Method and apparatus for regulating the filling force of tobacco in cigarettes

The filling force of compacted tobacco in the fillers of filter cigarettes which issue from a filter tripping machine is measured for the purpose of increasing the quantity of tobacco in the filters when the filling force decreases and visce versa. The filling force can be measured by pneumatically deforming successive increments of the wrappers of discrete cigarettes and ascertaining the extent of deformation or by mechanically deforming an entire stack of cigarettes and ascertaining the reduction of the combined volume of cigarettes. The quantity of tobacco can be regulated by removing a larger or smaller quantity of tobacco from a continuous stream which is thereby converted into the filler of a cigarette rod or by changing the speed of a conveyor in the distributor of the cigarette making machine so that the conveyor withdraws a larger or smaller quantity of tobacco per unit of time. The measurement of the filling force is carried out with a delay following severing of the cigarette rod so as to enable the filling force to rise to a value which is at least close to the final value. In addition to regulation of the quantity of tobacco in the fillers of cigarettes in response to ascertainment of the filling force, such quantity is further regulated when it deviates from a preselected value. The necessary measurements are carried out by a beta ray detector which is adjacent the path of the cigarette rod.

BACKGROUND OF THE INVENTION 
The present invention relates to a method and apparatus for regulating the 
filling force of elastically deformable particulate materials which 
constitute the fillers of cigarettes, cigarillos, cigars and/or other 
rod-shaped articles which, in turn, constitute or form part of smokers' 
products. More particularly, the invention relates to improvements in a 
method and apparatus for adjusting the feed of tobacco or other smokable 
particulate material in cigarette making and analogous machines for the 
purpose of insuring that the pressure (filling force) which the confined 
particulate material applies against the internal surface of the tubular 
wrapper of a cigarette or the like will be maintained within a desired 
range. Still more particularly, the invention relates to improvements in a 
method and apparatus for regulating the quantity of elastically deformable 
particulate smokable material in a stream which is about to be draped into 
a web of cigarette paper or the like to constitute the filler of a 
continuous rod which is thereupon severed to yield discrete cigarettes or 
analogous rod-shaped articles of unit length or multiple unit length. 
The definition "smokable particulate material" embraces natural tobacco, 
reconstituted tobacco, artificial tobacco made of cellulose or the like, 
and mixtures of such substances. The material can be rendered particulate 
by shredding, slitting, tearing or by resorting to any other suitable 
comminuting technique. The rod-shaped articles which contain smokable 
particulate material may constitute plain or filter tipped cigars, 
cigarillos or cigarettes. For the sake of simplicity, the invention will 
be described with reference to the production of plain and filter 
cigarettes; however, it will be understood that the invention can be 
practiced in conjunction with the manufacture of any and all types of 
rod-shaped articles which constitute or form part of smokers' products and 
which involves the confinement of a continuous stream of particulate 
smokable material into a wrapper prior to subdivision of the resulting 
continuous wrapped stream into discrete rod-shaped articles of desired 
length. 
In the manufacture of cigarettes in conventional cigarette making machines, 
a continuous stream of tobacco is transported lengthwise on to a wrapping 
station where the stream is draped into a continuous web of cigarette 
paper. As a rule, the stream is trimmed ahead of the wrapping station and 
is thereby converted into a trimmed stream or filler having a constant or 
substantially constant cross-sectional area. The trimming device removes 
the surplus from an uneven side of the stream which is transported in the 
groove of an endless conveyor in the form of a belt, wheel or the like. It 
is customary to monitor the quantity of tobacco in the stream and to 
change the quantity of tobacco per unit length of the stream when the 
monitored quantity deviates from a desired value. In many instances, the 
monitoring means includes a source of corpuscular radiation (e.g., a 
source of beta rays) and an ionization chamber. It is also known to employ 
monitoring devices which embody a system of capacitors. The quantity of 
tobacco per unit length of the stream can be changed by resorting to one 
or more trimming or equalizing devices with rotary knives which are 
movable relative to the stream to remove a variable quantity of tobacco, 
i.e., a quantity which is a function of the difference between the 
measured quantity and the desired quantity of tobacco per unit length of 
the stream. Alternatively, the quantity of tobacco in the stream can be 
varied by adjusting the distributor which draws tobacco from a source of 
supply and converts the withdrawn tobacco into a continuous stream. As a 
rule, the distributor is designed to convert withdrawn tobacco particles 
into a relatively wide and thin sliver or carpet which is thereupon 
converted into a narrow stream. The aforementioned adjustment may involve 
regulation of the rate at which the distributor draws tobacco particles 
from the source of supply. 
The desired or preferred mode of operation of those parts of a cigarette 
making machine which form the continuous tobacco stream is such that each 
finished article (plain cigarette) contains a predetermined quantity for 
tobacco particles. The weight of the filler of a cigarette cannot be 
reduced below a predetermined minimum value; therefore, and in order to 
achieve savings in tobacco, the manufacturers of cigarettes strive to 
produce cigarettes wherein the weight of the tobacco filler matches or is 
only slightly above the minimum permissible weight. However, two 
cigarettes of identical weight (the weight of the tubular wrapper is 
negligible and can be disregarded) can exhibit different characteristics, 
especially as concerns the "feel" of the cigarette in the hand of a 
smoker. Thus, a cigarette wherein the weight of the filler matches a 
desired value can create the impression of a densely packed article by 
offering a pronounced resistance to deformation in response to the 
application of a pinching or squeezing force against the exterior of the 
wrapper. Such cigarettes are preferred by a great majority of the smokers. 
