Systems and methods for an automatic filling machine

A rolling system including a measuring station. The measuring station includes a hopper for receiving a smokable product, a vibratory bowl for receiving the smokable product from the hopper, a weigh bowl for receiving the smokable product from the vibratory bowl, a weigh module attached to the weigh bowl for measuring the smokable product in the weigh bowl, and a puck defining a plurality of cavities for receiving the smokable product therein. Each cavity of the plurality of cavities is configured to receive a predetermined amount of smokable product within a predetermined tolerance of the predetermined amount.

TECHNICAL FIELD

The present invention is in the technical field of weighing and filling systems and more particularly to an accurate net weight-based filling system for producing prerolls that are compliant, consistent, repeatable, and scalable for automatic cone filling.

BACKGROUND

Currently available systems for weighing products and filling containers do not fill the container with an accurately measured amount of the substance. For example, in the smokable products industry, prerolled smokable products are typically hand filled and rolled. The person manually filling and rolling the product typically measures an amount of the smokable product on a weighing device and manually fills a preroll with the weighed smokable product. The weighing device may be of low quality and may not be accurate and smokable product may be lost in the transfer from the weighing device into the preroll. As such, an unknown amount of the smokable product may be filled in the preroll.

Additionally, federal, state, and local regulations may require that the amount of smokable substance within the preroll be within a predetermined tolerance. Specifically, at least some regulations require that the prerolled smokable product have an actual weight that is within the predetermined tolerance of a predetermined weight. More specifically, at least some regulations require that the actual weight of the prerolled smokable product be within ±3% or the predetermined weight. For example, some regulations require that the actual weight of the prerolled smokable product be with ±3% of 0.5 grams (g). Manually weighing and filling of prerolled smokable product may result in loses of up to 20% of the smokable product because the roller may not accurately weigh the product, resulting in the prerolled smokable product being discarded.

Currently available systems for automatically filling and weighing the prerolled smokable products use a volume method that is unreliable and not useful for many critical applications. Specifically, the volume method typically does not accurately weigh the product such that the actual weight of the prerolled smokable products is within the predetermined tolerance of the predetermined weight. More specifically, the volume method, and other weighing methods, have difficultly accurately weighing smokable products with speed and accuracy.

Therefore, there is a need for a weighing and filling system that overcomes the above referenced limitations by providing an accurate net weight based rolling system producing prerolls that are compliant, consistent, repeatable, and scalable for automatic cone filling.

SUMMARY

An aspect of the present disclosure relates to a weighing and filling system including a measuring station. The measuring station includes a hopper for receiving a smokable product, a vibratory bowl for receiving the smokable product from the hopper, a weigh bowl for receiving the smokable product from the vibratory bowl, a weigh module attached to the weigh bowl for measuring the smokable product in the weigh bowl, and a puck defining a plurality of cavities for receiving the smokable product therein. Each cavity of the plurality of cavities is configured to receive a predetermined amount of smokable product within a predetermined tolerance of the predetermined amount.

Another aspect of the present disclosure relates to a method of manufacturing a plurality of prerolled cones containing a smokable product using a measuring station and a tamping station. The measuring station includes a hopper, a vibratory bowl, a weigh bowl, a weigh module, and a puck. The tamping station includes an upper tube assembly including a plurality of tight tubes for containing the plurality of prerolled cones, a lower tube assembly including a plurality of loose tubes for containing the plurality of prerolled cones, and a seating platform. The method includes receiving the smokable product into the vibratory bowl. The method also includes metering the smokable product from the vibratory bowl to the weigh bowl. The method further includes measuring the smokable product in the weigh bowl using the weigh modules. The method also includes determining that the smokable product in the weigh bowl is within a predetermined tolerance of a predetermined amount of smokable product. The method further includes moving the smokable product from the weigh bowl to a plurality of cavities within the puck. The method also includes transferring the puck to the tamping station. The method further includes stacking the upper tube assembly on the lower tube assembly and the puck on the upper tube assembly. The method also includes vibrating the upper tube assembly, the lower tube assembly, and the puck with the seating platform to tamp the smokable product in the plurality of cavities into the plurality of prerolled cones.

DETAILED DESCRIPTION

FIG.1illustrates a perspective view of an accurate net weight based rolling system100for producing prerolls that are compliant, consistent, repeatable, and scalable for automatic cone filling, according to one embodiment of the present invention. The accurate net weight based rolling system100includes a measuring station200and a tamping station600.FIG.2illustrates a perspective view of the measuring station200shown inFIG.1.FIG.3illustrates a front view of the measuring station200shown inFIG.1.FIG.4illustrates a side view of the measuring station200shown inFIG.1.FIG.5illustrates a top view of the measuring station200shown inFIG.1.FIG.6illustrates a perspective view of the tamping station600shown inFIG.1.FIG.7illustrates a front view of the tamping station600shown inFIG.1.FIG.8illustrates a side view of the tamping station600shown inFIG.1.FIG.9illustrates a top view of the tamping station600shown inFIG.1.

