Aligning Device for Rod-Like Articles in Tobacco Trays
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Solution Overview
Problem
Current methods in the tobacco industry fail to simultaneously verify and correct the positioning of rod-like articles in trays and intermediate stores, leading to jamming and distorted arrangements that disrupt the production process.
Innovation Solution
A method and device utilizing sensors to verify the correct positioning of rod-like articles, with an aligning device that levels the plane of end faces, ensuring proper filling and arrangement by detecting irregularities and interrupting the process when errors are found.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are used to verify the positioning of rod-like articles, then the detection of incorrect filling and arrangement is improved, but the device complexity increases
Solution Approach 1:
The patent combines the verification function (sensors) and the correction function (aligning device) into a single integrated system. The aligning device includes both sensing elements that detect positioning errors and actuating elements that correct them, merging what would otherwise be separate systems into one unified apparatus that simultaneously verifies and corrects article positioning in trays.
Solution Approach 2:
The aligning device is designed to perform multiple functions: it verifies positioning through sensors, corrects positioning through aligning elements, and can operate on both filling and emptying sides of the production line. This multi-functional design reduces the need for separate dedicated systems for each function, thereby managing complexity while improving measurement and correction capabilities.
2Manufacturing precision
If an aligning device is added to correct article positioning, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The aligning device performs correction actions in advance, during the filling or emptying process itself, rather than allowing mispositioned articles to proceed through the system. By detecting and correcting positioning errors at the point of occurrence (using sensors and aligning elements positioned within the tray handling system), the device prevents defective articles from being produced, improving manufacturing precision without requiring complex post-processing systems.
Solution Approach 2:
The aligning device is designed to automatically detect and correct its own positioning errors without external intervention. The sensors monitor the position of rod-like articles, and when mispositioning is detected, the aligning elements automatically adjust the article positions within the tray. This self-correcting mechanism improves manufacturing precision while minimizing the need for complex external control systems.
3Reliability
If the production process is interrupted to remove irregularities, then the reliability is improved, but the productivity decreases
Solution Approach 1:
The sensors in the aligning device provide real-time feedback on article positioning status during the filling or emptying process. When mispositioned articles are detected, the system immediately corrects them through the aligning elements, creating a closed-loop feedback system. This continuous monitoring and immediate correction eliminates the need to interrupt production for quality checks, thereby maintaining both high reliability (through continuous verification) and high productivity (through uninterrupted operation).
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures uninterrupted unloading and reduces the number of defective trays by aligning the articles correctly, maintaining production flow and output in high-speed tobacco production lines.
Implementation Method 1
a verification of positioning of the articles is effected by means of sensors
Implementation Method 2
an improvement of positioning of the articles is effected by aligning the plane of end faces of the articles correctly filling the inside of the tray or the intermediate store
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A method, where a verification of positioning of articles (3) is effected by means of sensors (14), and an improvement of positioning is effected by aligning a plane of end faces of the articles (3), consists in that the verification and improvement of positioning of rod-like articles (3) is effected simultaneously by means of an aligning device (1) provided with sensors (14), where the sensors (14) detect correct filling and/or arrangement of the articles (3), and the aligning device (1) aligns the plane of end faces of the articles (3) correctly filling the inside of a tray (6, 6') or an intermediate store (7,7'), and in the event of detection of incorrect filling and/or arrangement the aligning device (1) is switched off and the operation of the entire unit is interrupted. An apparatus for using the method has an aligning device (1) in the form of a plate (2) coming in contact with end faces of the articles (3), provided with at least one sensor (14) for the control of filling of the tray (6, 6') or the intermediate store (7, 7'). The plate (2) consists of multiple pushers (4) whose number corresponds to the number of segments (5) of a multi-segment tray (6) or intermediate store (7), and a gap (8) between the pushers (4) corresponds to the thickness of a partition (9) between the segments (5), where on each pusher (4) one sensor (14) is situated. The sensors (14) may constitute an optical element operating in the range of visible or invisible radiation, or an ultrasonic element, respectively. Between the pushers (4), movable gates (11) eliminating the gap (8) in the event of using conventional trays (6') or intermediate stores (7') with one compartment are situated.