Abstract:
A method, system and apparatus for registering different objects in filter rod shaped articles, for example as found in the tobacco processing industry. The method, system and apparatus can include a rod containing cigarette filter components; one or more sensors that determine the constitution of segments of the rod and transmits one or more signals regarding segments of the rod; a processor that receives the one or more signals from the one or more sensors, performs a comparison between the one or more signals and known data and transmits a signal based upon results of the comparison; and an ejector that receives the signal from the processor and removes any segment of the rod that does not conform with the known data.

Description:
BACKGROUND 
       [0001]    Cigarettes and other smoking articles commonly include filter portions (known as filter segments) which may be used to remove some impurities and toxins from cigarette smoke as it is inhaled. To make this process more efficient, filters with several different segments have been developed in the tobacco industry—for example duo filter, triple filter and the like. The segments may differ in size, shape and construction. For example there are filter segments made of carbon, accetate, paper, tobacco and other products and items. Further, they may have any of a variety of shapes, for example conical, cylindrical, etc. Recently filters with different ingredients inside have been developed, such as breakable capsules, mini capsule and massive pieces from different chemical elements. These may be used for a variety of purposes, such as imparting flavor or reducing some chemical elements from the cigarette smoke as it is inhaled by the smoker. 
         [0002]    As mentioned above, one method of imparting flavor to a cigarette may be to include a flavor capsule within the filter portion of a cigarette. When the capsule is ruptured, it releases flavorings or aromatic material into the air stream passing through the filter. These capsules may also alter other characteristics of the inhaled smoke, such as, for example, cooling or moistening the smoke such that the smoker is provided with an enhanced smoking experience. 
         [0003]    Additionally, specialized cigarette filters are known to incorporate a variety of elements, for example filter segments including acetate, carbon and paper elements, as well as empty or “recess” areas. Different numbers of elements are combined in varying forms in different types of filters. Further, filter elements can include both fragment elements and solid elements. Fragment elements may be distributed throughout a filter whereas solid elements may be larger than fragment elements and may be located at disposed at predetermined locations in a filter. The location of both fragment elements and solid elements may be related to the overall quality of the filter. Current methods and systems for the construction or manufacture of filters are slow and can not meet the demands of filter construction, for example with respect to the design and variety of filters. 
       SUMMARY 
       [0004]    An apparatus that registers different objects in rod shaped articles. The apparatus can include a rod containing cigarette filter components; one or more sensors that determine the constitution of segments of the rod and transmits one or more signals regarding segments of the rod; a processor that receives the one or more signals from the one or more sensors, performs a comparison between the one or more signals and known data and transmits a signal based upon results of the comparison; and an ejector that receives the signal from the processor and removes any segment of the rod that does not conform with the known data. 
         [0005]    A method for making cigarette filters may also be described. The method can include passing a continuous filter rod through a plurality of sensors; determining the composition of segments of the continuous with the sensors; comparing the composition of the segments to predetermined data; and rejecting segments whose composition does not correlate to the predetermined data. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is an exemplary diagram of an apparatus for producing any of a variety of types of cigarette filters. 
           [0007]      FIG. 2  is a view of an exemplary embodiment of a registration system. 
           [0008]      FIG. 3  is a view of an exemplary diagram showing modularity of a variety of sensors. 
           [0009]      FIG. 4   a  is an exemplary diagram showing an embodiment of a sensor. 
           [0010]      FIG. 4   b  is an exemplary diagram showing another embodiment of a sensor. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows. 
         [0012]    As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiment are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation. 