As shown inFIG.2, the measuring station200includes at least one hopper202and204. In the illustrated embodiment, the measuring station200includes two hoppers202and204for receiving the smokable product and feeding the smokable product to the rest of the measuring station200. In alternative embodiments, the measuring station200may include any number of hoppers202and204that enables the measuring station200to operate as described herein. The measuring station200also includes at least one linear feeder pan206and208that is connected to the hoppers202and204such that the hoppers202and204feed the smokable product to the linear feeder pans206and208. In the illustrated embodiment, the measuring station200includes two linear feeder pans206and208for receiving the smokable product from the hoppers202and204and feeding the smokable product to the rest of the measuring station200. In alternative embodiments, the measuring station200may include any number of linear feeder pans206and208that enables the measuring station200to operate as described herein.

The measuring station200further includes at least one vibratory bowl210and212that is connected to the linear feeder pans206and208such that the linear feeder pans206and208feed the smokable product to the vibratory bowls210and212. In the illustrated embodiment, the measuring station200includes two vibratory bowls210and212for receiving the smokable product from the linear feeder pans206and208and feeding the smokable product to the rest of the measuring station200. In alternative embodiments, the measuring station200may include any number of vibratory bowls210and212that enables the measuring station200to operate as described herein. The measuring station200also includes at least one weigh bucket scoop214and216for receiving the smokable product from the vibratory bowls210and212. In the illustrated embodiment, the measuring station200includes two weigh bucket scoops214and216for receiving the smokable product from the vibratory bowls210and212and feeding the smokable product to the rest of the measuring station200. In alternative embodiments, the measuring station200may include any number of weigh bucket scoops214and216that enables the measuring station200to operate as described herein.

The measuring station200further includes at least one weigh modules218and220is attached to the weigh bucket scoops214and216for weighing the smokable product in the weigh bucket scoops214and216. In the illustrated embodiment, the measuring station200includes two weigh modules218and220for weighing the smokable product in the weigh bucket scoops214and216. In alternative embodiments, the measuring station200may include any number of weigh modules218and220that enables the measuring station200to operate as described herein. The measuring station200also includes at least one feeder222and224for receiving the smokable product from the weigh bucket scoops214and216. In the illustrated embodiment, the measuring station200includes two feeders222and224for receiving the smokable product from the weigh bucket scoops214and216and feeding the smokable product to the rest of the measuring station200. In alternative embodiments, the measuring station200may include any number of feeders222and224that enables the measuring station200to operate as described herein.

The measuring station200further includes a puck226defining a plurality of cavities228for receiving the smokable product from the feeders222and224. In the illustrated embodiment, the measuring station200includes one puck226including240cavities for receiving the smokable product from the feeders222and224. In alternative embodiments, the measuring station200may include any number of pucks226including any number of cavities228that enables the measuring station200to operate as described herein. The measuring station200further includes at least one X-axis orienter230and at least one Y-axis orienter232that are connected to the puck226for positioning the cavities228below the feeders222and224to ensure that the smokable product is loaded into a cavity228without losing smokable product. The puck226is removably attached to a system chassis234of the measuring station200such that the puck226may be moved to the tamping station600without losing smokable product. The measuring station200also includes a main control console236is also attached to the system chassis234.

During operation of the measuring station200, smokable product is loaded into the hoppers202and204and the hoppers202and204feed the smokable product into the linear feeder pans206and208. As discussed in greater detail below, the hoppers202and204and the linear feeder pans206and208are designed to feed the smokable product to the measuring station200in consistent manner. The linear feeder pans206and208then feed the smokable product to the vibratory bowls210and212, which meters the smokable product to the weigh bucket scoops214and216in a controlled and predictable manner such that each weigh bucket scoop214and216is filled with a precise, predetermined amount of smokable product. The weigh modules218and220then precisely weigh the smokable product in each weigh bucket scoop214and216to ensure that each cavity228is filled with the predetermined amount of smokable product. If the smokable product in the weigh bucket scoops214and216is within a predetermined tolerance of the predetermined amount of smokable product, the weigh bucket scoops214and216feed the smokable product into the feeders222and224which feed the smokable product into the cavities228. The X-axis orienter230and the Y-axis orienter232move the puck226such that empty cavities228are positioned below the feeders222and224and the process is repeated until all of the cavities228are filled. The puck226is then moved to the tamping station600for packing as described below. Additionally, as described below, each portion of the measuring station200has been precisely designed to feed a consistent amount of smokable product through the measuring station200such that each cavity228contains the predetermined amount of smokable product within the predetermined tolerance.

As shown inFIGS.6-9, the tamping station600includes a table602, an air nozzle604, a pneumatic piston606, a seating platform608, a first thin layer of low friction UHMW610, an upper tube assembly612, a lower tube assembly614, a short air cylinder616, a long air cylinder618, and a receiving tray620. The table602provides structural support for the tamping station600and the air nozzle604, the pneumatic piston606, the seating platform608, the first thin layer of low friction UHMW610, the upper tube assembly612, the lower tube assembly614, the short air cylinder616, the long air cylinder618, and the receiving tray620are supported by or attached to the table602.