On the other hand, a cigarette wherein the weight of the filler is 
identical with the weight of a "densely packed" cigarette can create the 
impression of a soft and readily deformable rod whose wrapper will yield 
to minute finger pressure. The differences between "densely packed" and 
"soft" cigarettes are attributable to the condition of tobacco particles 
which constitute the filler. The main factor is the elasticity of tobacco 
particles and such elasticity, in turn, depends on the length of tobacco 
particles (shreds) and/or the crimp of the particles. Thus, a cigarette 
wherein the filler consists of relatively long shreds which exhibit a 
pronounced crimp will invariably create the impression of a densely packed 
product when compared with a cigarette having a filler of identical weight 
but containing a higher percentage of short tobacco and/or straight 
(uncrimped) shreds. Therefore, in addition to monitoring the quantity 
(weight) of tobacco per unit length of the stream (normally a trimmed 
stream or filler) which is to be draped into a web of cigarette paper, 
many manufacturers of tobacco further resort to measurement of the filling 
force of the filler of a finished cigarette, i.e., to the testing of 
cigarettes in order to ascertain the force with which the compacted filler 
of a cigarette bears against the internal surface of its wrapper. The 
results of such measurements are used to vary the quantity of tobacco per 
unit length of the stream, i.e., to insure that a cigarette whose filler 
consists of short tobacco and/or only slightly curled or crimped tobacoo 
will contain more tobacco than a cigarette wherein the filler consists of 
tobacco particles which are crimped and constitute or include a high 
percentage of long shreds. Of course, and even if the filler consists of 
highly satisfactory (long and crimped) tobacco particles, the quantity per 
unit length of the stream cannot be reduced to such an extent that the 
weight of the filler of a cigarette would be less than the minimum 
permissible weight (i.e., less than the lower threshold value of the 
acceptable range of weights). 
The monitoring of filling force of the fillers of cigarettes is normally 
carried out in a laboratory. Such monitoring involves the testing of a 
relatively small percentage of the total output of a cigarette maker and 
is desirable not only when the maker processes different types of tobacco 
but also when the maker is set to produce a given brand of cigarettes 
wherein the filler consists of a given type of tobacco. The reason is 
that, even during such mode operation, the quality of tobacco particles 
which form the stream is likely to undergo rather pronounced changes, 
i.e., the length of the shreds and/or the extent of crimp of the shreds is 
likely to undergo long-range variations above and below the desired 
optimum value. 
The presently known methods of ascertaining the filling force of fillers in 
cigarettes are time-consuming and must be practiced by resorting to 
skilled labor. Moreover, and since the samples are withdrawn at intervals 
and must be transferred into a laboratory, the known methods do not allow 
for immediate or practically immediate adjustment of the filling force 
when the measured filling force is unsatisfactory. 
It is further known to equip a cigarette making machine with apparatus 
which can automatically ascertain the filling force of successive 
increments of a continuous tobacco stream. Reference may be had to U.S. 
Pat. No. 3,595,067 granted July 27, 1971 to von der Lohe et al. The 
apparatus which is disclosed in this patent can ascertain the filling 
force of a filler prior to subdivision of the wrapper filler into discrete 
cigarettes. Moreover, the apparatus can achieve accurate measurements of 
the filling force. However, the nature of measurements and of the signals 
which are indicative of the measured value of the filling force is such 
that the results of measurements cannot be readily utilized for automatic 
adjustment of the machine for the purpose of maintaining the filling force 
of the fillers of cigarettes within a desired range. 
OBJECTS AND SUMMARY OF THE INVENTION 
An object of the invention is to provide a novel and improved method of 
ascertaining the filling force of the fillers of cigarettes or the like in 
such a way that the results of tests can be readily utilized for 
adjustment of the quantity of particulate material in the fillers when the 
measured filling force deviates from a desired filling force. 
Another object of the invention is to provide a method which can be 
resorted to for ascertaining the filling force of fillers of successive or 
selected discrete rod-shaped articles, of the entire output of a machine 
for the mass-production of cigarettes or the like, or of a desired 
percentage of the total output. 
A further object of the invention is to provide a novel and improved method 
of regulating the quantity of smokable particulate material in a stream 
which is to be converted into the fillers of cigarettes or the like for 
the purpose of insuring that the filling force of tobacco in the 
cigarettes will match or closely approximate a desired optimum filling 
force. 
An additional object of the invention is to provide a novel and improved 
apparatus which can be utilized for the practice of the above outlined 
method and which can automatically adjust the quantity of tobacco and/or 
other smokable material in the fillers of cigarettes or analogous 
rod-shaped articles in order to insure that the filling force of the 
filler of each article will match or closely approximate an optimum value. 
Another object of the invention is to provide the apparatus with novel and 
improved means for simultaneously ascertaining the filling force of plural 
rod-shaped articles. 
A further object of the invention is to provide the apparatus with novel 
and improved means for adjusting the quantity of particulate material in 
the fillers of finished articles in dependency on several factors 
including the filling force of the fillers. 
Another object of the invention is to provide an apparatus which can be 
readily incorporated in existing machines for the mass-production of plain 
or filter tipped cigarettes, cigars or cigarillos. 
An additional object of the invention is to provide an apparatus which is 
relatively simple, which requires little or no attention on the part of 
the attendants, and which can be readily adjusted to select the desired 
filling force. 
An ancillary object of the invention is to provide the apparatus with novel 
and improved means for evaluating the results of measurements of the 
filling force of the fillers of cigarettes or the like. 
One feature of the invention resides in the provision of a method of 
processing elastically deformable particulate material, especially tobacco 
(e.g., tobacco shreds which are to be converted into fillers of plain or 
filter tipped cigarettes). The method comprises the steps of converting 
smokable material into a continuous stream (e.g., a filler stream of the 
type formed in a cigarette making machine for wrapping in cigarette 
paper), moving the stream lengthwise, compacting the moving stream and 
applying around the moving compacted stream a continuous wrapper whereby 
the material of the compacted stream tends to expand and exerts a force 
against the interior of the applied wrapper (for example, the compacting 
step can be carried out in the wrapping mechanism of a cigarette making 
machine wherein a rod-like filler stream of tobacco shreds is transported 
by a garniture during draping of a web of cigarette paper therearound), 
subdividing the moving wrapped stream into discrete rod-shaped articles of 
unit length or multiple unit length while the filling force is on the 
increase, at least at times, toward a final value, measuring the filling 
force in at least some articles with a delay which follows the completion 
of the subdividing step and is long enough to allow the filling force to 
reach a value sufficiently close to the final value for ascertainment of 
the final value on the basis of the measured value of the filling force, 
and regulating the quantity of material in the stream prior to wrapping as 
a function of variations of the measured value of the filling force. The 
regulating step includes reducing the quantity of material when the 
measured value of the filling force increases and vice versa. 
