Rod-Like Article Counting Module for Tobacco Transport Containers
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Solution Overview
Problem
Current systems for counting rod-like articles in transport containers in the tobacco industry lack accuracy, often resulting in discrepancies due to disturbances or defects during the counting process, and previous methods provide only about 5% accuracy, which is insufficient for determining the exact number of articles.
Innovation Solution
An apparatus with a counting module that uses a sensor to image and count individual rod-like articles in the transport container, allowing for precise counting and adjustment of the filling level based on the determined number, using electromagnetic radiation sensors or other imaging technologies to analyze the arrangement and quantity of articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If rod-like articles are counted during single-layer flow on a belt or drum before entering a hopper, then the counting process can be performed, but the accuracy is compromised due to disturbances, jams, or defects during the flow
Solution Approach 1:
The patent applies preliminary action by performing the counting operation after the articles have already been filled into the container, rather than before. The sensor records the position of articles as they are being filled, and the counting is finalized once the container is complete. This ensures that the counted articles are exactly those that ended up in the container, eliminating discrepancies caused by articles falling off or being rejected during transport.
2Measurement precision
If traditional counting systems are used to determine the number of rod-like articles, then the counting process is simple, but the accuracy is only about 5% which is insufficient for exact determination
Solution Approach 1:
The patent replaces mechanical counting systems with an optical sensing system. A sensor records the position of each article as it is filled into the container, and a processing unit analyzes these position signals to determine the exact number of articles. This substitution of mechanical counting with optical detection and electronic processing achieves high precision (exact counting) while maintaining reasonable system complexity through the use of standard sensor and processing technologies.
3Loss of time
If articles are counted before filling to determine container contents, then the counting can be performed early in the process, but discrepancies occur between counted articles and actual articles in the container
Solution Approach 1:
The patent implements feedback by continuously monitoring the position of articles during the filling process using a sensor, and using this information to determine the final count. The system receives position signals from the sensor as articles are being filled, processes these signals to identify individual articles, and generates a definitive count based on the actual articles that made it into the container. This real-time feedback approach ensures both timeliness (counting during the process) and accuracy (counting only articles that ended up in the container).
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 solution provides real-time, high-accuracy counting of rod-like articles, reducing uncertainties related to geometric assumptions and irregularities in the filling process, ensuring correct filling levels and minimizing defects or overfilling.
Implementation Method 1
The sensor (7) is designed to receive an image of the rod-like articles (R) in the transport container (14)... electromagnetic radiation sensors
Data Source
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Figure 3~4
Figure 5
AI summary
The object of the invention is an apparatus for filling transport containers (1) with rod-like articles of the tobacco industry, provided with an area (2) receiving the rod-like articles in the form of a mass flow, a rod-like article storage area (3) comprising at least two sidewalls, a filling unit (4) constituting the bottom wall of the storage area for transferring the rod-like articles from the storage area to the transport container, a lowering conveyor (5) working together with the filling unit (4), adapted to lower the transport container while filling with the rod-like articles. The apparatus is characterised by being further provided with a counting module (6) designed to count the rod-like articles in the transport containers, adapted so that the individual rod-like articles being in the transport container are counted.