The air nozzle604is attached to the table602and is configured to seat cones into the upper tube assembly612such that the cones receive the smokable product while minimizing loss of the smokable product. Specifically, the preassembled cones are manually placed in the upper tube assembly612and the air nozzle604is used to manually seat the cone in the upper tube assembly612such that each cone fits snuggly in the upper tube assembly612. In the illustrated embodiment, the air nozzle602includes a flat brush design that allows the operator to swiftly seat the cones into position for tamping. In the illustrated embodiment, the air nozzle604is configured to disperse air evenly into two cones simultaneously. In alternative embodiments, the air nozzle604may be configured to disperse air evenly into any number of cones simultaneously.

The seating platform608is attached to the table602and configured to tamp and fill the cones. The seating platform608is attached to the short air cylinder616and the long air cylinder618. The seating platform608supports and tamps the cones to form an even pack while seated in the loose cones. The seating platform608has two positions, “up”, or “start”, and “down”, or “tamp”. The long air cylinder618moves the seating platform608from the filling position (tight tubes) to the tamping position (loose tubes) and back up to be transferred onto the lower tube assembly614. The short air cylinder616is equipped with specialty software and hardware to control the short air cylinder's616amplitude and stroke for a desired tamping action and bounces the cones to compaction according to customer preferences.

The pneumatic piston606is configured to vibrate the upper tube assembly612, the lower tube assembly614, and the puck226. The vibrations caused by the pneumatic piston606is used to settle the smokable product into the cones and assist in the tamping process. The receiving tray620allows the operator to move the packed cones away from the upper tube assembly612and the lower tube assembly614for twisting and packaging.

During operations, the cones are preassembled and placed in the upper tube assembly612and seated into the upper tube assembly612using the air nozzle604. The puck226is filled with smokable product as described above. The first thin layer of low friction UHMW610is attached to the puck226such that the smokable product remains in the cavities228. The puck226and the first thin layer of low friction UHMW610are stacked onto the upper tube assembly612and the lower tube assembly614as shown inFIGS.6-9. The seating platform is in the state position and the first thin layer of low friction UHMW610is removed to enable the smokable product to fall into the cones. The upper tube assembly612, the lower tube assembly614, and the puck226are vibrated by the pneumatic piston606to settle the smokable product in the cones. The puck226is removed and returned to the measuring station200. The seating platform608is lowered to tamping position by the long air cylinder618. The cones descend from the upper tube assembly612to the loose, frictionless lower tube assembly614and are continuously vibrated. The short air cylinder616has software and hardware that control amplitude and stroke for a tamping action and bounces the cones to compaction. The upper tube assembly612is removed to expose the filled, tamped cones. The precisely filled, tamped cones are then slid onto the receiving tray620with no loss of product and are slightly elevated to expose the cones for ease of access for removal and/or end twisting.

FIG.10is a perspective view of the hoppers202and204and the linear feeder pans206and208.FIG.11is a schematic side view of the hoppers202and204and the linear feeder pans206and208.FIG.12is a schematic front view of the hoppers202and204and the linear feeder pans206and208.FIG.13is a schematic top view of the hoppers202and204and the linear feeder pans206and208.

As shown inFIGS.10-13, the hoppers202and204include a V-shaped container1002including a screen1004and a gate1006. The screen1004has a predetermined mesh size that ensures that the smokable product is small enough to fit into the cavities228and the cones. More specifically, the screen1004is used to filter out inconsistencies in the product such as clumps. The container1002is sized and shaped to ensure that the smokable product is consistently fed to the linear feeder pans206and208. Specifically, as shown inFIG.12, the container1002has sides1008that are arranged at an angle α relative to the horizontal1010. In the illustrated embodiment, the angle α is about 70° to about 75° or about 71.0111°. The angle α is configured to consistently feed the smokable product to the linear feeder pans206and208. The gate1006is configured to open and close to feed the smokable product to the linear feeder pans206and208. The angle of the V-shaped container1002allows the product to flow consistently. Too steep or too shallow of an angle may cause product to clog.

The linear feeder pans206and208are configured to transfer smokable product from the V-shaped container1002to the vibratory bowls210and212with minimal noise. The linear feeder pans206and208include a sensor (not shown) that activates the linear feeder pans206and208when the smokable product is low in the vibratory bowls210and212. The linear feeder pans206and208include a sloped channel1012that is attached to the V-shaped container1002and a vibratory feeder1014configured to vibrate the V-shaped container1002and the sloped channel1012to move the smokable product. Specifically, vibration of the vibratory feeders1014vibrates the V-shaped container1002, the screen1004, and the sloped channel1012to move the smokable product through the screen1004, the V-shaped container1002, and the sloped channel1012. As discussed herein, the main control console236includes a plurality of controls that variably and adjustably control the hoppers202and204and the linear feeder pans206and208.

