Multi-segment Filter Gap Filling via Pneumatic Granule Conveying
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Solution Overview
Problem
Existing methods for filling gaps between filter segments in the tobacco processing industry often result in incomplete filling, especially at high strand conveying speeds, leading to inefficiencies in the production of multi-segment filters.
Innovation Solution
A method involving a granulate filling device that uses an air flow enriched with granules, where the granules have a movement component in the conveying direction, facilitated by a mechanical device such as an airflow guide or a helical conveying channel, to ensure even and complete filling of gaps between filter segments. This device can include features like centrifugal separation and a slit-shaped outlet to optimize granule distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If granules are conveyed using traditional gravity-fed or suction methods, then the filling process is simple, but the gaps between filter segments are not completely filled at high conveying speeds
Solution Approach 1:
The patent employs pneumatic conveying by introducing an air flow enriched with granules into the gaps between filter segments. The air flow carries granules at controlled velocities to ensure complete filling even at high strand conveying speeds, replacing traditional gravity-fed or suction methods with a pneumatic delivery system that maintains filling completeness across varying production speeds
Solution Approach 2:
The patent controls the velocity of granules in the air flow to match or exceed the strand conveying speed. By adjusting parameters such as air flow rate, granule size distribution, and injection timing, the system ensures that granules are delivered with sufficient kinetic energy to completely fill gaps while maintaining synchronization with the moving strand, thereby resolving the contradiction between filling completeness and production speed
2Manufacturing precision
If granules are introduced without movement component in conveying direction, then the device structure is simple, but the filling uniformity is poor
Solution Approach 1:
The patent incorporates sensors that detect the presence and filling status of granules in the gaps between filter segments. This feedback information is used to adjust the air flow rate and granule injection timing in real-time, ensuring uniform filling across all gaps while maintaining a relatively simple device structure through intelligent control rather than complex mechanical mechanisms
Solution Approach 2:
The system dynamically adjusts the velocity and distribution of granules in the air flow based on the moving strand's position and speed. The granules are introduced with a movement component in the conveying direction that matches the strand's motion, creating a dynamic filling process that adapts to varying production conditions and achieves uniform filling without requiring complex mechanical positioning devices
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
The solution enables efficient and complete filling of gaps between filter segments, ensuring a high degree of uniformity and productivity in the production of multi-segment filters, with granules accelerated to match or exceed the speed of the strand, thereby preventing gaps from remaining unfilled.
Implementation Method 1
If the granulate is moved along a curved wall of the granulate filling device due to a centrifugal force acting on the granulate
Implementation Method 2
the granulate can be discharged very efficiently from the granulate filling device into the gaps
Implementation Method 3
If the granulate is separated from the air stream on the outlet side of the granulate filling device, in particular before the gaps are filled with granulate
Data Source
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AI summary
The invention relates to a method for manufacturing a multi-segment filter (19) for the tobacco processing industry, a granule filling device (14), and a stranding machine (10) for the tobacco processing industry. Gaps (20) between filter segments (15) are filled with granules (16), wherein the granules (16) are given a velocity component by an airflow (31) to fill the gaps (20) in the conveying direction (21) of the stranding machine (10).