (600) with the tilting mechanism (700) provides several technical advantages in at least some embodiments of the present invention. The optical sensing approach directly measures the parameter of interest, which is fill height, rather than using weight as a proxy measurement. This direct measurement is substantially independent of material properties such as moisture content and density, which can vary significantly between different materials and even between batches of the same material. The optical system requires minimal calibration compared to weight-based systems, as it relies on detecting the presence or absence of obstruction rather than measuring absolute force values that can drift over time due to mechanical wear or environmental factors.

[0188] The tilting multi-position system provides significant advantages over the single-position approach in at least some embodiments. By separating the material path from the compressionpath through angular positioning, the design eliminates the shared conduit that was prone to clogging from resinous material buildup. The direct drop from the processing unit (230) to the cigarette paper when in fill position minimizes material adhesion surfaces and travel distance. The separate access for the pushing rod (140) when the holding arrangement (130) is in tamping position eliminates the need for a rod to pass through the material conduit, simplifying sealing and preventing material infiltration into internal mechanisms.

[0189] As used herein, the term 'content delivery path' refers to the route traveled by processed material from the processing element through the conduit to the rolled cigarette paper, while the term 'compression path’ refers to the route traveled by the pushing rod when advancing to apply compression force to material within the rolled cigarette paper. The multi- position configuration achieves separation of these paths by orienting the holding arrangement differently for filling versus compression operations, such that the content delivery path extends from the conduit outlet downward into the cigarette paper when in the fill position, while the compression path extends from the pushing rod downward along the pushing axis when the holding arrangement is in the tamping position.

[0190] The coordination of the funnel door (812) with the tilting position through the cam-lever mechanism (720) ensures that material can only exit the compartment (110) when a cigarette paper is properly positioned to receive it, preventing spills. The sealed compartment configuration when the door (812) is closed contains odors and maintains material freshness, addressing consumer preferences for discreet operation and multi-day material storage.

[0191] The use of a single positioning motor (714) to control multiple functions through the cam- lever mechanism (720) reduces system complexity and cost compared to using separate actuators for tilting, door operation, and ejection. The mechanical coordination ensures proper sequencing of operations without requiring complex control logic or multiple sensors to verify each function. Spring-loaded cam engagement provides inherent positioning accuracy and failsafe door closure in the event of power loss.

[0192] The force sensor (840) on the pushing rod (140) enables force-controlled compression that automatically adapts to material characteristics. Materials that compact easily will reach target force at greater compression distances, while materials that resist compaction will reach target force sooner. This force-based control works synergistically with the optical height detection to provide comprehensive process monitoring, with the optical system confirming that material has been added and the force sensor confirming that adequate compression has been achieved.The optional removable cartridge assembly (830) enables commercial applications beyond personal use. Pre-loaded cartridges with different materials can be swapped quickly without tools, enabling efficient changeovers for users who prefer different materials or blends. For commercial or medical applications, cartridges may be pre-loaded by a supplier and sealed to ensure material authenticity and freshness. Disposable cartridges with integrated grinding elements eliminate cleaning requirements for commercial applications where hygiene and contamination prevention are paramount.

[0193] The system responds dynamically to the specific characteristics of each cigarette being prepared. If optical sensors (614) indicate that material is settling significantly during initial filling, the controller (180) may increase the fill height target for subsequent cycles to compensate. If the force sensor (840) indicates that material is packing more densely than expected, the controller (180) may reduce subsequent fill quantities to avoid over-packing. This adaptive behavior, implemented through the controller (180) analyzing feedback from multiple sensor types across multiple cycles, enables consistent results despite variations in material moisture content, particle size distribution, and other properties that affect packing behavior.

[0194] The reduction in cycle time achieved through concurrent vibration during filling, combined with the elimination of material transfer losses due to the direct drop configuration, improves overall throughput. Typical preparation cycles may be reduced from approximately 90 seconds to 45 seconds or less while maintaining or improving quality consistency. The elimination of frequent cleaning requirements through the separated material paths and sealed compartment design further improves effective throughput in practical applications.

[0195] The controller (180) coordinates vibration timing with both the dispensing operations and the positioning system state. When the holding arrangement is in the fill position and material dispensing is active, the controller commands the one or more vibrators (150) to operate at a predetermined frequency and amplitude suitable for settling. The vibration activation may be synchronized with the start of material dispensing, beginning within approximately 100 milliseconds of when the processing element begins delivering material to the conduit. This concurrent activation ensures that material experiences vibrational settling from the moment it enters the cigarette paper.