Specifically, the main control console236includes controllers that include variable amplitude and frequency control that is adjustable. Because the consistency of the smokable product varies greatly, the amplitude and frequency of the vibrations of the vibratory feeders1014may be varied to ensure the consistency of the smokable product fed to the measuring station200remains constant. That is, the vibratory feeders1014may be mechanically and electronically adjusted for product consistency. In the illustrated embodiment, the vibratory feeders1014are powered by digitally adjustable RC 24 vdc variable amplitude and frequency control devices. The RC control devices and the angles α of the sides1008of the V-shaped container1002are designed and configured to ensure that the consistency of the smokable product that is fed to the measuring station200remains constant.

FIG.14is a perspective view of the vibratory bowls210and212.FIG.15is a schematic side view of the vibratory bowls210and212.FIG.16is a schematic front view of the vibratory bowls210and212.FIG.17is a schematic top view of the vibratory bowls210and212. The vibratory bowls210and212are the key to achieving an accurate weight. The process of weighing out a product is dependent on the flowability of the product. The vibratory bowls210and212enable a thin consistent flow of product that can be quickly shut off once the weigh modules218and220reach the target weight.

The vibratory bowls210and212are customized to meter the smokable product into the weigh bucket scoops214and216in a controlled and predictable way. As shown inFIGS.14-17, the vibratory bowls210and212include a bowl1402, a sweep1404, and a channel1406. The bowl1402is configured to contain and receive the smokable product from the linear feeder pans206and208. The sweep1404is positioned within the bowl1402and is adjustable to control the flow of smokable product to the channel1406. In the illustrated embodiment, the sweep1404includes a cork-screw ramp that is rotatably positioned within the bowl1402to move smokable product from the bowl1402to the channel1406. The sweep1404is configured to rotate within the bowl1402such that smokable product is raised to the channel1406. The speed and duration of rotation of the sweep1404may be adjusted to control the amount and consistency of smokable product fed to the channel1406and the weigh bucket scoops214and216. The channel1406is attached to and extends from the bowl1402such that the channel1406extends over the weigh bucket scoops214and216. As the smokable product is fed to the channel1406by the sweep1404, the smokable product on the channel1406is push off the channel1406onto the weigh bucket scoops214and216. The channel1406is sized and shaped to smoothly deliver smokable product to the weigh bucket scoops214and216in a controlled and consistent manner. The vibratory bowls210and212include supports1408that double isolate the vibratory bowls210and212from the remainder of the measuring station200to prevent vibration from affecting the rest of the system. As discussed herein, the main control console236includes a plurality of controls that variably and adjustably control the vibratory bowls210and212.

Specifically, the main control console236includes controllers that include variable amplitude and frequency control that is adjustable. Because the consistency of the smokable product varies greatly, the controllers that control the vibratory bowls210and212may be varied to ensure the consistency of the smokable product fed to the measuring station200remains constant. The variable amplitude and frequency controllers that control the vibratory bowls210and212are used to meter the smokable product in a controlled and predictable manner. The vibratory bowls210and212can be both mechanically and electronically adjusted for product consistency. In the illustrated embodiment, the vibratory bowls210and212are powered by custom digitally adjustable 24 vdc variable amplitude and frequency controllers. As such, the vibratory bowls210and212rapidly flow the smokable product to the weigh bucket scoops214and216mounted on the weigh modules218and220, to achieve fast cycle time, then slow down to meter the smokable product more precisely as the net weight nears the target. Accordingly, the vibratory bowls210and212are designed to precisely meter the smokable product to the weigh bucket scoops214and216.

FIG.18is a perspective view of the weigh bucket scoops214and216.FIG.19is a schematic side view of the weigh bucket scoops214and216.FIG.20is a schematic front view of the weigh bucket scoops214and216.FIG.21is a schematic top view of the weigh bucket scoops214and216.FIG.22is a perspective view of the weigh modules218and220.FIG.23is a schematic side view of the weigh modules218and220.FIG.24is a schematic front view of the weigh modules218and220.FIG.25is a schematic top view of the weigh modules218and220. The weigh bucket scoops214are specially designed with shallow sides to minimize the product drop height from the vibratory bowls210and212. This allows the weigh modules218and220to capture a more accurate weight. The closer the output of the vibratory bowls210and212is to the weigh bucket scoops214, the more accurate the system will be.

The weigh bucket scoops214and216and the weigh modules218and220are used to precisely weigh the smokable product that is to be deposited into cavities228. The weigh bucket scoops214and216are pivotably attached to the weigh modules218and220such that the smokable product is weighed and transferred to the cavities228by the weigh bucket scoops214and216and the weigh modules218and220. Specifically, the weigh bucket scoops214and216are configured to receive the smokable product from the vibratory bowls210and212and pivot relative to the weigh modules218and220to deposit the smokable product in the cavities228. The weigh modules218and220are configured to measure the weight of the smokable product to ensure that the amount of smokable product dispensed by the vibratory bowls210and212is within the predetermined tolerance of the predetermined amount of smokable product.

