Automated Cigarette Manufacturing Machine with Sensor-Controlled Tobacco Compaction
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Solution Overview
Problem
Cigarette manufacturing machines for home and personal use, known as roll-your-own (RYO) machines, lack the ability to automatically produce cigarettes precisely, uniformly, and efficiently without manual intervention, often resulting in damaged tubes and insufficient tobacco compaction, and fail to accommodate user preferences for tobacco quantity and environmental conditions like humidity.
Innovation Solution
A cigarette manufacturing machine with a control system, including a computer processor and sensors, that automates the tobacco compaction and cigarette formation process, ensuring precise and uniform cigarette production by monitoring tobacco levels and humidity, and integrating a carriage assembly, tube magazine, and carrot forming assembly to manage tobacco insertion and tube handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual operation is used in typical RYO machines, then the device complexity is reduced, but the manufacturing precision and productivity deteriorate due to inability to produce cigarettes precisely and uniformly
Solution Approach 1:
The system performs self-measurement and self-control through integrated sensors that automatically detect tobacco compaction levels and tube positioning, eliminating the need for manual monitoring and adjustment while maintaining precise manufacturing standards
Solution Approach 2:
Manual mechanical operations are replaced with an automated control system that uses electronic sensors and computer processing to manage tobacco compaction, tube insertion, and carriage positioning, achieving both automation and precision
2Device complexity
If manual operation is used in typical RYO machines, then the device complexity is reduced, but the productivity deteriorates due to inability to efficiently manufacture multiple cigarettes
Solution Approach 1:
The system enables continuous automated operation where the carriage repeatedly cycles through tobacco compaction, tube insertion, and cigarette formation without manual intervention, maintaining consistent production flow and maximizing manufacturing efficiency
Solution Approach 2:
The machine autonomously manages the entire cigarette manufacturing process through self-controlled carriage movement, automatic tobacco dosing, and precise tube positioning, eliminating operational bottlenecks and sustaining high productivity
3Device complexity
If typical RYO machines operate without automated control, then the device complexity is reduced, but the reliability deteriorates due to tube damage and insufficient tobacco compaction
Solution Approach 1:
Sensors provide real-time feedback on tobacco compaction levels and tube positioning, allowing the control system to automatically adjust parameters and correct deviations, ensuring consistent cigarette quality and preventing defects
Solution Approach 2:
Manual mechanical control is replaced with an automated electronic control system that precisely manages carriage speed, tobacco dosing, and tube insertion force, eliminating human error and improving operational reliability
4Device complexity
If typical RYO machines lack environmental monitoring, then the device complexity is reduced, but the adaptability deteriorates due to inability to accommodate humidity and tobacco quantity preferences
Solution Approach 1:
Environmental sensors provide feedback on humidity and tobacco levels, allowing the control system to automatically adjust manufacturing parameters to accommodate environmental conditions and user preferences for tobacco quantity
Solution Approach 2:
The system dynamically changes manufacturing parameters such as tobacco dosing amount and compaction force based on sensor readings of environmental conditions, enabling adaptation to varying humidity levels and user preferences
Data Source
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AI summary
In one aspect, an apparatus for manufacturing cigarettes includes a housing, a mandrel extending from the housing, and a movable member operably coupled to the housing and adapted to carry a first cigarette tube. The movable member is movable, relative to each of the housing and the mandrel, in a first direction and a second direction that is opposite the first direction. In another aspect, a method of manufacturing cigarettes includes loading a first cigarette tube on a mandrel, holding the first cigarette tube on the mandrel, and inserting a push rod and a carrot of pre-cut tobacco leaves into the first cigarette tube, the carrot of pre-cut tobacco leaves having a generally cylindrical shape. An offset distance is defined between the first cigarette tube and the mandrel after the push rod and the carrot of pre-cut tobacco leaves are inserted into the first cigarette tube.