Abstract:
A cigarette assembly machine that accepts loose tobacco and cigarette blanks that include a filter and an empty tobacco holding portion and produces cigarettes. The machine includes a tobacco plug forming mechanism, adapted to accept loose tobacco and form it into a plug of tobacco in the shape of the tobacco holding portion; a cigarette blank accepting and holding mechanism, adapted to hold the cigarette blank, so that the empty tobacco holding portion is facing the tobacco plug forming mechanism; a shaft aligned to the accepting and holding mechanism; and a two-stroke shaft moving assembly, adapted to move the shaft through a first stroke, which pushes the tobacco plug into the tobacco holding portion to create a cigarette, and through a second stroke that moves the cigarette out of the cigarette blank accepting and holding mechanism.

Description:
BACKGROUND 
     There is an advantage to a tobacco store in providing a machine, for customer use, that accepts cigarette blanks and loose tobacco, and produces finished cigarettes. Although such machines currently exist, these machines suffer from a number of drawbacks. First, ease and simplicity of use is extremely important for this type of machine, as minimally trained customers are to use it. Unfortunately, currently available customer operated cigarette machines are not as simple to operate as would be desirable. Second, high reliability and easy servicing is very important for any machines that is used in a small shop setting, by a shop owner who may not have a high level of mechanical skills, and for whom the need to repair a machine would constitute a very unwelcome intrusion into an already busy schedule. Moreover, in this case machine down time results in a loss of revenue, which may never be recouped. Unfortunately, currently available machines require a fairly high level of maintenance. Also, in currently available machines, some occasionally necessary adjustments are difficult to make and are frequently required as the machines go out of adjustment/alignment due to constant motion with every cycle. 
     SUMMARY 
     The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
     In a first separate aspect, the present invention is a cigarette assembly machine that accepts loose tobacco and cigarette blanks that include a filter and an empty tobacco holding portion and produces cigarettes. The machine includes a tobacco plug forming mechanism, adapted to accept loose tobacco and form it into a plug of tobacco in the shape of the tobacco holding portion; a cigarette blank accepting and holding mechanism, adapted to hold the cigarette blank, so that the empty tobacco holding portion is facing the tobacco plug forming mechanism; a shaft aligned to the accepting and holding mechanism; and a two-stroke shaft moving assembly, adapted to move the shaft through a first stroke, which pushes the tobacco plug into the tobacco holding portion to fill the cigarette, and through a second stroke that moves the assembled cigarette off of the cigarette blank accepting and holding mechanism. 
     In a second separate aspect, the present invention may take the form of a cigarette assembly machine, having a hopper that accepts cigarette blanks from a blanks box having box sidewalls, the hopper delivering the blanks to a delivery point. The hopper includes a support structure; a bottom wall, supported by the support structure having an upper surface that slopes downwardly toward the delivery point, for at least a portion of the bottom wall&#39;s extent; a pair of hopper sidewalls, joined together by a cross member and hinged to the support structure, so that they rotate vertically about the bottom wall; and having a lower portion that extends below the bottom wall and rests on the support structure, to define a hopper sidewall resting position. Accordingly, a user can slide the blanks box, facing downward and with its lid open, between the sidewalls and over the upper surface of the bottom wall; then rotate the pair of hopper sidewalls upwardly, causing the blanks to empty out of the box to be retained by the bottom wall and the lower portions of the hopper sidewalls; and then remove the box and lower the sidewalls to the resting position. 
     In a third, separate aspect, the present invention is a cigarette assembly machine, having a hopper that accepts cigarette blanks from a blanks box having box sidewalls and a lid that is flexibly attached to one of the sidewalls, the hopper delivering the blanks to a delivery point. The hopper includes a support structure; a bottom wall, supported by the support structure having an upper surface that slopes downwardly toward the delivery point, for at least a portion of the bottom wall&#39;s extent; a pair of hopper sidewalls; wherein a first one of the hopper sidewalls defines a slot sized to be traversed by the lid of the blanks box. Accordingly, a user can slide the blanks box, facing downward and with its lid open, between the sidewalls, with the box lid extending through the slot; and above the upper surface of the bottom wall, thereby delivering a box of blanks to the hopper. 