As shown inFIGS.18-21, the weigh bucket scoops214and216include a scoop1802, a hinge1804, and a servo pivot attachment1806. In the illustrated embodiment, the scoop1802is custom 3D printed out of amphora polymer for a light net weight design that complies with FDA regulations. In alternative embodiments, the scoop1802may be formed of any material and by any method that enables the weigh bucket scoops214and216to operate as described herein. The weigh bucket scoops214and216include a servo mechanism (not shown) to dump the smokable product into the feeders222and224after the predetermined amount of smokable product has been received. Additionally, the weigh bucket scoops214and216also include a small magnet that ensures stability when the scoop1802returns to its resting position and an air blow-off to clean the scoop1802after each cycle.

As shown inFIGS.22-25, the weigh modules218and220include a scoop mount2202and isolation supports (not shown). In the illustrated embodiment, the weigh modules218and220include weight sensors that have a capacity from 1 gram to 100 kilograms. Preferably, the weigh modules218and220have a capacity of 1 kilogram. Additionally, the weigh modules218and220provide a resolution of 0.01 g, +/−0.02 g accuracy with the custom software. An analog output is read in increments of 1/10,000 of a millivolt (mv); or one millionth of a volt from the weigh modules218and220. The weigh modules218and220are fitted with a custom cover to reduce interference and protect each weigh modules from damage. The scoop mount2202mount the weigh modules218and220to the hinge1804and the isolation supports isolate the weigh modules218and220from the rest of the measuring station200.

One or more of the designed hoppers202and204, the linear feeder pans206and208, the vibratory bowls210and212, the weigh bucket scoops214and216, and the feeders222and224may include a coating that enables the system100to process a wider variety of smokable products. For example, at least some smokable products include infused smokable products and surfaces with a decreased coefficient of friction process infused smokable products more efficiently. As such, equipment within the system100that contacts the smokable product may be coated with a coating that decreases the coefficient of friction for the equipment and enable the equipment to process infused smokable product. In the illustrated embodiment, the portions of the designed hoppers202and204, the linear feeder pans206and208, the vibratory bowls210and212, the weigh bucket scoops214and216, and the feeders222and224that directly contact the smokable product are coated with a polytetrafluoroethylene (Teflon®) coating that is water resistant and lowers the coefficient of friction of the equipment.

As shown inFIG.3, the feeders222and224each include a vertical channel302and a cone304. The vertical channel302is attached to the system chassis234and the cone304is attached to the vertical channel302. The vertical channel302receives the smokable product from the weigh bucket scoops214and216and feeds the smokable product to the cone304. The cone304is cone shaped with a hole306at an end308of the cone304such that the smokable product is funneled into select cavities228.

FIG.26is a perspective view of the puck226.FIG.27is a schematic side view of the puck226.FIG.28is a schematic front view of the puck226.FIG.29is a schematic top view of the puck226. The puck226is specially designed to capture pre-weighed product in individual cavities that can be transported to a container without losing product. The low friction UHMW610has holes offset to the cavities that create an opening when the cavity and the hole are aligned.

As shown inFIGS.26-29, the puck226includes a puck body2602and two handles2604. The puck body2602defines the plurality of cavities228, the handles2604are attached to the puck body2602, and the first thin layer of low friction UHMW610is attached to a bottom2606of the puck body2602. Preferably, the puck body2602defines240cavities228and is formed from any suitable material. In alternative embodiments, the puck body2602defines any number of cavities228that enables the puck226to operate as described herein. Preferably, the puck226is a custom designed and machined piece of acetal specially designed to catch all the dispensed product and transfer it to the feeders222and224with minimal product loss, less than 0.007 g. Additionally, the puck cavities are specifically designed and machined at a special angle α, depending on the smokable product being deposited in the preroll cones, with a large enough diameter to prevent clogging.

The first thin layer of low friction UHMW610maintains the smokable product in the cavities228when the puck226is moved to the tamping station600for further processing. More specifically, the first thin layer of low friction UHMW610is used as a slide plate and latched in place with a latch (not shown). Once the puck226is filled and positioned above the preroll cones, the latch is released and the first thin layer of low friction UHMW610slides to allow the smokable product to fall into the preroll cones.

FIG.30is a perspective view of the puck226, the X-axis orienter230, and the Y-axis orienter232.FIG.31is a schematic side view of the puck226, the X-axis orienter230, and the Y-axis orienter232.FIG.32is a schematic front view of the puck226, the X-axis orienter230, and the Y-axis orienter232.FIG.33is a schematic top view of the puck226, the X-axis orienter230, and the Y-axis orienter232

As shown inFIGS.30-33, the puck226is attached to the X-axis orienter230, the X-axis orienter230is attached to the Y-axis orienter232, and the Y-axis orienter232is attached to the system chassis234. The X-axis orienter230and the Y-axis orienter232together define an XY orienter3002. The X-axis orienter230and the Y-axis orienter232each include at least two linear actuators driven by high precision smart motors. Additionally, the X-axis orienter230and the Y-axis orienter232are specifically programmed with custom software comprising instructions executable on at least one processor to move with 1/10,000 of an inch precision. The X-axis orienter230includes at least one 250 mm stroke motor and the Y-axis orienter232includes at least one 450 mm stroke motor. Both actuators of the X-axis orienter230and the Y-axis orienter232work with each other to move to the puck226so that all240cavities on the puck226can be filled by the measuring station200.

