Bellows Folding Drum for High-Precision Tubular Filter Insertion
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Solution Overview
Problem
Existing manufacturing machines for tubular elements with filters struggle to achieve high productivity and quality standards while being economical and easy to operate, particularly in the production of truncated cone-shaped filters for cigarettes.
Innovation Solution
A manufacturing machine with an intermittent conveyor system, an inserting device with a tubular body and gripper mechanism, and a folding drum with holding heads, which efficiently folds and inserts filters into tubular elements, ensuring gentle handling of card stock sheets to maintain shape and position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional continuous conveyor system is used, then productivity is reduced, but manufacturing precision and quality control are improved
Solution Approach 1:
The patent employs an intermittent conveyor system that alternates between movement phases and stopping phases. During movement, filters are transported along the folding path; during stopping phases, folding operations are performed with precise positioning. This periodic action enables both high productivity through continuous cycling and high manufacturing precision through controlled stopping points for accurate folding operations.
2Manufacturing precision
If complex manual folding operations are used, then manufacturing precision is improved, but device complexity and ease of manufacture are worsened
Solution Approach 1:
The folding mechanism is designed to automatically perform bellows-folding of the inner portion of card stock sheets without requiring complex manual operations. The system uses self-contained folding stations with integrated guides and actuators that automatically fold the material as it passes through, eliminating the need for complex manual intervention while maintaining high folding accuracy.
3Manufacturing precision
If gentle handling of card stock is implemented, then manufacturing precision is improved, but productivity is reduced
Solution Approach 1:
The patent introduces a specifically designed holding head that acts as an intermediary between the conveyor and the card stock sheet. This holding head gently retains the sheet during transport and folding operations, preventing damage while maintaining sheet integrity. The intermediary mechanism allows gentle handling without significantly impacting productivity, as it is integrated into the high-speed intermittent conveyor system.
Data Source
AI summary
Manufacturing machine and manufacturing method for the production of a filter for a tubular element for a smoking article. The following are provided: a folding drum which rotates around a rotation axis to move, along a circular folding path at least one holding head designed to accommodate a sheet having an inner portion and an outer portion; a feeding station where the holding head receives the sheet and engages the sole outer portion of the sheet leaving the inner portion of the sheet free; an insertion station where the holding head releases the sheet having the inner portion folded like a bellows; and a folding device which is arranged along the folding path between the feeding station and the insertion station and is configured to fold the inner portion of the sheet like a bellows. The holding head is mounted on the folding drum so as to radially translate outwards in the feeding station to receive the sheet and so as to radially translate outwards in the insertion station to release the sheet.