[0196] The controller may modulate vibration parameters during the filling phase based on realtime feedback. For example, if the fill-height sensing system indicates that material is accumulating faster than expected, suggesting bridging or clumping, the controller may temporarily increase vibration frequency or amplitude to break up the accumulation. If fill height is progressing steadily, the controller may maintain constant vibration parameters. The controllermonitors the dispensing operation and commands vibration cessation when dispensing stops, ensuring vibration operates only when material is present to be settled.

[0197] When the controller commands the positioning system to move the holding arrangement from the fill position to the tamping position, the controller also commands the vibrators to cease operation or reduce to minimal amplitude. This deactivation prevents material from being displaced or ejected when the pushing rod enters the cigarette paper and begins applying compression force. The timing of vibration deactivation may be coordinated with the positioning motor movement. In one implementation, the controller commands vibration cessation when the positioning motor begins rotation away from the fill position. In another implementation, the controller maintains vibration until the holding arrangement has rotated past a threshold angle, for example 10 degrees from the fill position, ensuring any residual material in the conduit is fully settled before vibration stops.

[0198] During the tamping phase when the pushing rod is applying compression, the controller maintains vibration in the inactive state or at very low amplitude. Low-amplitude vibration, if employed during compression, may facilitate material flow within the cigarette paper to achieve uniform density, but must be carefully controlled to prevent upward displacement of material around the pushing rod. The controller may monitor the compression force sensor output during any compression-phase vibration, and if force decreases unexpectedly indicating loss of material contact, the controller immediately ceases all vibration to prevent material ejection.4

[0199] After compression completes and the pushing rod retracts, the controller may optionally apply a brief settling vibration pulse, for example 1 second at moderate amplitude, to allow any material disturbed by rod retraction to resettle. This post-compression vibration is brief and optional, used primarily when sensor feedback indicates non-uniform density or when material properties suggest a tendency to cling to the pushing rod.

[0200] Embodiments described above provide technical advantages in several key areas. Notably, the single- station design eliminates transfer operations between processing stages, thereby significantly reducing material loss and improving operational efficiency. By not moving the rolled cigarette paper between stations throughout the entire preparation process, the system achieves better material utilization efficiency compared to typical multi-station systems that may experience 10-15% material loss during transfers. Multi-cycle filling and packing also minimize overflow during filling. The multi-cycle filling and packing protocols implemented through the controller (180) optimize material distribution and density control. This staged approach, with specifically timed vibration and compression sequences, achieves controlled density distribution that conventional single-pass systems cannot match.Production cycle times are reduced by approximately 40% while maintaining higher quality standards, resulting in significant operational cost savings.

[0201] The modular design approach significantly reduces maintenance time and improves system reliability. Quick-access panels and tool-free component removal enable routine maintenance to be completed in less than 2 minutes, compared to 10 minutes or more required for conventional systems. Mean time between failures (MTBF) is increased by approximately 200% due to the realtime sensing capabilities, reduced mechanical stress and improved component design.

[0202] The following example illustrates the operation of device (100) according to some embodiments of the present invention. This example is provided for illustration purposes and is not intended to be limiting.

[0203] An operator places raw material into the compartment (110), and inserts a standard rolling paper into the holding arrangement (130), which is configured to maintain the paper in a rolled cylindrical form with a top opening (134) and bottom opening (136) and oriented at approximately 45 degrees from vertical for ergonomic access.

[0204] The operator initiates the preparation process by activating the device (100) through the control panel connected to controller (180). The controller (180) executes initialization protocols, including initial sensor calibration and moving the holding arrangement (130) to a vertical operating position precisely aligned with pushing axis (A).

[0205] The controller (180) executes a calibration sequence, including verifying the presence of rolled cigarette paper, centering the rolled cigarette paper in the cone holder, detecting the length and weight of the rolled cigarette paper, and verifying the rolled cigarette paper’s structural integrity. The holding arrangement (130) positions the rolled paper precisely below the conduit opening (122).

[0206] The controller (180) activates the processing unit (230), beginning with an a first cycle, initial grinding and filling cycle (3062): The rotating shaft (220) drives the processing element (233) in a bidirectional pattern, alternating between clockwise rotation periods (T1) and counterclockwise periods (T2). The material sweeping element (225) coordinates with this rotation to guide processed material toward the conduit (120).