The aforementioned delay is at least one second and preferably more than 
three seconds; this insures that the filling force increases to a value 
which matches or is sufficiently close to the final value prior to start 
of the measuring or testing step. During the interval between severing and 
testing, the articles can be provided with rod-like components, e.g., with 
filter plugs or mouthpieces and can be stacked or otherwise arrayed in 
orderly fashion for further processing and/or for introduction into the 
testing station. 
The measuring step may include testing a fraction of the total number of 
articles which the trapped stream yields as a result of the subdividing 
step. For example, discrete articles which are obtained as a result of the 
subdividing step can be conveyed along a predetermined path (e.g., in the 
form of a single row wherein the articles move sideways); the measuring 
step then comprises testing each n-th article of the row, preferably by 
removing each n-th article from the row and transferring the removed 
article to the testing station. 
The testing step may comprise directing a stream of pressurized fluid 
(e.g., compressed air) against the exterior of the wrappers of the 
articles which are chosen for testing and monitoring the extent of 
deformation of the wrappers under the action of the fluid stream. 
In accordance with a presently preferred embodiment of testing selected 
(e.g., n-th) articles, the measuring or testing step comprises testing 
successive increments of articles and generating first signals denoting 
the filling force of each tested increment of an article under test. The 
method then further comprises (or preferably comprises) the step of 
generating a second signal denoting the average intensity or another 
characteristic of first signals which are obtained on testing of a given 
article, and the regulating step then comprises varying the quantity of 
material in the stream as a function of the extent of deviation of the 
intensity of each second signal from a reference signal of predetermined 
or variable intensity. 
The measuring step may comprise simultaneously testing a plurality of 
articles; the testing step then preferably comprises simultaneous 
application of a deforming stress to a plurality of articles (e.g., a 
deforming stress applied by a weight which is allowed to descend onto a 
stack or another orderly array of articles which together constitute a 
plurality of articles), and monitoring the changes of the combined volume 
of such plurality of articles in response to the application of the 
deforming stress. 
The regulating step may comprise removing from the stream material at a 
rate which is a function of the measured value of the filling force. For 
example, the stream can be transported toward the compacting station in 
such a way that it contains a surplus of particulate material, and such 
surplus is removed by a trimming or equalizing device which is adjustable 
in dependency on the measured value of the filling force so that it 
removes more material when the measured value of the filling force 
increases and vice versa. 
Alternatively, the converting step may comprise forming a continuous carpet 
of sliver of smokable material (e.g., in the distributor of a cigarette 
making machine) and converting the carpet into the aforementioned 
continuous stream of smokable particulate material. The regulating step 
then comprises (or may comprise) varying the quantity of material per unit 
length of the carpet or sliver as a function of measured value of the 
filling force. This can be achieved by driving a conveyor of the 
distributor at a speed which varies as a function of variations of the 
measured value of the filling force. 
The method may further comprise the steps of generating first signals which 
denote the quantity of material per unit length of the moving stream and 
comparing the first signals with a reference signal denoting the desired 
quantity of material per unit length of the moving stream. The regulating 
step then further comprises varying the quantity of material in the moving 
stream when a first signal deviates from the reference signal or when the 
average value of a series of first signals deviates from the reference 
signal. The step of generating first signals may comprise directing a beam 
of corpuscular radiation (e.g., beta rays) transversely of and against 
successive increments of the moving stream and monitoring the intensity of 
radiation which penetrates through the respective increments of the 
stream. Alternatively, the step of generating first signals may include a 
capacitive or other suitable measurement of the quantity of material per 
unit length of the moving stream. The measuring step may comprise 
generating third signals which denote the filling force of tested articles 
and the regulating step may comprise modifying the reference signal when 
the intensity of the third signal deviates from a predetermined value 
denoting a desired filling force. The arrangement is preferably such that 
the modifying step includes increasing the intensity of the reference 
signal when the intensity of the third signal is below the predetermined 
value, and vice versa. The modifying step is preferably interrupted when 
the measured quantity of material drops to a predetermined lower threshold 
value; this insures that the quantity of smokable material per unit length 
of the finished articles cannot be reduced below a minimum permissible 
value regardless of whether or not the filling force is higher than 
desired. 
The novel features which are considered as characteristic of the invention 
are set forth in particular in the appended claims. The improved apparatus 
itself, however, both as to its construction and its mode of operation, 
together with additional features and advantages thereof, will be best 
understood upon perusal of the following detailed description of certain 
specific embodiments with reference to the accompanying drawing.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
FIG. 1 shows a portion of a production line including a cigarette making 
machine 1 and a filter tipping machine 2 which is directly coupled to the 
machine 1. The machine 1 is of the type known as "GARANT" (trademark) 
produced by Hauni-Werke Korber & Co. KG., of Hamburg, Federal Republic 
Germany, and the machine 2 is of the type known as "MAX", also produced by 
Hauni-Werke. For the sake of clarity, FIG. 1 merely shows those component 
parts of the two machines which are important for full understanding of 
the invention. 
The cigarette making machine 1 comprises a distributor 3 (e.g., a 
distributor of the type disclosed in commonly owned U.S. Pat. No. 
3,996,944 granted December 14, 1976 to Alfred Hinzmann). The distributor 3 
comprises a conveyor 3A (e.g., a carded drum) for drawing elastically 
deformable particles of smokable material (assumed to be tobacco shreds) 
from a suitable source of supply 4, e.g., a magazine or a duct whose 
discharge end is disposed above the apex of the carded drum 3A. The 
distributor 3 comprises means, e.g., a customary endless apron conveyor at 
a converting station 6, for converting the withdrawn tobacco particles 
into a relatively thin and wide carpet or sliver which is thereupon 
converted into a continuous stream 7 containing a surplus of tobacco 
particles. The stream 7 is narrow and its cross-sectional area exceeds the 
cross-sectional area of the filler of a finished cigarette. The means for 
transporting the stream 7 in the direction of arrow 7A comprises an 
endless belt conveyor 7B which advances the stream 7 past a material 
removing station accommodating a regulating unit here shown as a trimming 
or equalizing device 12. The device 12 comprises one or more rotary knives 
10 which are movable at right angles to the direction of transport of the 
stream 7 to remove the surplus and to convert the stream 7 into a trimmed 
stream of filler 7a ready to be wrapped into a web 11 of cigarette paper 
or the like. The device wherein the trimmed stream or filler 7a is 
confined in the web 11 is shown at 8; this device comprises means for 
compacting or condensing the filler 7a so that it constitutes a rod which 
tends to expand and thereby exerts a force against the internal surface of 
the tubular wrapper*. In a manner known per se, the web 11 is drawn off a 
bobbin 9 and one of its marginal portions is coated with adhesive which is 
supplied by a conventional paster. The wrapping device 8 comprises a 
customary garniture which folds the marginal portions of the web over each 
other so that the marginal portions adhere to each other and form an 
elongated seam extending lengthwise of the resulting continuous cigarette 
rod 16 (wrapped stream 7a). The wrapping device 8 may further comprise or 
may be associated with a conventional sealer which promotes the setting of 
adhesive in the seam by cooling the seam if the adhesive is a hotmelt and 
by heating the seam if the adhesive is a wet adhesive which sets in 
response to the application of heat. The aforementioned belt conveyor 7B 
is preferably made of foraminous material and travels along a suction 
chamber which causes the particles of the streams 7 and 7a to adhere to 
the respective surface of the conveyor 7B during transport to the wrapping 
device 8. 