FIG.34is a perspective view of the upper tube assembly612, the lower tube assembly614, and the puck226.FIG.35is a schematic side view of the upper tube assembly612, the lower tube assembly614, and the puck226.FIG.36is a schematic front view of the upper tube assembly612, the lower tube assembly614, and the puck226.

As shown inFIGS.34-36, when the puck226is moved to the tamping station600, a second thin layer of low friction UHMW3402is stacked on the lower tube assembly614, the upper tube assembly612is stacked on the second thin layer of low friction UHMW3402, the first thin layer of low friction UHMW610is stacked on the upper tube assembly612, and the puck226is stacked on the first thin layer of low friction UHMW610. The pneumatic piston606is attached to the second thin layer of low friction UHMW3402to enable the pneumatic piston606vibrate the upper tube assembly612, the lower tube assembly614, and the puck226to settle smokable product in the cones.

During operations, the cones are preassembled and placed in the upper tube assembly612and seated into the upper tube assembly612using the air nozzle604. The puck226is filled with smokable product as described above. The first thin layer of low friction UHMW610is attached to the puck226such that the smokable product remains in the cavities228. The puck226and the first thin layer of low friction UHMW610are stacked onto the upper tube assembly612and the lower tube assembly614. The seating platform is in the state position and the first thin layer of low friction UHMW610is removed to enable the smokable product to fall into the cones. The upper tube assembly612, the lower tube assembly614, and the puck226are vibrated by the pneumatic piston606to settle the smokable product in the cones. The puck226is removed and returned to the measuring station200. The seating platform608is lowered to tamping position by the long air cylinder618. The cones descend from the upper tube assembly612to the loose, frictionless lower tube assembly614and are continuously vibrated. The short air cylinder616has software and hardware that control amplitude and stroke for a tamping action and bounces the cones to compaction. The upper tube assembly612is removed to expose the filled, tamped cones. The precisely filled, tamped cones are then slid onto the receiving tray620with no loss of product and are slightly elevated to expose the cones for ease of access for removal and/or end twisting.

The procedure described above produces the final product in two stages. The first stage is a tight stage, and the second stage is a loose stage. Before the puck226is placed on the upper tube assembly612, the cones are placed in the custom-made upper tube assembly612then seated with the air nozzle604. The puck226is placed on top of the upper tube assembly612and then product is vibrated into the cones. Because the cones fit tightly (hence the need to seat them with air) there is no leakage. The next step is to lower the filled prerolled cones to the second level of loose tubes of the lower tube assembly614by removing the puck226while simultaneously using both air and vibration to get the filled prerolled cones and the seating platform608support into the lower tube assembly614. Now that the filled preroll cones are in the bottom, loose, tubes of the lower tube assembly614, the custom designed seating platform608vibrates up and down causing the cones to be tamped. The duration of this process determines the degree of firmness which is set by the operator. The precisely filled, tamped cones are then slid onto the receiving tray620with no loss of product so that the final cone net weight remains the regulatory required +/−3%. The tops of the cones are slightly elevated to expose them for ease of access for removal and/or end twisting.

The upper tube assembly612guides all the smokable product into the preroll cones. Additionally, the pneumatic piston606is attached to the upper tube assembly612to move all the smokable product from the puck226to the lower tube assembly614. The lower tube assembly614, also referred to as loose fit tubes, are also custom sized for frictionless tamping.

FIG.37is a perspective view of the seating platform608, the short air cylinder616, and the long air cylinder618.FIG.38is a schematic side view of the seating platform608, the short air cylinder616, and the long air cylinder618.FIG.39is a schematic front view of the seating platform608, the short air cylinder616, and the long air cylinder618.FIG.40is a schematic top view of the seating platform608, the short air cylinder616, and the long air cylinder618.

The long air cylinder618moves the seating platform608from the filling position (tight tubes) to the tamping position (loose tubes) and back up to be transferred onto the lower tube assembly614. The short air cylinder616is equipped with specialty software and hardware to control the short air cylinder616amplitude and stroke for a desired tamping action and “bounces” the cones to compaction according to customer preferences. The seating platform608supports and tamps the cones to form an even pack while seated in the “loose” tubes. the platform has two positions, “up”, or “start”, and “down”, or “tamp”.

FIG.41illustrates a perspective view of a digital scale4102for measuring the accuracy of the smokable product contained in the prerolls. Quality control, if desired, may then be done by randomly selecting cones of the finished rack of 240 prerolls and emptying the contents into a container on the NTE approved milligram tabletop balance or digital scale4102.

