Coupling Insert to Cigarette Group Using Segmented Spindle Extraction
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Solution Overview
Problem
The existing methods for coupling an insert to a group of cigarettes in packaging machines are complex and inefficient, especially at high speeds, due to the lack of a stable support surface and precise positioning requirements, which hinders the production of packets with perfect folding angles.
Innovation Solution
A coupling method and unit utilizing a rotating coupling wheel with spindles that feed and fold a reinforcing element in a 'U'-shape around the cigarettes, allowing for precise placement and efficient coupling without direct contact, enabling high-speed operation with precise folding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a common extracting device is used to couple the insert to the group of cigarettes, then the device complexity is reduced, but the manufacturing precision of folding angles deteriorates at high speeds
Solution Approach 1:
The coupling device is segmented into separate feeding paths for cigarettes and inserts, with individual seats for each component. The extracting device is also segmented into multiple extracting elements that can independently position each component, allowing precise folding angles even at high speeds while maintaining relatively simple overall device structure.
Solution Approach 2:
The insert is preliminarily positioned in a dedicated seat alongside the cigarettes before extraction. This preliminary positioning ensures that when the extracting elements pull both components, the insert is already aligned for precise folding, resolving the contradiction between simple device structure and high precision folding angles.
2Productivity
If the insert is fed directly into contact with the group of cigarettes, then the coupling efficiency is improved, but the stability of positioning deteriorates due to lack of uniform support surface
Solution Approach 1:
The dedicated seat acts as an intermediary structure between the insert and the cigarettes. It provides a stable, uniform support surface for the insert while maintaining close proximity to the cigarettes, enabling both high coupling speed and stable positioning without direct contact on an unstable surface.
Solution Approach 2:
The seat serves multiple functions: it supports the insert stably, positions it precisely relative to the cigarettes, and works in conjunction with the extracting device. This multi-functionality resolves the contradiction by providing both the stability needed for positioning and the efficiency needed for high-speed coupling.
3Reliability
If the insert is arranged between the inner wrap and the outer casing, then the protection function is improved, but the coupling complexity increases due to precise positioning requirements
Solution Approach 1:
The feeding of cigarettes and inserts is merged into a single coordinated process using the same coupling wheel and extracting device. This merging reduces overall device complexity while ensuring precise positioning of the insert between the inner wrap and outer casing, maintaining both protection function and coupling simplicity.
Solution Approach 2:
The insert is preliminarily positioned in the dedicated seat in the correct orientation and location before the wrapping process begins. This preliminary action ensures that when the insert is subsequently placed between the inner wrap and outer casing, it is already in the precise position needed for protection, reducing the complexity of the coupling mechanism.
Data Source
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AI summary
Coupling method and unit (26) to couple an insert (18) to a group (14) of cigarettes in a packaging machine (24); the group (14) of cigarettes is fed into a tubular spindle (31), which is internally hollow and has the shape of a parallelepiped; the insert (18) is laid on an outer surface of the spindle (31); and the group (14) of cigarettes and the insert (18) are extracted from the spindle (31) together by means of a single common extracting device (32) so as to cause the insert (18) to rest against the group (14) of cigarettes.