[0207] During this phase, the controller (180) continuously monitors processing parameters through sensor feedback, adjusting rotation speed and direction to precisely fill the cone up to a desired weight, targeting approximately 0.5 grams. The pushing elements (912) of the material sweeping element (225) ensure consistent material flow while preventing accumulation.- The pushing rod (140) applies gentle initial compression (e.g., 2N force), then the vibrators (150) activate at a high frequency (e.g., 60Hz) for a long duration (e.g. 6 seconds) to ensure even initial distribution.

[0208] Second Cycle (3070):

[0209] - Additional material is processed and dispensed to reach approximately 0.8 grams total

[0210] - The pushing rod (140) applies moderate compression (e.g., 3N force)

[0211] - Vibration initiates at a reduced frequency to a medium frequency (e.g., 40Hz) for a short duration (e.g. 4 seconds)

[0212] - The controller (180) verifies density uniformity through sensor feedback

[0213] Third Cycle (3080):

[0214] - Final material processing and dispensing to achieve target weight

[0215] - The pushing rod (140) applies firm final compression (e.g., 5N force)

[0216] - Vibration initiates at a low frequency (e.g., 20Hz) for a short duration (e.g. 4 seconds)-Comprehensive density uniformity verification through multiple sensor measurements Throughout the process, the controller (180) implements continuous adaptive control based on one or more of following sensor feedbacks:

[0217] - Weight sensor (170) monitors material accumulation with 0.01g precision

[0218] - The pushing rod (140) position is tracked with 0.05mm accuracy

[0219] - Vibration patterns adjust based on density measurements

[0220] - Processing parameters modify in response to material properties

[0221] If measurements indicate deviation from target specifications, the controller (180) automatically adjusts one or more of:

[0222] - Processing intensity through rotation speed modification

[0223] - Material feed rate through dispensing control

[0224] - Vibration parameters for optimal distribution

[0225] - Compression force through pushing rod position adjustment

[0226] Upon achieving target weight and density specifications, the controller (180) initiates the one or more of the following completion sequences:

[0227] - Final compression holds for stabilization

[0228] - Verification of all quality parameters

[0229] - Return of pushing rod (140) to home position

[0230] - Movement of holding arrangement (130) to unloading positionThe holding arrangement (130) may tilt to the unloading angle (e.g., 60 degrees from vertical), allowing the operator to remove the completed product. The controller (180) records all processing parameters for quality tracking and system optimization.

[0231] It is expected that during the life of a patent maturing from this application many relevant devices and units will be developed and the scope of the term a controller, a sensor and a processing unit is intended to include all such new technologies a priori.

[0232] As used herein, the term "about" refers to different ranges depending on the parameter being measured. For dimensional measurements of major components (compartment, conduit, holding arrangement), "about" means within ±5% of the specified value. For operational parameters (rotation speed, vibration frequency), "about" means within ±10%. For measured quantities (weight, density), "about" means within ±2%. For timing parameters, "about" means within ±15%. For angular measurements, "about" means within ±3 degrees.

[0233] The terms "comprises", "comprising", "includes", "including", “having” and their conjugates mean "including but not limited to".

[0234] The term “consisting of’ means “including and limited to”.

[0235] The term "consisting essentially of" means that the composition, method or structure may include additional ingredients, steps and / or parts, but only if the additional ingredients, steps and / or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.

[0236] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination or as suitable in any other described embodiment of the invention. Certain features described in the context of various embodiments are not to be considered essential features of those embodiments, unless the embodiment is inoperative without those elements.

[0237] Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications and variations that fall within the spirit and broad scope of the appended claims.

[0238] It is the intent of the Applicant(s) that all publications, patents and patent applications referred to in this specification are to be incorporated in their entirety by reference into the specification, as if each individual publication, patent or patent application was specifically and individually noted when referenced that it is to be incorporated herein by reference. In addition,citation or identification of any reference in this application shall not be construed as an admission that such reference is available as prior art to the present invention. To the extent that section headings are used, they should not be construed as necessarily limiting. In addition, any priority document(s) of this application is / are hereby incorporated herein by reference in its / their entirety.

Claims

WHAT IS CLAIMED IS:

1. A device for automated cigarette preparation, comprising:a compartment connected to a conduit having a conduit opening;a holding arrangement configured for holding a cigarette paper rolled to form a rolled cigarette paper top opening and a rolled cigarette paper bottom opening, below the conduit opening;a pushing rod;one or more vibrators mounted to vibrate the cigarette paper and the content confined by the cigarette paper;one or more motors mechanically connected to actuate at least one of the pushing rod and the holding arrangement along a pushing axis;a sensor adapted for sensing at least one of an amount and a density uniformity of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement; a controller adapted to control the one or more motors and the one or more vibrators according to outputs of the sensor.