     In a fourth, separate aspect, the present invention may take the form of a mechanism for delivering uniform cylindrical objects, in individuated sequence, to a predetermined location. The mechanism includes a hopper for holding the cylindrical objects; a shuttle plate, having a holder for a single one of the cylindrical objects, and reciprocating so that the holder repetitively enters and exits the hopper, thereby delivering a single one of the cylindrical objects to the predetermined location. The hopper includes a bottom wall defining an upper surface having a downward slope, toward the shuttle plate, and which defines a terminal edge at the shuttle plate, and wherein a portion of the shuttle plate reciprocates directly under the bottom wall. Finally, the reciprocating motion pushes the cylindrical objects against the terminal edge, thereby causing the cylindrical objects to align with the terminal edge and the holder as they are pushed by the shuttle plate reciprocation, against the terminal edge. 
     In a fifth separate aspect, the present invention may take the form of a mechanism for loading a cylindrical object having a flexible circular sidewall defining an outer diameter, onto a transversely round receiver, from a first position aligned to the receiver. The mechanism includes a push rod, positioned to push the cylindrical object onto the receiver; and a round-shaping element interposed between the first position and the receiver, the round-shaping element defining a transversely round through-passage between the first position and the receiver, the through passage having a progressively smaller diameter as it extends toward the receiver, with the through passage exit diameter being substantially equal to the outer diameter of the circular sidewall, so that as the cylindrical object progresses towards the receiver, imperfections in circular sidewall are smoothed out, rendering it more precisely circular. 
     In a sixth separate aspect, the present invention may take the form of a cigarette assembly machine that accepts loose tobacco and cigarette blanks. The machine includes a fill tube sized to receive the blanks; a singulation device, that delivers a sequence of the blanks to a predetermined position that is enclosed in dimension transverse to each the blank, and wherein each the blank when in the predetermined position is aligned to the fill tube; a push rod, adapted to sequentially push the blanks from the predetermined position onto the fill tube. Finally, the push rod has a tip that is softer than pine wood and substantially as wide as the blanks. 
     In a seventh separate aspect, the present invention may take the form of a cigarette assembly machine that accepts loose tobacco and cigarette blanks. The machine includes a fill tube sized to receive the blanks; a singulation device, that delivers a sequence of the blanks to a predetermined position that is enclosed in dimension transverse to each the blank, and wherein each the blank when in the predetermined position is aligned to the fill tube; a push rod, adapted to sequentially push the blanks from the predetermined position onto the fill tube. Finally, the push rod is loosely mounted, with at most 2 degrees of play. In a preferred embodiment, the push rod has at most 1 degree of play. In another preferred embodiment the push rod has at most 0.5 degrees of play. In another preferred embodiment the push rod has at most 0.25 degrees of play. 
     In a eighth separate aspect, the present invention may take the form of a cigarette assembly machine that accepts loose tobacco and cigarette blanks. The machine includes a fill tube sized to receive the blanks; a singulation device, that delivers a sequence of the blanks to a predetermined position that is enclosed in dimension transverse to each the blank, and wherein each the blank when in the predetermined position is aligned to the fill tube; a push rod, adapted to sequentially push the blanks from the predetermined position onto the fill tube. Finally, the transverse enclosure of the predetermined position is chamfered at the opening entered by the push rod, so that the push rod has less chance of catching on the opening. 
     In an ninth, separate aspect, the present invention may take the form of a mechanism for delivering cigarette blanks, in individuated sequence, to a predetermined location. The mechanism includes a hopper for holding the cylindrical objects; a shuttle plate, having a holder for a single one of the cylindrical objects, and reciprocating so that the holder repetitively enters and exits the hopper, thereby delivering a single one of the cylindrical objects to the predetermined location. The hopper includes a bottom wall defining an upper surface having a downward slope, toward the shuttle plate, a portion of the shuttle plate reciprocates directly under the bottom wall. Finally, the holder is in the form of a trough, having a surface bottom portion having curvature substantially matching that of a cigarette, and a surface top portion with a gentle upward slope, as said surface top portion extends outwardly, so that cigarette blanks are encouraged to roll in. 