The system100further comprises software, firmware, and custom circuit boards to provide precision net weigh automation to achieve resolution and accuracy of 0.01 g using weigh module technology. The system100therefore achieves a resolution and accuracy others can only achieve with force restoration technology.

As can be seen, the measuring station200is completely enclosed in the system chassis234to isolate contact surfaces from major electronics, pneumatics, wires, etc. housed in the system chassis234. Access hatches allow for easy access during service. Additionally, all electronics, logical components, control boards, interface elements are located an in exterior mounted enclosure. Polyethylene Terephthalate (P.E.T.) buckets minimize static electricity providing product accrual prevention and limiting product loss of USDA/FDA compliant material.

The main control console236is also attached to the system chassis234. The main control console236is located in the front of the measuring station200and electronically connected to a main control box in a box in the rear of the measuring station200that is sized to contain all the electronics required to operate the measuring station200. Controls contained in the main control box can be adjusted manually through a custom graphical user interface on the main control console236using an input device selected from the group consisting of a touchscreen, a stylus, a keyboard and mouse combination, or voice control. Preferably, the input device is a touchscreen. All functions of the measuring station200are controlled through the main control console236using instructions executable on a proprietary, custom programmed and manufactured microprocessor-based firmware, hardware and software that sets parameters for the measuring station200, and when programmed, are maintained in a storage for use later on similar smokable products run through the measuring station200to speed production.

The customize software comprises instructions operable on a processor to control and/or adjust parameters of the measuring station200for various different smokable products, such as, for example, cone capacity, fill/tap tray, a position fill puck, the expanded aperture hoppers, coordinated with back feeders, to accommodate unique flow characteristics of smokable material, the high amplitude, pneumatic hopper vibrators for even product supply distribution, includes pneumatic control valves, air fittings, hopper modifications for mounting, etc., the feeder bowls for product singulation and flow control for accurate weighing with coordinating “top-off” lane gates, a plurality of input dip funneling assemblies prevent product loss as a result of spillage, a plurality of simultaneous dual cone filling positions for added speed, fully programmed with orienting, breeze shield to prevent disturbance from ambient disturbed air during operation, 360° access door as well as top loading access door that can be configured with lockout options, a specialized P.E.T., weigh bucket to achieve accuracy, provide stability and ensure highest possible resolution, high resolution weigh modules integrated with special custom analog to digital (A/D) hardware and custom programming to achieve unsurpassed and consistent prerolls, adjustable leveling feet to accommodate irregular facility floors.

For example, using the main control console236, and operator can set the following parameters, assuming a custom high precision 500-gram weigh modules with 150% safe overload. Then assume a 250-gram dead load that includes the weigh bucket scoops214and216weigh bucket scoops214and216hardware. The maximum resolution of the system100with high precision standard controls would be 0.002% of 500 gram or 1/100 gram if great care is taken in regard to other combined load factors. However, actual accuracy as defined above, under normal operating conditions could not be guaranteed to be greater than 0.025 grams; i.e., +/−0.01 accuracy could be achieved but expect +/−0.02.

The measuring station200further comprises variable amplitude and frequency control in an enclosed space. Depending on the smokable product that is being prerolled, the amount and height of the frequency used to vibrate the smokable product from the vibratory bowls210and212into the weigh modules218and220will need to be varied. Additionally, these parameters will need to be adjusted for the size of the preroll cones and the speed that a user requires for the filling of the prerolls. Various types of smokable product can be used with the system100and all of these parameters are controlled using the main control console236.

In this embodiment, a 24 vdc variable amplitude and frequency control is used to rapidly achieve a fast cycle time, then slow down to meter the smokable product more precisely as the net weight nears the target. The variable amplitude and frequency control also maintains consistent speeds, regardless of the head pressure of the smokable product.

The variable amplitude and frequency control is adjustable because ground smokable product consistency varies greatly. The variable amplitude and frequency control also control the vibratory bowls210and212is used to meter the ground smokable product in a controlled and predictable way. The vibratory bowls210and212is in turn fed by linear feeder pans206and208that is small, specially designed and mounted on the vibratory bowls210and212, that is fed from custom designed hoppers202and204comprise special angles, screens and other innovations that allow the system100to adapt to the consistency of the smokable product. The linear feeder pans206and208and vibratory bowls210and212can be both mechanically and electronically adjusted for product consistency. In one embodiment, the linear feeder pans206and208is powered by proprietary digitally adjustable RC controls and the vibratory bowls210and212is powered by custom digitally adjustable 24 vdc variable amplitude and frequency-controlled devices. The vibratory bowls210and212rapidly flow the smokable product to weigh bucket scoops214and216mounted on the weigh modules218and220, to achieve fast cycle time, then slow down to meter the smokable product more precisely as the net weight nears the target.

Using instructions executable on a processor in the main control console236the system100is capable of achieving a resolution of 0.01 grams, +/−0.02 grams accuracy. An analog output from the weigh modules218and220is converted from increments of 1/10,000th of a millivolt (mV), or one (1) millionth of a volt, 0.00000001 V into a digital equivalent number for use by the main control console236. The weigh modules218and220is also fitted with a custom cover to reduce electrical interference to protect the weigh modules218and220from damage.

