Filter Segment Positioning Control for Tobacco Manufacturing

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Solution Overview

Problem

There is a lack of a practical and reliable method for setting the reciprocal position of filter segments on the grouping tape during the preparation of the production line for multi-segment filters in the tobacco industry, which results in inefficiencies and material loss.

Innovation Solution

A method involving the registration of segment positions and lengths using sensors, with the information stored in a control system to adjust the mechanisms, allowing for precise arrangement of segments on the carrier element, enabling efficient sequence setting and reducing material loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If manual methods are used to set the reciprocal position of filter segments on the grouping tape, then the setup process is simple, but the time consumption increases and material loss occurs

Engineering Contradiction:

Improvetime for setting segment positionVSAvoidcomplexity of positioning system

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-registering the position and length of each segment from multiple modules on the carrier element before final assembly. The control system stores this information and uses it to automatically calculate and set the reciprocal positions, eliminating the need for manual trial-and-error positioning during production setup.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback through sensors that detect the actual position and length of segments on the carrier element. This measured information is fed back to the control system, which compares it with the registered data and automatically adjusts the positioning mechanisms to achieve the desired reciprocal arrangement, ensuring precision while reducing setup time.

Inventive Principle:

Principle #23Feedback

2Loss of substance

If segments are positioned manually during production line preparation, then equipment complexity is low, but material loss increases

Engineering Contradiction:

Improvematerial loss of filter segmentsVSAvoidautomation of segment positioning

Core Design Contradiction:

Loss of substanceVSExtent of automation

Solution Approach 1:

The system performs preliminary registration of segment positions and lengths before actual production. By storing this information in the control system and using it for automated positioning calculations, the system eliminates wasted material that would otherwise occur during manual setup adjustments and trial productions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual mechanical positioning with an automated control system that uses registered segment data to calculate and execute precise positioning. This substitution of mechanical manual operations with automated control reduces material loss by ensuring correct positioning from the first attempt.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If the production line is reconfigured for different filter structures, then product versatility is improved, but the reconfiguration time increases

Engineering Contradiction:

Improveability to change filter structureVSAvoidreconfiguration time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system applies preliminary action by registering segment information in advance and storing it in the control system. When reconfiguration is needed, the control system retrieves stored data and automatically adjusts positioning parameters, enabling quick adaptation to different filter structures without time-consuming manual resetup.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements dynamics by making the positioning system adaptable and reconfigurable through the control system. The system can dynamically adjust the reciprocal positions of segments from multiple modules based on stored registration data, allowing rapid reconfiguration for different filter structures while maintaining precision.

Inventive Principle:

Principle #15Dynamics

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

This method significantly saves time during filter structure changes and reduces material loss by ensuring accurate positioning of filter segments on the grouping unit, enhancing the efficiency of the manufacturing process.

Implementation Method 1

the sensor may constitute an optical element operating in the range of visible radiation or invisible radiation

Methodology Applied

Scientific EffectOptical detection: Optical Fibre

Implementation Method 2

or constitute an ultrasonic element

Methodology Applied

Scientific EffectUltrasonic detection: Ultrasound

Data Source

PatentUS8991587B2Method of setting reciprocal position of filter segments on a carrier element of a grouping unit in a process of manufacturing multi-segment filters

Publication Date: 2015.03.31 PHILIP MORRIS PRODUCTS SA

AI summary

Setting of reciprocal position of filter segments (3) delivered from multiple modules (1) of a machine for manufacturing filters is accomplished by registering the position and the length of a segment (3) from each module (1) on a carrier element (2) of a grouping unit when the filter manufacturing process is switched off, after which the reciprocal position of the segments (3) and the length between the segments (3) are set. The said operations may be accomplished by means of a sensor (4), the registering element (12) or by mapping the relative positions of adjacent segments (3) in the control system.