FNT *A suitable wrapping mechanism which compacts the filler is disclosed in 
U.S. Pat. No. 3,030,965 (FIG. 8-15). 
The equalizing device 12 further comprises a reversible motor 13 which can 
move the knife or knives 10 toward or away from the conveyor 7B to thereby 
change the quantity of tobacco particles per unit length of the stream 7a. 
The removed surplus is preferably returned to the source of supply 4 in a 
manner not specifically shown in FIG. 1. The reference character 14 
denotes a control circuit which transmits appropriate signals to the motor 
13 in order to move the knife or knives 10 toward or away from the path of 
movement of the stream 7. A trimming or equalizing device which can be 
used in the cigarette making machine 1 is disclosed, for example, in 
commonly owned U.S. Pat. No. 3,261,366 granted July 19, 1966 to Willy 
Richter et al. 
The means for monitoring the quantity of tobacco per unit length of the 
stream 7a upstream of the wrapping device 8 comprises a detector 17 
including a source 18 of corpuscular radiation (e.g., beta rays) and an 
ionization chamber 19. The parts 18 and 19 are disposed opposite each 
other at the opposite sides of the path for the stream 7a, and the 
ionization chamber 19 transmits signals whose intensity or another 
characteristic is proportional to the intensity of corpuscular radiation 
which penetrates through successive increments or unit lengths of the 
continuously moving stream 7a. The signals at the output of the ionization 
chamber 19 are transmitted to the corresponding input of an integrating 
circuit 21 whose output transmits a signal (denoting the actual quantity 
of tobacco per given length of the stream 7a) to the input a of a signal 
comparing stage 22. The input b of the signal comparing stage 22 receives 
a reference signal which is transmitted by a preferably adjustable source 
23 of reference signals (e.g., a potentiometer). The reference signal 
which is applied to the input b of the signal comparing stage 22 denotes 
the desired (optimum) quantity of tobacco particles per given length of 
the stream 7a. The connection between the output of the source 23 and the 
input b of the signal comparing stage 22 comprises a signal modifying 
circuit 92 (preferably a subtracting circuit) which can modify the 
reference signal in dependency on the monitored filling force of finished 
rod-shaped articles. The output c of the signal stage 22 transmits a 
signal which represents the difference between the intensities of signals 
transmitted to the inputs a and b of the stage 22, and such output signal 
is transmitted to the control circuit 14 for the motor 13 to effect 
appropriate adjustment of the knife or knives 10 in dependency on the 
monitored quantity of tobacco in the stream 7a. The adjustment is such 
that the knife or knives 10 are moved upwardly (as viewed in FIG. 1) when 
the monitored quantity of tobacco particles in the stream 7a is less than 
the desired quantity, and vice versa. In other words, the control unit 14 
insures that the quantity of tobacco in the stream 7a matches or closely 
approximates the quantity which is denoted by the reference signal 
furnished to the input b of the signal comparing stage 22. 
The cigarette making machine 1 further comprises a device 24 (commonly 
known as cutoff) which severs the continuous cigarette rod 16 at regular 
intervals so that the rod 16 yields a file of discrete plain cigarettes 20 
of unit length or multiple unit length. It is assumed that each cigarette 
20 is of unit length. The cutoff 24 comprises one or more orbiting knives 
which move forwardly (arrow 7A) at the speed of the rod 16 during severing 
and thereupon move backwards on their way into renewed severing engagement 
with the rod 16. A suitable cutoff is disclosed in commonly owned U.S. 
Pat. No. 3,518,911 granted July 7, 1970 to Helmut Niemann et al. 
Successive plain cigarettes 20 are propelled into successive flutes of a 
rotary drum-shaped row forming conveyor which forms part of the filter 
tipping machine 2 and is mounted at a row forming station 26. The conveyor 
converts the single file of plain cigarettes 20 into two rows A and B 
wherein the cigarettes move sideways and wherein each cigarette 20 of the 
row A is in axial alignment with but is spaced from a cigarette 20 of the 
row B. The gaps between pairs of coaxial cigarettes 20 of the rows A and B 
are shown at 25; the width of such gaps at least equals but preferably at 
least slightly exceeds the length of a filter mouthpiece or plug 27 of 
double unit length. These filter plugs are supplied by a filter making 
machine 28 which includes means for supplying a single row of registering 
filter plugs 27 to an inserting station 29 where each plug enters the gap 
25 between two aligned cigarettes 20 of the rows A and B so that each plug 
27 constitutes one component of a group of three coaxial rod-like 
components including two plain cigarettes 20 and a plug 27 therebetween. 
The filter tipping machine 2 further comprises or is associated with a 
device 31 which supplies a single file of adhesive-coated uniting bands 32 
serving to connect each filter plug 27 with the adjacent end portions of 
the respective plain cigarettes 20 so as to convert the respective group 
into a filter cigarette 20A of double unit length. The attachment of 
uniting bands 32 to the respective groups takes place at a station 33 
downstream of the inserting station 29 (as considered in the direction of 
movement of cigarettes 20 forming the rows A and B). The manner in which 
the uniting bands 32 are formed by coating a continuous web of artificial 
cork or the like with adhesive and by severing the web to yield discrete 
uniting bands is well known in the art. Reference may be had to commonly 
owned U.S. Pat. No. 3,962,957 granted June 15, 1976 to Alfred Hinzmann. 
