Automated Preroll Cone Forming With Tamping and Fold Plates
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Solution Overview
Problem
The traditional process of forming preroll joints is labor-intensive and time-consuming, requiring skilled operators to twist and finish approximately 100 prerolls in an hour, which hinders efficient production and increases operational costs.
Innovation Solution
A preroll filling system that includes an unloading tray, tamping tool, fold plate, and press to automate the process, allowing operators to produce 2000 prerolls per hour with a team of 4 relatively inexperienced technicians, achieving a throughput of 16,000 prerolls per day.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual twisting and finishing is used, then skill level can be maintained, but productivity is low and labor cost is high
Solution Approach 1:
The system enables self-service automation where the mechanical assembly performs twisting and finishing operations without human intervention. The automated mechanism handles the prerolls through multiple stations that automatically complete the forming process, eliminating the need for skilled manual manipulation while maintaining consistent quality across all produced prerolls.
Solution Approach 2:
Manual mechanical twisting and finishing operations are replaced with an automated mechanical system. The patent employs a mechanically automated assembly that guides prerolls through standardized forming stations, substituting human hand movements with controlled mechanical actions that achieve the same functional result at higher speed and consistency.
2Productivity
If automated assembly is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The automated assembly is divided into discrete functional stations including feeding, forming, twisting, and finishing stations. Each station performs a specific operation independently, allowing the complex process to be broken down into manageable modules that can be maintained and operated separately, reducing overall system complexity despite high productivity.
Solution Approach 2:
The automated assembly is designed as a multi-functional device that handles multiple operations (feeding, forming, twisting, finishing) within a single integrated system. This universal approach consolidates what would otherwise require multiple separate devices into one coordinated machine, increasing productivity while managing complexity through functional integration.
Data Source
AI summary
A system may include an unloading tray configured to receive filled paper preroll cones from a knock box. The unloading tray includes a mold defining apertures, each sized to receive a single cone. A tamping tool has a base and a plurality of rods depending therefrom, each being positioned on the base to align with a corresponding mold aperture. A fold plate includes a plurality of chamfers configured to fold a portion of each cone inwards, each chamfer being positioned to align with a corresponding mold aperture, and defining a hole sized to allow a tamping tool rod to pass therethrough. The tamping tool is positioned with the rods extending through the holes, and receives first and second downward forces, which are applied to the cones, causing the folded cone to close and to pass through the mold apertures, sealing the cones and expelling the cones from the unloading tray.