         [0013]    Exemplary  FIG. 1  can show a known system for producing cigarette filters  100  using a preparation machine. The machine  100  can include a preparation machine  102 . The preparation machine  102  can include any number of different modules having a variety of functions. The preparation machine  102  can prepare raw materials and form them into a rod or assemble filter segments into a desired order. The terms “rod” and “filter”, amongst others used herein, can be used to describe any of a variety of known rod and filter types independent of construction or stage-of-construction, for example single or multiple segment filters, carbon or paper filters and the like. Additionally, machine can put solid or any other type of objects inside a rod  104 , for example, as a rod is moved through machine  102 . Rod  104  may be, in some exemplary embodiments, a continuous filter rod which can further have a number of components or segments and which may be formed or cut into any number of cigarette filters. The continuous filter rod  104  may then go through sensor  106  of the registration system  200  (described in more detail below). The continuous rod  104  may then be cut by a cutting device  108  at a desired length. However, if sensor  106  detects a bad or malformed filter, for example a filter having an undesired constitution, such as one or more missing or improperly positioned objects, construction or components the registration system can reject it with ejector  110 . 
         [0014]    Turning to exemplary  FIG. 2 , a modular registration system  200  may be shown and described which can have a variety of applications, while being highly flexible, reliable and precise. Registration system  200  can include any number of components, for example sensor  106  which can include one or more different types of sensors  222 ,  224  and  226 , as described above, a junction and acceleration module  202 , one or more digital high speed modules  204 , encoder  206 , converter  208 , programmable logic controller (PLC)  210 , interface  212  (which may be a human-machine interface (HMI)) and ejector  110 . As described in further detail below, junction and acceleration module  202  may act to boost or increase the signal strength of any signal from sensors  222 ,  224  and  226  in sensor  106 , digital high speed module  204  may convert signals from one form to another and make comparisons, encoder  206  may determine a time or times when one or more sensors  222 - 226  are active, converter  208  may convert any signals into appropriate or acceptable format for PLC  210  and PLC  210  may have a memory that can include stored data for comparisons. 
         [0015]    As further shown in exemplary  FIG. 3 , a more detailed diagram of sensor  106 , one or more sensors may be shown. Sensor  106  may include any number of sensors, which may be plug and play modular sensors, for example modules  222 ,  224  and  226 , as described above. Modules  222 ,  224  and  226  may be any type of modules, for example modules that include some form of sensing or sensory capability. As mentioned above, modules  222 ,  224  and  226  may further be such that they can enjoy plug and play compatibility which can allow them to be changed, replaced, swapped out or otherwise altered in a short amount of time. Any of sensors  312 ,  314  and  316  can be mounted in a separate standardized module  222 ,  224  and  226 , in some further exemplary embodiments. For example any single module or any number of modules  302  through  310  or  222  through  226  may be removed and replaced quickly and easily, for example through a utilization of quick release device  320 . Quick release device  320  may allow for fast and precise mounting of any sensors with respect to rod  104 . Further, depending on different types of filters that may be desired to be made, different modules may be utilized and the plug and play compatibility of modules  222  through  226  may allow for the utilization of any desired modules within a minimal amount of time. Modules  222  through  226  can be any type of modules, for example sensory modules such as optical, laser, inductive, capacity, microwave, pneumatic, any other type of wave, video, any type of cameras or any other known type of module or sensor that can allow for the sensing of any desired property. Additionally, modules  222  through  226  may be any combination of modules, for example separate or unique types of modules for each of modules  222 ,  224  and  226 . Any of modules  222  through  226  may then be formed into or coupled to form one or more sensors  312 ,  314  or  316 . For example, one or more modules  222  through  226  can be coupled together in any number of orientations to form a sensor, as further described below. Additionally, other modules, for example modules  302  and  310  may be utilized or used in a similar manner. Further, each sensor or any desired number of sensors may be positioned inside a housing, for example housing  340 . Housing  340  may be formed out of any desired material and may protect any components inside housing  340  from mechanical, chemical or other forms of damage or interference. In some further exemplary embodiments, housing  340  may act to seal any internal components from outside elements. 