2. The device of claim 1, wherein the device is a single-station device for automated cigarette preparation, wherein the rolled cigarette paper remains stationary during preparation operations.

3. The device of claim 1, wherein the holding arrangement configured for maintaining the cigarette paper in a fixed position throughout preparation operations.

4. The device of claim 1, wherein the pushing axis maintains a vertical alignment within 0.5 degrees throughout operation.

5. The device of claim 1, wherein the compartment having a processing surface with a compartment opening; wherein the device further comprising a rotating shaft having a top end threaded via the compartment opening and mechanically connected to a processing element.

6. The device of claim 5, wherein the conduit is adapted to be mounted around at least some of the rotating shaft and an outer surface of the processing surface.

7. The device of claim 1, wherein the processing element is an impeller.

8. The device of claim 1, wherein the compartment comprises:- a processing surface with a compartment opening;- a bidirectional rotating shaft extending through the compartment opening;- a processing element mechanically connected to the rotating shaft;- wherein the controller is adapted to alternate the rotating shaft between clockwise and counterclockwise rotations based on sensor feedback.

9. The device of claim 5, further comprising one or more pushing elements mounted to sweep ground material into the conduit.

10. The device of claim 9, wherein the one or more pushing elements comprise a dispensing rotor mounted to sweep the content into the conduit opening.

11. The device of claim 10, wherein the dispensing rotor is mounted on a rotating shaft mechanically connected to a processing element mounted to process the content in the compartment.

12. The device of claim 1, wherein the holding arrangement comprises at least one holding element which is tiltable for facilitating loading and unloading of the cigarette paper in a rolled configuration.

13. The device of claim 1, wherein the holding arrangement comprises at least one holding element which is vertically adjustable along a motorized linear rail.

14. The device of claim 1, wherein the holding arrangement is configured to move along the pushing axis to adjust a vertical position of the rolled cigarette paper for different stages of preparation.

15. The device of claim 1, wherein the holding arrangement is configured to press the rolled cigarette paper against the conduit opening during a stage of content packing.

16. The device of claim 1, wherein the sensor is a weight sensor integrated into the holding arrangement for sensing at least one of the amounts and the density of the content confined within the rolled cigarette paper.

17. The device of claim 16, wherein the weight sensor is a load cell.

18. The device of claim 1, wherein the controller is further adapted to implement multicycle filling and packing protocols, dynamically adjusting filling rate, vibration intensity, and pushing rod pressure based on real-time feedback from the sensor.

19. The device of claim 2, wherein the controller is further adapted to dynamically adjust processing intensity performed using the processing element based on real-time feedback from the sensor.

20. The device of claim 1, wherein the controller is further adapted to implement customizable protocols for different types of content to be confined within the rolled cigarette paper.

21. The device of claim 1, wherein the controller is further adapted to implement two or more of: multi-cycle filling and packing protocols, dynamically adjusting filling rate, vibration intensity, milling intensity, and pushing rod pressure based on real-time feedback from the sensor.

22. The device of claim 1, wherein the controller is further adapted to instruct the one or more motors to implement a multi-cycle protocol comprising:a first cycle of dispensing a portion of the content and applying high-intensity vibrations; a second cycle of dispensing additional content and applying gentle pressure with the pushing rod; anda third cycle of dispensing remaining content to reach a target weight and applying firm pressure with the pushing rod.

23. The device of claim 1, wherein the controller is adapted to control the one or more vibrators according to the outputs of the sensor.

24. The device of claim 1, wherein the one or more vibrators comprise at least one of: an electromagnetic vibrator, an eccentric rotating mass (ERM) vibrator, a piezoelectric vibrator, a linear actuator vibrator, a multi-axis vibration generator, a variable frequency vibrator, or a pulsed vibration generator.

25. The device of claim 2, wherein the rotating shaft and the pushing axis are parallel to each other.

26. The device of claim 1, further comprising a housing, wherein the milling compartment, the conduit, the holding arrangement, the pushing rod, and the sensor are integrated within the housing.

27. The device of claim 1, further comprising a linear rail system including:an elongated rail member having a precision-ground surface extending parallel to the pushing axis;a carriage assembly mounted on the rail member;a linear position encoder providing continuous position feedback with micron-level precision.