The means for convoluting each uniting band 32 about the respective filter 
plug 27 and the inner end portions of the corresponding plain cigarettes 
20 is installed at a rolling station 35 which is located downstream of the 
station 33 and may accommodate an apparatus of the type disclosed in the 
commonly owned U.S. Pat. No. 3,527,234 granted Sept. 8, 1970 to Alfred 
Hinzmann. For example, the rolling station 35 may accommodate a rotary 
drum-shaped conveyor which advances the groups (each of which carries a 
uniting band) past a stationary or mobile rolling surface which defines 
with the drum a gap having a width less than the diameter of a filter plug 
27. This causes the groups to rotate about their respective axes whereby 
the uniting bands 32 are convoluted around the filter plugs 25 and the 
inner end portions of the associated plain cigarettes 20. 
The thus obtained filter cigarettes 20A of double unit length are severed 
seriatim by a rotary disk-shaped knife 37 so that each cigarette 20A 
yields two coaxial filter cigarettes 20B of unit length. The knife 37 is 
installed at a severing station 36. The filter cigarettes 20B of the row A 
are thereupon inverted end-for-end by a turn around device 38, e.g., a 
device of the type disclosed in commonly owned U.S. Pat. No. 3,583,546 
granted June 8, 1971 to Gerhard Koop. The device 38 places the inverted 
cigarettes 20B of the row A between the non-inverted cigarettes 20B of the 
row B so that the filter plugs 220B of all cigarettes 20B face in the same 
direction and the inverted and non-inverted cigarettes 20B form a single 
row C which advances downwardly, as viewed in FIG. 1, i.e., all cigarettes 
20B move sideways and are in accurate register with each other. The 
cigarettes 20B which form the row C are transported on to a packing 
machine PM (e.g., a machine of the type disclosed in commonly owned U.S. 
Pat. No. 3,805,477 granted Apr. 23, 1974 to Friedel Kruse et al.), or to 
another processing station. 
In accordance with a feature of the invention, there is further provided a 
withdrawing or transferring device 41 which can remove selected (n-th) 
cigarettes 20B from the row C at a withdrawing station or transfer station 
41 at which the row C advances in the flutes of a rotary drum-shaped 
conveyor 53. The withdrawing or transferring device 42 comprises a timer 
43 which effects the withdrawal of each nth (e.g., each 1000th or 5000th) 
cigarette 20B from the path for the row C. The signal at the output of the 
timer 43 is transmitted to a solenoid-operated valve 46 which directs a 
jet of compressed air against the end face of the adjacent cigarette 20B 
in the row C to thereby transfer such cigarette onto the upper reach of a 
belt conveyor 54 serving to deliver the thus withdrawn cigarette to the 
testing station. The valve 46 is installed in a conduit 52A which 
communicates with a suitable source 52 of compressed air, and the orifice 
of the nozzle of the valve 46 faces the adjacent end faces of cigarettes 
20B in the row C, i.e., of cigarettes in the flutes of the conveyor 53. 
The timer 43 comprises a disk 47 which is driven in synchronism with moving 
parts of the filter tipping machine 2 and has an annulus of pulse 
generating pins 48 travelling past a proximity switch 49 which transmits 
signals to a control circuit 44 via amplifier 51. The step-down ratio 
between the prime mover (not shown) of the filter tipping machine 2 and 
the shaft 47A of the disk 47 is selected in such a way that the valve 46 
expels from the row C each nth cigarette 20B, e.g., each 1000th or 5000th 
cigarette of the row C. 
The belt conveyor 54 derives motion from the prime mover of the filter 
tipping machine 2 and is sufficiently long to insure that the cigarettes 
20B which have been chosen for testing remain on its upper reach for a 
selected interval of time so that the length of the interval which elapses 
between the compacting of the filler of such cigarette in the wrapping 
device 8 (or between the separation of the respective cigarette from the 
rod 16 by a knife of the cutoff 24) exceeds a predetermined minimum 
interval, e.g., at least one second but preferably three or more seconds. 
The testing or measuring device 56 receives selected cigarettes 20B from 
the discharge end 58 of the belt conveyor 54 and is designed to ascertain 
the filling force of the fillers of cigarettes 20B which are delivered 
thereto by the conveyor 54. The purpose of the delay which is achieved by 
causing the selected cigarettes 20B to travel with the upper reach of the 
belt conveyor 54 is to insure that the filling force of tobacco which is 
confined in such cigarettes increases sufficiently to reach, during 
testing, a value which is identical with or close to the final value. At 
any rate, the aforementioned interval should be long enough to enable the 
measuring or testing device 56 to ascertain the momentary filling force of 
the filler of the tested cigarette at a time when the measured value of 
the filling force is sufficiently close to the final value so that one can 
ascertain the final value of the filling force or that one can estimate 
such final value with a degree of certainty which is sufficient to allow 
for appropriate automatic adjustment of the quantity of tobacco in the 
stream 7a as a function of deviations of the final filling force from a 
desired or predetermined optimum value. The filling force at one end of 
each cigarette 20B is also reduced as a result of severing by the knife 
37; therefore, the distance between the station 36 and the testing device 
56 should be sufficient to enable the filling force to increase to the 
aforediscussed value which is identical with or at least close to the 
final value. 
The testing or measuring device 56 has a funnel-shaped inlet 57 wherein an 
oncoming filter cigarette 20B descends in such a way that the filter 
mouthpiece 220B is located at the lower end. The inlet 57 is located at a 
level above a ring-shaped testing nozzle 63 the details of which are shown 
in FIG. 1a. The nozzle 63 defines a vertical passage 63A wherein the 
cigarette 20B descends and the nozzle is further formed with a narrow 
annular clearance 64 which communicates with the passage 63A and receives 
a compressed gaseous testing fluid (preferably air) from a source 59 by 
way of a conduit 59A containing an electrically controllable shutoff valve 
61 and a preferably adjustable flow restrictor 62. Compressed air which 
flows from the annular clearance 64 into the passage 63A deforms the 
tubular wrapper 320B of the cigarette 20B while the cigarette descends in 
the passage 63A, and the extent of deformation of the wrapper 320B 
(against the opposition of the confined compacted tobacco filler) is 
indicative of the filling force of the filler, i.e., of the force with 
which the compacted and confined filler bears against the internal surface 
of the wrapper 320B. The diameter of the passage 63A (and hence the inner 
diameter of the annular clearance 64) slightly exceeds the diameter of the 
wrapper 320B in undeformed condition of the cigarette. 
