Pre-Roll Cone Packing and Folding With Multi-Axis Compression Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional techniques for forming filled and closed pre-roll cones are inefficient, leading to challenges in stabilizing the cone position, resulting in time-consuming processes, significant filler material loss, and inconsistent density and folding of the open end.
Innovation Solution
A multi-axis positioning system with a computerized controller controls the movement of a carriage and platform to precisely compress and fold pre-roll cones, using actuators and sensors to ensure consistent filler material density and folding, supported by a cone holder assembly with cavities and a folder assembly for alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hand-filling and hand-folding techniques are used, then operational flexibility is maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The device is divided into distinct functional modules: a cone holder assembly with multiple cavities to hold pre-roll cones, a loader assembly with a hopper and vibration mechanism to fill cones with filler material, and a folder assembly with folders to fold the open ends. This segmentation allows each module to perform its specific function efficiently while maintaining overall system manageability.
Solution Approach 2:
The vibration mechanism automatically agitates the filler material in the hopper to facilitate gravity-fed filling of the cones without requiring manual intervention. The folders automatically fold the open ends of the cones as they pass through, eliminating the need for hand-folding and significantly improving productivity.
2Manufacturing precision
If hand-folding technique is used, then adaptability is maintained, but manufacturing precision of folding is inconsistent
Solution Approach 1:
Each folder in the folder assembly is specifically designed with a folding surface and folding edge tailored to the geometry of the pre-roll cone. The folders are positioned and oriented to apply force at specific locations on the cone's open end, ensuring consistent folding quality across all cones processed.
Solution Approach 2:
The manual hand-folding action is replaced with a mechanical folder assembly that uses controlled mechanical force to fold the cone ends. This substitution eliminates the variability inherent in manual operations and provides consistent, repeatable folding results.
3Productivity
If manual filling is used, then material loss is minimized through careful handling, but productivity is significantly reduced
Solution Approach 1:
The loader assembly uses a vibration mechanism to agitate the filler material in the hopper, causing it to flow uniformly into the cones through gravity. This controlled flow mechanism ensures complete filling of each cone without excessive material spillage or waste, while maintaining high filling speeds.
Solution Approach 2:
The filling process operates continuously as cones are fed through the holder assembly and filled by the vibration mechanism. This continuous operation eliminates the start-stop nature of manual filling, significantly increasing productivity while the controlled material flow prevents waste.
4Manufacturing precision
If conventional techniques are used, then device complexity is low, but manufacturing precision of compression is inconsistent
Solution Approach 1:
The filler material is pre-agitated in the hopper by the vibration mechanism before being deposited into the cones. This preliminary action ensures uniform material flow and distribution, resulting in consistent compression density across all filled cones without requiring complex compression control systems.
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 system enables efficient and consistent packing and folding of pre-roll cones, reducing material loss and ensuring uniform density and folding quality, thereby improving production efficiency and consistency.
Implementation Method 1
cause the carriage to move in a downward direction along the Y-axis toward the cavity, thereby causing the plunger to contact at least one of the pre-roll cone or the filler material within the pre-roll cone received within the cavity
Implementation Method 2
an X-axis actuator configured to drive movement of the carriage along an X-axis of the multi-axis positioning system; a Y-axis actuator configured to drive movement of the X-axis stage along a Y-axis
Data Source
AI summary
Systems, apparatus, and methods for compression of pre-roll cones supported in a cone holder assembly. In some examples, a multi-axis positioning system can be configured for compressing a filler material within pre-roll cones supported in a cone holder assembly. In some examples, a multi-axis positioning system can be configured for folding open-end portions of pre-roll cones supported in a cone holder assembly and having a filler material disposed therein. In some examples, a computerized controller can operate the multi-axis positioning system to control relative positioning of a carriage having a plunger attached thereto and a platform via one or more actuators, such as X-axis, -axis, and/or Z-axis actuators. In some examples, the computerized controller can control movement of a carriage and/or a platform based on one or more compression criteria.