     In a tenth separate aspect, the present invention may take the form of a mechanism for delivering cigarette blanks, in individuated sequence, to a predetermined location. The mechanism includes a hopper for holding the cigarette blanks; a shuttle plate, defining a trough sized and shaped to hold a single one of the blanks, and reciprocating so that the trough repetitively enters and exits the hopper, thereby delivering a single one of the cylindrical objects to the predetermined location. The hopper includes a bottom wall defining an upper surface having a downward slope, toward the shuttle plate, and a front wall defining an opening, through which the shuttle plate reciprocates, wherein the front wall supports a projection just above the opening, and the projection is shaped so as to facilitate a single blank filling the trough as the shuttle plate enters the hopper. 
     In an eleventh, separate aspect, the present invention is a cigarette assembly machine having a fill tube adapted to receive a cigarette blank over its exterior surface. The fill tube has a first end, where tobacco is introduced and a second end, where the blank is introduced over it. A pair of optical sensors, one at the first end and one at the second end verify that the blank has been slid all the way onto the fill tube and has not ripped, exposing the fill tube at the second end. The optical sensors can also distinguish the brown paper of the blank filter from the fill tube material. They also function when both ends are white or the same color. 
     In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Exemplary embodiments are illustrated in referenced drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. 
         FIG. 1  is an isometric view of a cigarette assembly machine, according to the present invention, taken from a vantage point to the top, front and side of the machine. 
         FIG. 2  is an expanded isometric view of the blank filling portion of the machine of  FIG. 1 , taken from a similar perspective, showing a cigarette blank in position to be pushed onto a fill tube. 
         FIG. 3  is a front view of the mechanism for placing a blank on a fill tube, which is part of the machine of  FIG. 1 . The mechanism is shown with a cigarette blank positioned to be pushed onto a fill tube. 
         FIG. 4  is a front view of the mechanism of  FIG. 3 , with the cigarette blank filled most of the way onto the fill tube. 
         FIG. 5  shows the same view as  FIG. 2 , with the cigarette blank being pushed off of the fill tube, after having been filled with tobacco. 
         FIG. 6  is a detail sectional view of the machine of  FIG. 1 , taken along line  6 - 6  of  FIG. 3 . 
         FIG. 7  is a detail sectional view of the machine of  FIG. 1 , taken along line  7 - 7  of  FIG. 3 , and showing a blank in the process of entering the round shaping element. 
         FIG. 8  shows the same detail section view of  FIG. 7 , but in this case, the blank has been forced into a round transverse shape by the round-shaping element. 
         FIG. 9  is an isometric view of the blanks hopper of the machine of  FIG. 1 , taken from perspective point F 9 , of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring to  FIG. 1 , in gross overview a cigarette assembly machine  10  includes a tobacco hopper  12 , a blanks hopper  14 , a singulation assembly  16 , a tube fill assembly  18  and a reject assembly  20 . To operate, user loads blanks  22  into blanks hopper  14 , and tobacco (not shown) into tobacco hopper  12 . Each blank  22 , includes a filter  23 , and blanks  22  are introduced into hoper  14 , so that the filter side of each blank  22  faces outwardly from the machine  10 . 
     The singulation assembly  16  removes a single blank at a time from blanks hopper  14  and positions it at a predetermined location, so that fill assembly  18  can push a blank  22  onto a fill tube  24 . Concurrently, a slug of tobacco (not shown) has been formed at the bottom of tobacco hopper  12 . This slug is pushed by a tobacco fill shaft  30  into fill tube  24 , and then shaft  30  pushes again, so that the tobacco in the fill tube  24  presses against the filter  23  ( FIG. 3 ) that closes each blank  22  at the far end from shaft  30 . This pushes blank  22 , now filled by tobacco off of fill tube  24 , thereby freeing the blank  22  so that it can drop into acceptance slot  34 . 
     Reject cases, including an improperly filled, crumpled or torn blank  22  are detected by reject assembly  20 , which actuates a first reject pneumatic cylinder  38 , moving fill tube  24 , so that it is in front of a reject shaft assembly  40 , which pushes a reject shaft  42  ( FIG. 2 ) through a reject shaft aperture  44 , to push rejected blank  22  off of fill tube  24  and into a reject slot  46 . 