It can be said that, as the cigarette 20B descends in the passage 63A, 
successive increments of its wrapper 320B are formed with ring-shaped 
constrictions (not specifically shown in FIG. 1a) which are identical if 
the filling force of the entire tobacco filler is constant or whose 
diameters vary in dependency on variations of the filling force of the 
filler in a direction from the lower toward the upper end of the 
tobacco-containing portion of the cigarette 20B in the passage 63A. 
The flow restrictor 62 is adjusted in such a way that the extent of 
deformation of the wrapper 320B in the nozzle 63 is within the elastic 
range of the material of the filler, i.e., that the filler expands (the 
constriction disappears) immediately or shortly after the cigarette leaves 
the nozzle 63. Thus, the tested cigarette again constitutes or resembles 
an elongated rod of constant diameter. Such selection of pressure of the 
testing fluid is particularly desirable if the tested cigarettes 20B are 
to be further processed, e.g., by admitting them into the magazine of the 
packing machine PM for introduction into soft or flip-top packs. 
As mentioned above, the extent of deformation of a portion of the wrapper 
320B under the action of compressed testing fluid flowing from the annular 
clearance 64 into the passage 63A is indicative of the filling force of 
the corresponding portion of the filler. Therefore, by ascertaining the 
degree or extent of deformation, one can ascertain the filling force of 
the filler at the time the respective cigarette 20B descends in the nozzle 
63. In order to ascertain the extent to which the wrapper 320B is 
deformed, one can monitor the pressure of testing fluid immediately 
downstream of the clearance 64 or in the clearance proper because such 
pressure varies with the extent to which the wrapper is deformed and 
allows testing fluid to flow from the clearance 64 into and from the 
passage 63A. 
Another mode of ascertaining the extent of deformation of the wrapper 320B 
is shown in FIG. 1a. Thus, the nozzle 63 is formed with an annular groove 
66 which communicates with the passage 63A immediately downstream of the 
locus of communication between the passage 63A and the clearance 64. The 
pressure of fluid which flows into the groove 66 is a reliable indicator 
of the extent of deformation of the corresponding portion of the wrapper 
320B. Thus, the filling force is more pronounced when the pressure in the 
groove 66 is higher, and vice versa. 
The valve 61 can be opened, via amplifier 67, by the output signal which is 
transmitted by a reflection type photoelectronic cell 68 installed in a 
conical portion 65 of the nozzle 63 at a level below the groove 66. The 
photodiode 69 of the cell 68 transmits a signal when the light beam 
issuing from the light source 71 of the cell 68 impinges upon white 
cigarette paper (i.e., the valve 61 can remain closed to prevent testing 
when the filter mouthpiece 220B of a cigarette 20B advances past the cell 
68 provided, of course, that the convoluted uniting band 32 does not 
reflect a sufficient amount of light onto the photosensitive surface of 
the diode 69). The cell 68 insures that the valve 61 is open only during 
that interval when a selected cigarette 20B descends in the passage 63A of 
the nozzle 63. 
A conduit 72 connects the annular groove 66 with a transducer 73 (e.g., a 
diaphragm transducer of the type disclosed in commonly owned U.S. Pat. No. 
3,412,856 granted Nov. 26, 1968 to Albert Esenwein). The transducer 
transmits electric signals to a summing amplifier 81 shown in FIG. 1. 
The filter plug 220B of a selected cigarette 20B which advances beyond the 
discharge end 58 of the belt conveyor 54 and descends in the inlet 57 and 
thereupon advances through the passage 63A descends onto the upper side or 
surface of a mobile stop 74 here shown as an arm which is attached to a 
vertically reciprocable toothed rack 76. The rack 76 is reciprocable in 
suitable bearings 76A, 76B and meshes with a pinion 77 which is driven by 
a reversible electric motor 78 by way of a belt transmission or the like. 
The motor 78 is mounted in or on the frame of the machine 2 or 1 and 
receives start, stop and reverse signals from an amplifier 79 of 
conventional design. The arrangement is such that the motor 78 is started 
in a direction to move the rack 76 and the arm 74 downwardly, as viewed in 
FIG. 1, when the input a of the amplifier 79 receives a signal from the 
output of the photodiode 69 of the cell 68. As mentioned above, the diode 
69 transmits such signal when the cell 68 detects the presence of white 
wrapping material in the nozzle 63, i.e., when the testing operation is to 
begin. The motor 78 then drives the pinion 77 at a constant speed so that 
the cigarette 20B whose filter mouthpiece 220B rests on the arm 74 
descends at a preselected speed and the testing fluid which issues from 
the clearance 64 deforms successive increments of the tubular wrapper 
320B. The fluid which flows along the wrapper 320B enters the groove 66 
and flows through the conduit 72 to effect the generation of a 
corresponding electric signal at the output of the transducer 73, i.e., 
such signal is indicative of the measured filling force of successive 
increments of the filler in the tubular wrapper 320B. The summing 
amplifier 81 totalizes the signals which are transmitted by the transducer 
73 in the course of a testing operation, i.e., the signal at the output of 
the amplifier 81 denotes the integrated value of the filling force of an 
entire filler. 
A limit switch 82 which is installed in the path of movement of the arm 74 
transmits a signal when the testing operation is to be completed. Such 
signal is transmitted to the corresponding input of the amplifier 67 which 
erases the signal at the amplifier input which is connected with the 
photodiode 69 so that the valve 61 is closed as soon as the upper end of 
the cigarette 20B descends below the clearance 64 and groove 66. At the 
same time, the limit switch 82 transmits a signal to the amplifier 81 
which transmits the integrated signal to an averaging circuit 83 whose 
output is connected with the aforementioned signal modifying or 
subtracting circuit 92 in the connection between the source 23 of 
reference signals and the input b of the signal comparing stage 22. The 
amplifier 81 is reset to zero as soon as the information which is stored 
therein is transmitted to the averaging circuit 83. Thus, the apparatus is 
ready for testing of the next selected cigarette 20B immediately after the 
arm 74 actuates the detector or limit switch 82. 