In one embodiment, the weigh modules218and220is a ceramic capacitance sensor that has a high resolution and easier to use in automation. The ceramic capacitance sensor works by measuring changes in capacitance. The net weight of the smokable product on the capacitance sensor changes the capacitance between the two conductors, and an electric field is created between them that is measured with a high degree of accuracy.

In another embodiment, the weigh modules218and220comprises a tuning fork type sensor. The tuning fork type sensor has a wire that is vibrated, under controlled conditions. When net weight is applied, and the vibration frequency is measured to accurately determine the net weight.

In another embodiment the weigh modules218and220use a weigh modules strain gauge. A 5-15 VDC input is sent through fine wires (strain gauges) precisely glued to various locations on body of the weigh modules218and220to compensate for side load, non-level conditions, etc. is used. The body of the weigh modules218and220bends, causing the fine wires to change conductivity and output a voltage in microvolts. This analog voltage is then measured to accurately determine the smokable product net weight, and, in some cases, converted and then digitized.

There is also provided a method for using the system100, comprising the steps of first providing, a two-stage cone holding/tamping tray system100.

First, the system100weighs and fills ground smokable product into “preroll” smoking cones, then compacts the smokable product to desired density, at the rate of 1500 cones per hour. The finished smoking cones contain a precise, regulatory compliant, +/−3% of labeled net weight. The flexible design allows the processing of products with diverse or difficult flow characteristics.

Because ground smokable product consistency varies greatly, the vibratory bowls210and212are used to meter the ground smokable product in a controlled and predictable way. The vibratory bowls210and212is in turn fed by small specially designed linear feeder pans206and208mounted on the vibratory bowls210and212from the hoppers202and204that is custom designed with special angles, screens and other innovations that allow the system100to adapt to the consistency of the smokable product. The linear feeder pans206and208and the vibratory bowls210and212can be both mechanically and electronically adjusted for product consistency. The linear feeder pans206and208is powered by proprietary digitally adjustable RC controls and the vibratory bowls210and212is powered by custom digitally adjustable 24 vdc variable amplitude and frequency-controlled devices. The vibratory bowls210and212rapidly flow the smokable product to weigh buckets mounted on net weight sensors, or weigh modules, to achieve fast cycle time, then slow down to meter the smokable product more precisely as the net weight nears the target.

To catch the correct net weight to 0.01 g resolution, +/−0.02 g accuracy the weigh modules analog output is read in increments of 1/10,000 millivolt (mv)—or one millionth of a volt. This highly specialized measurement device digitizes and registers tiny output changes in less than 10 milliseconds then makes decisions based on algorithms according to the my level. All functions including the vibratory bowl and vibratory feeder speeds are controlled instructions operable on one or more than one processor with custom firmware. The main controls comprise the custom based firmware, where the custom based firmware comprising instructions executable on the one or more than one processors, hardware, and software. The executable instructions set parameters that, once programmed, are maintained in a memory for use later for the same or similar products.

As the vibratory bowls feed the weigh buckets, stable target net weights are achieved. Then the verified weighed product is “ready” for discharge into cavities in the filling puck. The filling puck is mounted on a high precision servo driven XY orienter. Once the filling puck is in one of 120 predetermined positions, within +/−0.1 mm, the weighed product is emptied into the filling puck at that position. The size, angles and specialty materials of the filling puck and cavities are custom designed and machined in such a way that the smokable product can later be vibrated into the tamping station600with no loss, bridging, clogging or accrual of product.

FIG.42is a flow chart of a method4200of a method of manufacturing a plurality of prerolled cones containing a smokable product using a measuring station and a tamping station. The measuring station includes a vibratory bowl, a weigh bowl, a weigh module, and a puck. The tamping station includes an upper tube assembly including a plurality of tight tubes for containing the plurality of prerolled cones, a lower tube assembly including a plurality of loose tubes for containing the plurality of prerolled cones, and a seating platform. The method4200includes receiving4202the smokable product into the vibratory bowl. The method4200also includes metering4204the smokable product from the vibratory bowl to the weigh bowl. The method4200further includes measuring4206the smokable product in the weigh bowl using the weigh modules. The method4200also includes determining4208that the smokable product in the weigh bowl is within a predetermined tolerance of a predetermined amount of smokable product. The method4200further includes moving4210the smokable product from the weigh bowl to a plurality of cavities within the puck. The method4200also includes transferring4212the puck to the tamping station. The method4200further includes stacking4214the upper tube assembly on the lower tube assembly and the puck on the upper tube assembly. The method4200also includes vibrating4216the upper tube assembly, the lower tube assembly, and the puck with the seating platform to tamp the smokable product in the plurality of cavities into the plurality of prerolled cones.

What has been described is a new and improved system for an accurate net weight based rolling system producing prerolls that are compliant, consistent, repeatable, and scalable for automatic cone filling, overcoming the limitations and disadvantages inherent in the related art.