28. The device of claim 1, wherein the controller is adapted to:determine a number of fill-and-pack cycles based on at least one measured parameter of the rolled cigarette paper;implement a multi-cycle preparation protocol comprising the determined number of cycles;dynamically adjust processing targets for each cycle based on observed material behavior during previous cycles; wherein the number of cycles is determined based on detected cigarette paper length.

29. The device of claim 28, wherein the controller is further adapted to:monitor at least one process parameter during each cycle comprising at least one of fill height rate, compression force buildup rate, and material settling rate;calculate behavioral characteristics of the material based on the monitored parameters; adjust at least one of fill quantity targets, compression force targets, and vibration parameters for subsequent cycles based on the calculated behavioral characteristics.

30. The device of claim 1, wherein the controller implements adaptive processing comprising one or more of:real-time adjustment of processing parameters based on material properties; dynamic modification of vibration patterns;automated density distribution optimization;continuous uniformity verification.

31. The device of claim 1, further comprising a fill-height sensing system adapted for directly detecting a height of content within the rolled cigarette paper during filling operations, wherein the controller is adapted to control at least one of content dispensing and compression operations based on detected fill height.

32. The device of claim 31, wherein the fill-height sensing system is adapted to detect at least three distinct states at each height position comprising:an unobstructed state indicating no cigarette paper present;a partially obstructed state indicating empty cigarette paper present; anda fully obstructed state indicating cigarette paper containing material present.

33. The device of claim 1, further comprising a fill-height sensing system comprising a plurality of sensors arranged at different height positions along the holding arrangement, each sensor adapted to detect presence or absence of content at a corresponding height position, wherein the controller is adapted to control content dispensing based on outputs from the plurality of sensors.

34. The device of claim 2, wherein the controller is adapted to control content dispensing based on a determination whether the holding arrangement is at least partly obstructed or not, the determination is calculated based on readings of the plurality of sensors.

35. The device of claim 1, further comprising a fill-height sensing system comprising a plurality of sensors arranged at different height positions along the holding arrangement.

36. The device of claim 1, further comprising a fill-height sensing system comprising a plurality of sensors arranged at different height positions along the holding arrangement.

37. The device of claim 36, wherein the controller is adapted to:determine at least one characteristic of the rolled cigarette paper based on a pattern of sensor outputs across the plurality of sensors before content dispensing begins, and / or determine at least one characteristic selected from a length of the rolled cigarette paper, a presence of damage to the rolled cigarette paper, and a presence of pre-existing content within the rolled cigarette paper based on sensor outputs, and to adapt processing parameters based on the determined characteristic.

38. The device of claim 1, further comprising an optical fill-height sensing system comprising a plurality of optical sensor pairs arranged at different height positions along the holding arrangement, each optical sensor pair comprising a light emitter positioned on a first side of the holding arrangement and a light detector positioned on a second side of the holding arrangement opposite the first side, wherein light emitters and light detectors define optical axes that traverse an interior volume of the holding arrangement, and wherein the controller is adapted to determine fill height based on signal strength levels received from the light detectors.

39. The device of claim 37, wherein the plurality of optical sensor pairs comprising between 3 and 30 optical sensor pairs arranged along the holding arrangement with spacing between adjacent pairs ranging from 2 millimeters to 25 millimeters.

40. The device of claim 1, further comprising a positioning system adapted to rotate the holding arrangement about a pivot axis between at least two distinct angular positions comprising a first position where the rolled cigarette paper receives content from the conduit and a second position where the rolled cigarette paper is aligned with the pushing axis for compression by the pushing rod.

41. The device of claim 1, further comprising a positioning system adapted to move the holding arrangement between at least three distinct positions comprising a first position where the rolled cigarette paper is positioned to receive content through the conduit, a second position where the rolled cigarette paper is aligned for compression by the pushing rod, and a third position oriented to facilitate insertion and removal of the rolled cigarette paper.

42. The device of claim 1, further comprising a positioning system adapted to rotate the holdingarrangement between at least three distinct angular positions comprising a fill position at a first angle from horizontal where the rolled cigarette paper receives content, a tamping position at a second angle from horizontal substantially aligned with the pushing axis where compression is applied, and an insert-eject position at a third angle from horizontal oriented toward an operator access side of the device.