The motor 78 continues to move the arm 74 downwardly after actuation of the 
limit switch 82 whereby the arm 74 engages and actuates a further limit 
switch 84 which transmits a signal to the input b of the amplifier 79. 
This causes the amplifier 79 to supply the motor 78 with voltage of 
opposite polarity so that the motor 78 rotates the pinion 77 in a 
clockwise direction, as viewed in FIG. 1, and causes the rack 76 to return 
the arm 74 to the upper end position or starting position in which the arm 
is ready to intercept the next cigarette 20B which advances beyond the 
discharge end 58 of the belt conveyor 54. 
The upward movement of the arm 74 back to the starting position of FIG. 1 
is preceeded by expulsion of the freshly tested cigarette 20B into an 
intercepting container 89, e.g., a chute which can direct freshly tested 
articles onto a conveyor for transport into the magazine of the packing 
machine PM. The transfer of freshly tested cigarettes 20B from the arm 74 
into the container 89 is initiated by the signal which is generated by the 
limit switch 84 on actuation by the arm 74. Such signal is transmitted to 
the input b of the amplifier 79 (as described above) as well as to an 
amplifier 86 which causes a solenoid-operated valve 87 to open. The valve 
87 is installed in a conduit 87A which connects the source 59 or another 
source of compressed air with a nozzle 88. The nozzle then discharges a 
blast of compressed air which propels the freshly tested cigarette 20B 
from the arm 74 into the container 89 before the arm 74 begins to move 
back toward the illustrated starting position. When the arm 74 reaches 
such starting position, it actuates a limit switch 91 which transmits a 
signal to the input c of the amplifier 79 to thereby arrest the motor 78. 
The output signal of the averaging circuit 83 is transmitted to the 
subtracting circuit 92 wherein it is deducted from the reference signal 
which is transmitted by the source 23 of reference signals. The output 
signal of the subtracting circuit 92 constitutes the corrected reference 
signal and is transmitted to the input b of the signal comparing stage 22. 
Thus, the knife or knives of the equalizing device 12 are moved toward the 
conveyor 7B for the tobacco stream 7 when the filling force increases so 
that more tobacco is removed and, consequently, the finished cigarettes 
contain less tobacco. When the measured value of the filling force 
decreases, the knife or knives 10 of the equalizing device 12 are moved in 
the opposite direction, namely, away from the conveyor 7B, so that more 
tobacco remains in the stream 7a and the quantity of tobacco in the 
cigarettes 20 is increased. The subtracting circuit 29 has a lower 
threshold value for its output signal, i.e., the intensity of the output 
signal cannot decrease below such threshold value. This insures that the 
weight of the filler in each cigarette at least equals the prescribed 
minimum permissible weight. The averaging circuit 83 insures that the 
position of the knife or knives 10 is not changed in response to excessive 
deviation of filling force of a portion of the filler in a cigarette 20B 
from the desired value. 
In place of the illustrated ring-shaped testing nozzle 63, the filling 
force can also be measured in a different way. For example, it may be 
advantageous to ascertain the elastic deformation of a wrapped portion of 
the rod 16 by photoelectronic means in a manner as disclosed in British 
Pat. No. 1,422,991. 
Another mode of regulating the quantity of material in the stream 7a 
includes adjustment of the mass of tobacco in the carpet or sliver which 
is formed by the distributor 3 of the cigarette making machine 1. The 
control connection between the signal comparing stage 22 and an adjustable 
variable-speed transmission 93 for the tobacco supplying conveyor 3A or 
another conveyor of the distributor 3 is indicated by a broken line 94. 
The details of such controls are adequately shown in U.S. Pat. No. 
2,729,213 granted Jan. 3, 1956 to William C. Broekhuysen et al. so that a 
detailed description of such mode of regulating the quantity of tobacco in 
the stream 7a is not necessary. 
FIG. 2 shows a modified apparatus which differs from the embodiments of 
FIGS. 1 and 1a essentially in that, instead of testing discrete cigarettes 
for determination of the filling force of tobacco which is contained 
therein, the testing device 156 of the modified apparatus can 
simultaneously test a predetermined number of cigarettes which are 
confined in a container, a so-called charger or tray. This mode of testing 
can be resorted to for ascertainment of the filling force of tobacco in 
all cigarettes which issue from the filter tipping machine. 
Those components of the production line of FIG. 2 which are identical with 
or analogous to corresponding components of the production line of FIG. 1 
are denoted by similar reference characters plus 100. 
A comparison with FIG. 1 shows that the cigarette making machines 1, 101 
and the filter tipping machines 2, 102 are of identical construction all 
the way to the respective turn-around devices 38 and 138. The turn-around 
device 138 of FIG. 2 deviates from the turn-around device 38 in that it 
tip-turns the cigarettes 120B of the row B and places the inverted 
cigarettes between the non-inverted cigarettes 120B of the row A. 
The cigarettes 120B of the row C which are transported from the filter 
tipping machine 102 on a conveyor belt 153 are delivered to a charger 
filling machine 201 which is shown schematically in plan view. A charger 
filling machine which is especially suited for use in the production line 
of FIG. 2 is known in the cigarette industry under the name "CASCADE" 
(produced by Hauni-Werke) and is described in detail in U.S. Pat. No. 
3,308,600 granted Mar. 14, 1967 to Otto Erdmann et al. The reason that 
the machine 201 is especially suited for determination of filling force in 
a manner to be described below is that its suction head which is indicated 
at 202 invariably removes from the conveyor belt 153 a predetermined 
number of filter cigarettes 120B and sucks them upwardly into flutes which 
are adjacent to each other. Thus, during each filling stroke of a transfer 
member or pusher 203, a full row which contains a fixed number of filter 
cigarettes 120B is introduced into a charger 204 so that, when filled and 
transferred from the filling station 206 onto a belt conveyor 208 which 
advances in the direction indicated by arrow 207, the charger 204 
invariably contains a block or stack consisting of a predetermined number 
of arrayed filter cigarettes 120B (e.g., 6000 or 8000 cigarettes). Since 
the individual rows are placed on top of each other while laterally offset 
by one-half of a cigarette diameter so that the individual cigarettes of 
one row are always deposited in the gaps between the cigarettes of the row 
therebelow, the filled charger 204 contains a highly homogenous block or 
stack which, therefore, is suited for simultaneous determination of the 
filling force of tobacco in all cigarettes therein. 