     In greater detail, stepping through the machine  10  by assembly and describing each assembly operation, as best shown in  FIGS. 6 and 9 , the blanks hopper  14 , includes a ramped bottom wall  50 . The bottom support for blanks  22  is also provided by the top surface of a shuttle  53 , which forms part of singulation unit  16 , as well as part of blanks hopper  14 . A side wall unit  54  includes an inner sidewall  56 , facing the tobacco hopper  12 , and an opposed outer sidewall  58 . Sidewalls  56  and  58  are held together at three points, by a front cross member  60  (which can also serve as a handle), a rear cross member  62  and a hinge  64 . A blanks hopper pneumatic cylinder  66  rotates side wall unit  54  about hinge  64 , upon command of a user control (not shown), upwardly from the resting position shown in  FIG. 1 . A slot  70  ( FIG. 9 ) runs through inner sidewall  56  along the top edge of ramped bottom wall  52 . A front wall  72  retains cigarette blanks  22  at the front of hopper  14 . 
     Hopper  14  is filled by emptying a standard box of 200 blanks, having a side-hinged lid, into it. In greater detail, the box of blanks is opened, a sheet, roughly as wide as the box, is placed over the top of the box, and the box is flipped over. Then the box is introduced into hopper  14 , passing underneath cross member  62 , and with the box lid, now swung to the side, accommodated by slot  70 . The sheet is removed and the user activates the control to cause cylinder  66  to rotate sidewall unit  54  upwardly about hinge  64 , permitting and encouraging the blanks to fall free from the box onto bottom wall  52  and the top surface of shuttle  53 . The box is then removed and cylinder  66  is activated to lower unit  52  back to its resting position. 
     In one preferred embodiment the width of sidewall unit  54 , and therefore the width of hopper  14 , is adjustable. In one variant, this is achieved by cross members  60 ,  62  and a portion of hinge  64 , being rigidly attached to sidewall  56 , to form a replaceable unit. Similar units with longer or shorter cross members are kept on hand and when necessary, sidewall  56  is removed together with the cross members  60 ,  62  and  64 , and on of the replacement units is installed, to create a hopper having a different width, to accommodate longer or shorter blanks. 
     This process is advantageous over processes for currently available machines, first because the box lid is easily accommodated. Currently available system requires that the lid be cut off or folded awkwardly all the way up, where it can get in the way. Folding the lid requires firm grip on the box which compresses and damages the tube ends. Also, cylinder  66  eases the hopper  14  filling process by relieving the user of the need to manually rotate unit  54 . 
     As best shown in  FIG. 6 , singulation assembly  16  includes as its principal component shuttle  53 , defining trough  74 , which is shuttled into and out of hopper  14 . Trough  74  defines bottom through-holes  75  ( FIG. 4 ), to permit air to exit, to facilitate acceptance of a blank  22  rolling into trough  74 . In one preferred embodiment a vacuum source is connected to bottom through-holes  75 , to positively urge a blank to enter trough  74 . The detailed design of singulation assembly addresses many of the problems found in the prior art. First, the line defined by junction of ramp and shuttle  80  of ramped bottom wall  50 , straightens out blanks  22  that have gone askew during the unloading process, as shuttle  53  moves slot  74  toward ramp  50 , thereby backing blanks  22  against junction  80 . The roughened top surface  82  of shuttle  53  helps with this process by having sufficient friction to move blanks  22  toward ramp tip  80 . This movement of the blanks  22 , facilitated by the roughened top surface  82 , also prevents blanks  22  from forming a bridge, where a set of blanks arches up from front wall  72  to ramp  50 , preventing any blanking from falling into a trough  74 . Finally, a front lip  84  projecting outwardly from the front wall  72 , positions a blank  22  to easily role into trough  74 , when shuttle  53  enters hopper  14 . Lip  84  is curved like the outside of a blank, to facilitate holding a blank  22  in readiness and to apply well distributed pressure to the blank to keep it from collapsing and to facilitate a blank  22  rolling from lip  84  into trough  74 . This helps to prevent competition between blanks, which can result in two blanks partially fitting into trough  74 , with each blank  22  preventing the other from falling completely into trough  74 . 
