Packing Machine Control Method for Twin Packet Manufacturing
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Solution Overview
Problem
Packing machines for producing 'twin' packets of cigarettes face productivity issues due to cigarettes becoming 'crossed up' during the manufacturing process, leading to interruptions and increased waste, especially with shorter or conically shaped cigarettes.
Innovation Solution
A control method for the packing machine that allows continuous operation by disabling the extraction devices and associated components of malfunctioning output mouths, preventing the formation of orphan groups and reducing waste, while maintaining production using functional output mouths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cigarettes are fed through the hopper by gravity to multiple output mouths, then the packing machine can produce twin packets with two distinct groups of cigarettes, but crossed-up cigarettes occur during the fall, causing occlusions and requiring machine interruption
Solution Approach 1:
The system is divided into multiple independent output mouths (first and second output mouths) that can operate independently. When one output mouth experiences an occlusion, the other can continue operating, allowing the machine to maintain partial production rather than complete shutdown.
Solution Approach 2:
The extraction devices are designed to be independently controllable for each output mouth. The control unit dynamically adjusts operation by disabling only the affected extraction device while keeping others active, enabling adaptive response to localized problems without global shutdown.
2Ease of operation
If the packing machine is interrupted to manually remove crossed-up cigarettes, then occlusions are cleared, but productivity decreases due to downtime
Solution Approach 1:
The system enables operators to clear occlusions from individual output mouths without requiring machine shutdown. The self-service capability allows maintenance actions to be performed while the machine continues operating other functional channels, eliminating downtime for routine clearance operations.
Solution Approach 2:
The control unit maintains continuous operation of functional extraction devices while disabling only those affected by occlusions. This ensures that useful production action continues uninterrupted from healthy output mouths, maximizing overall system productivity during partial fault conditions.
3Reliability
If all extraction devices are stopped when one output mouth is occluded, then the machine is protected from damage, but productivity is significantly reduced
Solution Approach 1:
The extraction system is segmented into independently controllable units corresponding to each output mouth. This segmentation allows selective disabling of only the affected extraction device while maintaining operation of others, protecting the machine from damage at the problematic location while preserving production capacity elsewhere.
Solution Approach 2:
The control response is localized to the specific output mouth experiencing occlusion. The control unit applies different operational states to different parts of the system - disabling the affected extraction device while keeping others active - rather than applying a uniform shutdown to the entire system.
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 increases the long-term productivity of the packing machine by minimizing downtime and waste, allowing operators to address occlusions without stopping the machine and reducing the discard of cigarettes and wrapping materials.
Implementation Method 1
cigarettes fall down through the hopper by gravity
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A control method for a packing machine (8) manufacturing packets (1) of smoking articles each containing two separate groups (4) of smoking articles housed in an outer container (2) provided with a hinged lid; the packing machine (8) comprises: a forming unit (9) in which groups (4) of smoking articles are successively formed and which comprises a hopper (30) provided with at least four output mouths (31) from each of which one group (4) of smoking articles is extracted; and a plurality of wrapping drums (13, 20, 26) each of which has a plurality of wrapping heads (15, 22, 28) which are suitable to receive groups (4) of smoking articles together with corresponding wrapping materials (5, 6, 7). In the presence of a malfunctioning output mouth (31), the malfunctioning output mouth (31) and also the output mouth (31) associated with the malfunctioning output mouth (31) and the wrapping heads (15, 22, 28) that should receive the groups (4) of smoking items from the malfunctioning output mouth (31) and from the associated output mouth (31) are not used, avoiding feeding the corresponding wrapping materials (5, 6, 7) to the wrapping heads (15, 22, 28).