For the sake of clearer illustration of the testing device, the charger 204 
downstream of the arrow 209 is turned through 180 degrees so that is can 
be seen in front elevation as viewed in the direction of arrow 207. 
The testing device 156 of FIG. 2 comprises a plate-like weight 211 whose 
width corresponds to the width of the cigarette stack in the filled 
charger 204. The weight 211 can be moved up and down by a toothed rack 212 
and a pinion 213 which latter can be driven by an electric motor 216 by 
way of an electrically controllable clutch 214. 
When the filled charger 204 reaches the illustrated testing position, the 
input a of a control circuit 217 for the motor 216 receives a signal from 
a limit switch 218 which simultaneously arrests the drive for the conveyor 
belt 208. The control circuit 217 then supplies to the motor 216 voltage 
which initiates rotary movement in a direction to lower the weight 211. As 
soon as the weight 211 descends onto the cigarette stack in the filled 
charger 204, a plate-like sensor 219 (recessed into the underside of the 
weight 211) is displaced against the opposition of a spring 221 and 
thereby actuates a switch 222. This switch 222 transmits a signal to the 
input a of the clutch 214 whereby the power flow between the motor 216 and 
the pinion 213 is interrupted so that the weight 211 is released and its 
mass can apply a deforming stress to the cigarette stack therebelow. The 
distance which the weight 211 thereupon covers depends on the filling 
force of tobacco which is contained in the cigarettes of the stack so that 
one can ascertain the filling force on the basis of measurement of such 
distance. 
For the purpose of measuring the distance, the signal which is transmitted 
in response to closing of the switch 222 is further transmitted to the 
input a of a counter 223 to prepare the counter for reception of distance 
denoting signals at its input b. The distance denoting signals are 
transmitted by a stationary reflection type photoelectronic cell 224 which 
monitors a graduated raster 226 connected to the rack 212 and moving along 
the cell 224. The cell transmits a signal on detection of each graduation 
of the raster 226, and such signals are transmited to and counted by the 
counter 223. Rasters with strip-shaped graduations and associated 
monitoring means for measuring the distances covered by mobile parts are 
well known, especially in machine tools. 
The number of counted signals, i.e., the condition of the counter 223 after 
elapse of the measuring interval, is indicative of the distance covered by 
the weight 211 which thereby slightly reduces the height of the stack in 
the filled charger 204. Since this distance is a function of the filling 
force, it is indicative of the filling force proper. Actually, the 
distance is indicative of the average value of filling force of the 
fillers of all tested articles 20B in a charger 204. 
The means for terminating the measuring interval comprises a time-delay 
device 227 which delays the signal supplied thereto on actuation of the 
switch 222 and thereupon transmits the signal to the input c of the 
counter 223 whereby the information which is stored in the counter is 
transmitted to a storage 229 and the counter is simultaneously restored to 
its initial condition. 
The output signal of the time-delay device 227 is further transmitted to 
the input b of the control circuit 217 which thereupon supplies to the 
electric motor 216 voltage of opposite polarity so that the motor is 
started and rotates in the opposite direction. Since the output signal of 
the time-delay device 227 is also transmitted to the input b of the clutch 
214 and has caused engagement of the clutch, the rack 212 is moved 
upwardly until a limit switch 228 transmits a signal to the input c of the 
circuit 217 to terminate the supply of energy so that the motor 216 comes 
to a halt. A brake, not shown, which is actuated at the same time prevents 
unintentional lowering of the weight 211. Furthermore, and since the 
signal which has been generated as a result of closing of the switch 222 
disappears, further counting by the counter 223 of signals which are 
transmitted by the cell 224 is impossible. The limit switch 228 thereupon 
starts the drive means for the transporting belt 208 so that the charger 
204 which contains tested articles is removed from the range of the 
testing device 156 and the latter is available for the next-following 
charger. The testing device 156 can test the contents of each and every 
filled charger or the contents of each n-th charger. 
The signal which is stored in the storage 229 and denotes the measured 
filling force, and which corresponds to the integrated value (comparable 
to average value signal furnished by the circuit 83 of FIG. 1), is again 
transmitted to a subtracting or modifying circuit 192 wherein it is 
deducted from the reference signal supplied by the source 123 of reference 
signals. In a manner as shown in FIG. 1, the quantity of tobacco in the 
stream 107a is regulated via signal comparing stage 122 in dependency on 
the measured filling force, namely, either by adjustment of the regulating 
means including the equalizing device 112 or by adjustment of the 
distributor 103 in the cigarette making machine 101. 
The integrated measured values of filling force for tobacco in cigarettes 
120B which are confined in a charger 204 can be used, as in FIG. 1, for 
calculation of average values by means of an averaging circuit (not shown) 
which average values serve to influence the quantity of material in the 
stream 107a. 
If the ultimate products are plain cigarettes, the testing device 56 or 156 
receives some or all of the articles which issue from the cigarette making 
machine 1 or 101. It is further clear that the device 56 or 156 can test 
the plain cigarettes 20 or 120 prior to introduction of such cigarettes 
into the filter tipping machine 2 or 102. 
The aforementioned interval of at least one second and preferably more than 
three seconds can be greatly exceeded. This further insures that the 
measured filling force is close to or matches the final filling force, 
namely, the filling force which is ascertained by the purchaser prior to 
or during smoking. 
An important advantage of the improved method and apparatus is that the 
manufacture of cigarettes can be regulated not only in dependency on the 
mass of tobacco (which is not a satisfactory indicator of the quality of 
cigarettes) but also that the regulation is influenced, in a fully 
automatic way, by measured values of the filling force and that the 
measured values denote the actually achieved filling force, i.e., the 
measured values at least approximate the final value of the filling force. 
Without further analysis, the foregoing will so fully reveal the gist of 
the present invention that others can, by applying current knowledge, 
readily adapt it for various applications without omitting features that, 
from the standpoint of prior art, fairly constitute essential 
characteristics of the generic and specific aspects of my contribution to 
the art and, therefore, such adaptations should and are intended to be 
comprehended within the meaning and range of equivalence of the claims.