     Another feature of machine  10  that facilitates a blank  22  in falling into trough  74  is the slanted entry lip  90  of trough  74 , which encourages a blank  22  to begin rolling into trough  74 . The steeper sides of trough  74 , however, maintain the blank  22  tightly in correct position, once it has entered. 
     Referring, now, to  FIG. 2 , when shuttle  53  is at its stationary tube-fill position, trough  74  is aligned to fill tube  24 . A blank push rod  92 , powered by a blank push rod cylinder  94 , is aligned with blank  22  and is ready to push blank  22  onto fill tube  24 . A cantilevered top wall  96  retains blank  22  as it is pushed by rod  92 . One problem that has been encountered in this operation, is that push rod tip  98  (in a previous narrower form than that shown) has been known to push the filter forward in the blank, causing certain failure of the tobacco fill operation. Consequently, tip  98  has been widened, in comparison with tips used in previous developmental models. A wider tip, however, has a greater chance of colliding with the sides of trough  74 , which could potentially cause a malfunction that could stop operations and even damage machine  10 . 
     A number of design features are addressed at preventing any harmful collision between tip  96  and the sides of trough  74 . First, so that any collision will be less harmful, tip  96  is made of a soft material, such as rubber. Trough  74  and top wall  96  have chamfered surfaces  100  and  102  facing blank  22 , at the entry-point for rod  92 , to lessen the possibility of tip  98  missing the chamfered opening and hitting top wall  96 , or the shuttle  53 . The top wall also defines a chamfered lower surface  103  on the side closer to the fill tube  24  to prevent finished cigarette from hitting edge when ejected. Rod  92  is attached to a vertical arm  104 , which is moved by cylinder  94 . The mounting fixture  106  of rod  92  on vertical arm  104  is loose, permitting up to 0.020 inches of play, so that if tip  98  hits the walls of trough  74 , tip  98  can easily travel a little to the side so that it can slide into trough  74 , even in the case of minor misalignment. 
     In the process of pushing a blank  22  from trough  74  onto fill tube  24 , the blank  22  is pushed through a round-shaping element  104 , which defines a round, necked-down passageway  110 . Referring to  FIGS. 7 and 8 , if a blank  22  is not circular in cross-section, passageway  110  presses inwardly upon the outward portions, forcing blank  22  into a circle. This greatly facilitates the operation of pushing blank  22  onto fill tube  24 , as a misshapen blank  22  is likely to catch on fill tube  24 , rather than sliding onto it. 
     After blank  22  has been slid onto fill tube  24 , a pair of optical sensors  114  each transmit a beam of light (LED or laser) toward blank  22  and measure the return signal to determine if blank  22  is fully on fill tube  24 . Return from both the brown filter portion of the blank can be distinguished from the stainless steel of the fill tube  24 , in addition to the white paper of the remainder of the blank  22 . In addition to failing to be placed all the way onto the fill tube  24 , a blank could be torn, thereby exposing fill tube  24  in front of the sensor  114  that is closer to passageway  110 . If a damaged or improperly positioned blank is detected, it is disposed of by assembly  20 , as described earlier. 
     Both sensors must register proper tube placement contemporaneously with the placement of blank  22  on fill tube  24 , a slug of tobacco sized to fit into a blank  22  is formed, according to well-known techniques, in a portion (not shown) of the blank fill assembly  18 , beneath tobacco hopper  12 . When the tobacco slug has been formed, and blank  22  has been positioned (and verified) on fill tube  24 , the fill shaft  30  pushes the slug of tobacco into fill tube  24 . Fill shaft  30  then advances again, pushing the slug of tobacco against the closed filter portion of the blank  22 , which acts to push the blank  22 , retaining the tobacco, off of fill tube  24 . The finished cigarette then falls down the acceptance slot  34 . So that shaft  30  can advance twice, a fill shaft pneumatic cylinder  120  is piggy-backed onto a carriage servomotor  122 , that moves along a set of guide rods  124 , with the carriage servo  122  providing the first push, to fill tube  124 , and the fill tube cylinder  120  advancing to provide the second push, to eject the blank  22 . In another embodiment the carriage servomotor performs both the fill and eject strokes. 
     While a number of exemplary aspects and embodiments have been discussed above, those possessed of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the following appended claims and claims hereafter introduced are interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.