Optical Monitoring and Synchronized Rejection of Tobacco Rod-Like Articles
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Solution Overview
Problem
Existing methods for rejecting defective rod-like articles in a mass flow, such as cigarettes, often disrupt the flow process and are inefficient in identifying and removing defects on multiple surfaces simultaneously.
Innovation Solution
An apparatus with a monitoring unit using optical recorders and cameras to identify defects, a rejecting unit with synchronized movement along the flow, and restraining elements to maintain flow integrity, allowing for precise removal of defective articles without stopping the conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pneumatic devices are used to remove defective cigarettes in fixed positional relation with the sensor, then the rejection function is achieved, but the cigarette flow is disrupted and stepwise movement is required
Solution Approach 1:
The rejecting element is mounted to move synchronously along with the mass flow at the same speed as the defective rod-like articles, transitioning from a static fixed-position rejection system to a dynamic moving rejection system. This allows continuous flow maintenance while enabling precise defective article removal through coordinated motion between the rejecting element and the conveyor system
Solution Approach 2:
A synchronous drive mechanism acts as an intermediary between the conveyor system and the rejecting element, transferring motion in a coordinated manner. This intermediary system enables the rejecting element to follow the mass flow while maintaining precise positioning relative to defective articles, resolving the conflict between continuous flow and targeted rejection
2Measurement precision
If optical recorders and cameras are used to identify defects on multiple surfaces, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The monitoring unit integrates multiple optical recording devices and cameras into a single unified system that performs multiple detection functions simultaneously. This multi-functional monitoring unit can detect defects on multiple surfaces of rod-like articles using various optical methods, reducing the need for separate detection systems and managing complexity through functional integration
Solution Approach 2:
Multiple optical detection devices are merged into a single monitoring unit that operates in coordination. The system combines cameras, optical recorders, and processing electronics into an integrated assembly that shares common support structures, signal processing pathways, and control interfaces, thereby reducing overall system complexity while maintaining multi-surface detection capability
3Productivity
If the rejecting element moves synchronously with the mass flow, then flow disruption is minimized, but the rejection mechanism complexity increases
Solution Approach 1:
A synchronous drive mechanism serves as an intermediary between the existing conveyor system and the rejecting element. This intermediary utilizes the conveyor's motion to drive the rejecting element, eliminating the need for independent complex motion control systems while maintaining synchronous movement. The rejecting element is coupled to the conveyor through this intermediary drive mechanism, sharing its motion characteristics
Solution Approach 2:
The rejecting element utilizes the motion of the mass flow itself to achieve synchronous movement, rather than requiring an independent drive system. The system is designed so that the rejecting element is passively carried along with the flow and actively engages only when needed, using the flow's own kinetic energy and motion patterns to maintain synchronization
Data Source
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AI summary
An apparatus of the tobacco industry for the rejection of defective rod-like articles from a mass flow of rod-like articles, comprising a monitoring unit (100) adapted to optically determine geometrical parameters of rod-like articles (R), and at least one rejecting unit (200) adapted to remove a rod-like article from the mass flow (M) of rod-like articles (R), wherein the mass flow (M) being transported on the conveyor (10), such unit (200) being situated behind the monitoring unit (100) with reference to the direction (T) of the mass flow (M) of rod-like articles (R). The apparatus is characterised in that the monitoring unit (100) has optical recorders (101) recording images of opposite side surfaces of the mass flow (M) of rod-like articles (R) on a conveyor (10) wherein said side surfaces are formed by front surfaces or rod-like articles (R). The apparatus comprises the controller (300) which basing on the recorded images, using the criteria concerning geometrical parameters of the opposite front surfaces of rod-like articles (R), identifies defective rod-like articles (Rd) in the mass flow (M), and determines the position of the defective rod-like articles (Rd) in the mass flow (M), and the rejecting unit (200) comprises at least one rejecting element (201, 203, 204, 205, 205') adapted to reject the defective rod-like article (Rd), the rejection unit (200) being mounted in such a way that it moves along together with the mass flow (M) in a position enabling it to reject the defective rod-like article (Rd).