Filter Rod Manufacturing Machine with Integrated Positioning Unit
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Solution Overview
Problem
The tobacco industry lacks a simple and cost-effective method to manufacture mouthpieces with filtering material, where full and tube segments are juxtaposed, with fibers extending along the entire length, requiring a machine that can efficiently produce high-quality filter rods in a single operation.
Innovation Solution
A machine comprising a preparation unit for filtering fibers, a forming unit for continuous filter rods, a feeding unit for multiple-length objects, a cutting unit for single-length objects, a transferring unit with a spiral drum, a positioning unit with a rotary disc, and a gluing unit for precise placement and fixation of single-length objects within the filter rods, ensuring central positioning and uniform density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a complex multi-step process is used to manufacture filter rods with tube segments, then manufacturing precision and quality can be improved, but device complexity and production cost increase
Solution Approach 1:
The patent combines multiple functions (feeding, cutting, transferring, positioning, and gluing) into a single integrated machine that operates in one continuous technological operation. The machine merges the preparation of filtering fibers with the placement of tube segments, eliminating the need for separate manufacturing steps and reducing overall device complexity while maintaining positioning precision through coordinated operation of integrated units.
Solution Approach 2:
The patent applies preliminary action by pre-preparing filtering fibers in a strand and pre-positioning tube segments before they are incorporated into the final filter rod. The feeding unit prepares multiple-length longitudinal objects in advance, and the cutting unit pre-cuts them into single-length segments that are then transferred and positioned. This preliminary preparation enables precise positioning during the forming operation without requiring complex real-time adjustment mechanisms.
2Adaptability or versatility
If multiple separate operations are used to create filter rods with filtering fibers and tube segments, then manufacturing flexibility can be improved, but productivity and production efficiency decrease
Solution Approach 1:
The patent implements continuity of useful action through a machine that operates in a single continuous technological operation. The forming unit continuously forms filter rods while the feeding unit continuously supplies prepared filtering fibers and the positioning unit continuously places tube segments. This continuous operation eliminates idle time between steps and maintains constant production flow, significantly improving productivity while the integrated design preserves manufacturing flexibility for different filter rod configurations.
3Manufacturing precision
If tube segments are placed into filter rods after the rod is formed, then positioning precision can be improved, but manufacturing time and production cost increase
Solution Approach 1:
The patent applies preliminary action by pre-positioning tube segments in the positioning unit before they are incorporated into the forming filter rod. The positioning unit prepares and aligns tube segments in advance, so that when the forming unit creates the filter rod, the tube segments are already in their final positions. This eliminates the need for time-consuming post-forming positioning operations while maintaining precise central positioning through the pre-aligned configuration.
Solution Approach 2:
The patent merges the positioning operation with the forming operation into a single simultaneous process. The positioning unit and forming unit operate concurrently, with the positioning unit placing tube segments into the forming filter rod as the forming unit creates the rod structure. This merging eliminates sequential time losses and achieves both precise positioning and efficient production in one integrated 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
The machine achieves high-quality filter rods with precise positioning and central placement of tube segments, enabling efficient production of multi-segment mouthpieces with improved repeatability and uniformity.
Implementation Method 1
a transferring drum (26) having a spiral element (27) on its side surface
Implementation Method 2
a rotary positioning disc (30) having a horizontal axis, wherein the positioning disc may comprise transporting seats (31) for the single-length longitudinal objects
Implementation Method 3
a gluing unit (35) configured to supply glue onto the single-length longitudinal objects
Data Source
Figure 1~3
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Figure 5
AI summary
A machine for manufacturing tobacco industry filter rods (1), the filter rods (1) comprising single-length longitudinal objects (2), wherein the machine comprises: a preparation unit (11) for preparing a strand (F) of filtering fibers; a forming unit (12) for forming a continuous filter rod (CR) from the strand (F) of the filtering fibers; a feeding unit (13) for feeding multiple-length longitudinal objects (6); a cutting unit (14) for cutting the multiple-length longitudinal objects (6) into the single-length longitudinal objects (2); a transferring unit (15) for transferring the single-length longitudinal objects (2); a positioning unit (16) for placing the single-length longitudinal objects (2) in the continuous filter rod (CR) while it is being formed; a cutting head (17) for cutting the formed continuous filter rod (CR) that comprises the filtering fibers and the single-length longitudinal objects (2), into individual filter rods (1).