43. The device of claim 1, further comprising a positioning system mechanically connected to the holding arrangement, and a flow control element positioned to control material flow from the conduit, wherein the flow control element is mechanically coordinated with the positioning system such that material flow is permitted when the holding arrangement is in a first position for receiving content and blocked when the holding arrangement is moved away from the first position.

44. The device of claim 1, wherein the compartment is configured to be removable from the device as a removable cartridge assembly comprising the processing element and associated drive components, wherein the removable cartridge assembly includes mechanical alignment features that ensure proper positioning when installed in the device.

45. The device of claim 1, further comprising a compression force sensor adapted to measure force applied by the pushing rod during compression operations, wherein the controller is adapted to control compression based on measured force and to terminate compression when measured force reaches a target value.

46. The device of claim 1, further comprising a fill-height sensing system adapted to detect height of content within the rolled cigarette paper and a compression force sensor adapted to measure force applied during compression, wherein the controller is adapted to validate packing quality using both fill height information from the fill-height sensing system and force information from the compression force sensor.

47. The device of claim 1, further comprising an optical fill-height sensing system comprising a plurality of optical sensor pairs arranged at different height positions along the holding arrangement, and a compression force sensor integrated into the pushing rod, wherein the controller is adapted to cross-validate packing quality by comparing fill height data from the optical fill-height sensing system with compression force data from the compression force sensor.

48. The device of claim 1, further comprising an ejection system adapted to displace a completed cigarette from the holding arrangement, and a positioning system adapted to move the holding arrangement to an ejection orientation, wherein the ejection system is mechanically coordinated with the positioning system.

49. The device of claim 1, further comprising a positioning system adapted to move the holding arrangement between processing and ejection orientations, and an ejection mechanism comprising a pusher element that travels along an interior of the holding arrangement to displace completed cigarettes toward an open end, wherein the ejection mechanism is actuated by at least one of a cam-lever mechanism that translates rotational motion of the positioning system into linear ejection motion, a linear actuator, or a spring-loaded pusher.

50. A method for automated cigarette preparation, comprising:providing a device comprising:a compartment connected to a conduit having a conduit opening,a holding arrangement configured for holding a cigarette paper rolled to form a rolled cigarette paper top opening and a rolled cigarette paper bottom opening below the conduit opening and around a pushing axis,a pushing rod,one or more vibrators mounted to vibrate the cigarette paper and content confined by the cigarette paper, one or more motors mechanically connected to actuate at least one of the pushing rod and the holding arrangement along a pushing axis,a sensor adapted for sensing at least one of an amount and a density of content confined by the cigarette paper between the rolled cigarette paper top opening and the rolled cigarette paper bottom opening when the cigarette paper is held by the holding arrangement, anda controller adapted to control the one or more motors and the one or more vibrators according to outputs of the sensor; executing on the controller a code for:controlling transfer of content through the conduit into the rolled cigarette paper; sensing, using the sensor, at least one of an amount and a density of content confined within the rolled cigarette paper;controlling the one or more motors for adjusting the position of at least one of the holding arrangement and the pushing rod along the pushing axis for packing the content;controlling the one or more vibrators to vibrate the cigarette paper and the confined content;dynamically adjusting at least one of the content transfer, vibration, and packing based on real-time feedback from the sensor for producing a cigarette filled and packed with the content without removing the cigarette paper from the holding arrangement.

51. The method of claim 50, further comprising directly detecting a height of content within the rolled cigarette paper during filling using a sensing system comprising a plurality of sensors arranged to monitor multiple height positions along the rolled cigarette paper, and controlling at least one of content transfer and packing based on detected height.

52. The method of claim 50, further comprising determining at least one characteristic selected from length, damage, and pre-existing content of the rolled cigarette paper by analyzing a pattern of sensor outputs from a fill-height sensing system before content transfer begins, and adapting processing parameters based on the determined characteristic.

53. The method of claim 50, further comprising moving the holding arrangement between at least two distinct positions comprising a first position where the rolled cigarette paper receives content through a path from the conduit and a second position where compression is applied along the pushing axis, wherein the first position and second position are configured such that the content delivery path is separated from a compression path.

54. The method of claim 50, further comprising rotating the holding arrangement between a fill position where the rolled cigarette paper is positioned below a funnel outlet of the conduit, a tamping position where the rolled cigarette paper is substantially aligned with the pushing axis, and an insert-eject position oriented toward an operator access side, and mechanically coordinating opening of a flow control element with positioning in the fill position and closing of the flow control element with movement away from the fill position.

Images