Stepped Rotation Manufacturing Machine for Disposable Cartridge Production
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Solution Overview
Problem
Current manufacturing machines for disposable electronic cigarette cartridges face challenges in achieving high productivity while maintaining high-quality standards and are complex and costly to produce.
Innovation Solution
A manufacturing machine with a stepped rotation mechanism that supports multiple groups of seats for tubular casings, featuring a feeding unit, filling units, and a transfer unit to simultaneously process and fill cartridges, ensuring efficient production and quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a manufacturing machine is designed to operate with high hourly production rate, then productivity is improved, but device complexity increases and manufacturing cost rises
Solution Approach 1:
The manufacturing machine is divided into multiple independent modules: a first manufacturing drum for initial processing, a second manufacturing drum for final assembly, and intermediate transfer mechanisms. Each drum handles specific operations independently, allowing parallel processing of multiple cartridges simultaneously, thereby achieving high productivity without requiring a single complex monolithic machine
Solution Approach 2:
The machine transitions from linear sequential processing to two-dimensional parallel processing by implementing two rotating drums operating simultaneously. The first drum processes one set of cartridges while the second drum handles another set, effectively doubling the production capacity and reducing the need for complex sequential control mechanisms
2Productivity
If multiple filling units are used to increase productivity, then productivity is improved, but device complexity increases
Solution Approach 1:
Multiple filling units are integrated into a single rotating drum structure rather than being arranged as separate stationary machines. The first manufacturing drum incorporates multiple filling units that operate simultaneously as the drum rotates, combining what would otherwise be multiple independent complex systems into one unified mechanism
Solution Approach 2:
The filling units are pre-positioned on the rotating drum at specific angular intervals, allowing cartridges to be automatically presented to the correct filling unit at the right time during rotation. This preliminary arrangement eliminates the need for complex real-time positioning control systems during operation
3Manufacturing precision
If individual weighing and rejection of non-compliant cartridges is implemented, then manufacturing precision is improved, but productivity decreases due to additional processing time
Solution Approach 1:
Traditional mechanical weighing scales and manual rejection processes are replaced with automated sensing systems integrated into the manufacturing drum. Sensors detect tobacco quantity compliance during the drum's rotation, and non-compliant cartridges are automatically ejected without stopping the drum, maintaining continuous production flow while ensuring quality control
Data Source
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AI summary
A manufacturing machine (9) and manufacturing method for the production of disposable cartridges (1). Each disposable cartridge (1) has a tubular casing (2) and a quantity (4) of product housed in the tubular casing (2). The following are provided: a manufacturing drum (10), which is mounted so as to rotate in a stepped manner around a first vertical rotation axis (11) and supports at least one group (12) of first seats (13), each designed to house a corresponding tubular casing (2); and a feeding unit (18), which is designed to insert a plurality of tubular casings (2) into respective first seats (13) of the group (12) of first seats (13) standing still in a feeding station (S1). The feeding unit (18) has: a feeding drum (25), which is mounted so as to rotate in a stepped manner around a second vertical rotation axis (26) parallel to the first rotation axis (11), supports at least one group (27) of second seats (28), each designed to house a corresponding tubular casing (2), and at the feeding station (S1) partially overlaps the manufacturing drum (10), so that, in the feeding station (S1) each second seat (28) is vertically aligned with a corresponding first seat (13); a first transfer device (29) which is arranged in the feeding station (S1) and is designed to transfer the tubular casings (2) from the second seats (28) to the first seats (13) by means of a vertical movement; and a second transfer device (30) which is arranged in a first transfer station (S9) and is designed to transfer the tubular casings (2) to the second seats (28) by means of a vertical movement.