         [0016]    Still referring to exemplary  FIG. 3 , module  302  may be an entry module and may provide for an initial scanning or reading of rod  104  as it enters system  200 . Further, other components may be activated upon an initial scanning or reading of rod  104  performed by module  302 . Also, in some examples, a reading or scanning by module  302  may designate a leading edge of a filter segment that is to be cut from rod  104 . Additionally, another module, module  310 , may be an exit module. Thus, in some exemplary embodiments, a reading by module  310  may be a final reading or scan of rod  104  and may designate a trailing edge of a filter segment that is to be cut from rod  104 . 
         [0017]    Still referring to  FIG. 3 , some further exemplary embodiments can include cleaning nozzles  312 . Cleaning nozzles  312 , for example, may function by blowing clean or vacuuming clean any sensor onto which dirt or any other undesired contaminants may have accumulated. Further, any modules and sensors discussed herein may work together or otherwise in conjunction to provide sensory results with a high degree of accuracy. Further, additional sensors, for example sensors  314 , may be placed or otherwise oriented inside sensor  314 , for example as shown in exemplary  FIGS. 4   a  and  4   b.    
         [0018]    In exemplary  FIG. 4   a , an exemplary sensor orientation may be shown. Here, four sensors  314  may be mounted at approximately 90 degree angles from each other and may be disposed about rod  104  as it passed through system  200 . Additionally, each of sensors  314  may include cleaning nozzles  312  as described above. In another exemplary embodiment, as shown in  FIG. 4   b , three sensors  314  may be mounted at approximately 120 degree angles from each other and may be disposed about rod  104  as it passed through system  200 . Similarly, each of sensors  314  may include cleaning nozzles  312  as described previously. In further exemplary embodiments, sensors  314  may be mounted, disposed or coupled in any desire and may be able to scan rod  104  in any manner, for example a 360 degree scan. 
         [0019]    Referring back to exemplary  FIG. 3 , in one exemplary embodiment, each sensor, for examples the one or more sensors in modules  302  through  310 , may have a different or unique application. For example, module  222  may have a laser detector which may allow it determine the location of a capsule which may be disposed in a filter segment to be cut from rod  104 . Further, module  224  may have a microwave sensor which can determine a capsule position or broken capsule or capsule fragments in the constitution of a filter which may be disposed in a filter segment to be cut from rod  104 . Additionally, module  226  can have a capacity sensor, which may determine the humidity of a segment of rod  104  and the quantity of any different substances used to form a segment of rod  104 . Further, module  224  may have a video camera that provides a video signal, which may allow for the determination, either in a machine readable manner or human readable manner, of any visual defects or geometrical differences that might occur during production. Each module or any number of modules may work in parallel to provide any data collected thereby to junction and acceleration module  202 , as shown in exemplary  FIG. 2 . 
         [0020]    Junction and acceleration module  202  may help regulate or control signals from any of modules  302  through  310  as well as any plug and play sensors. Different numbers and type of modules can be attached to the said junction and acceleration module  202 . For example, junction and acceleration module  202  may boost or accelerate a signal from any sensors, allowing for a relatively low or weak signal or signals to become a more robust, higher signal or signals, or otherwise a signal or signals with greater strength. Any signals may then be sent from the junction and acceleration module  202  to digital high speed module  204 . Digital high speed module  204  may digitize any signals sent thereto, for example converting them from analog to digital if desired. Digital high speed module  204  may further have any desired number of inputs allow it to receive any number of signals from any number of transmitting sensors or modules, such as modules  302  through  310  or junction and acceleration module  202 , at any time. In some exemplary embodiments, it may also be desired to have a number of digital high speed modules that may be connected together. Such a grouping of digital high speed modules may in order to increase the capacity of the system  200  insofar as more sensors may be added, for example, in a plug and play manner. 
         [0021]    In a further exemplary embodiment, any number of sensors, such as sensors  314 , of a same or similar type may be disposed in system  200 . For example, a higher number of sensors  314  in system  200  may allow for the generation and compilation of a larger amount of signal data which may then be analyzed faster, for example simultaneously analyzing and processing the signals which may allow for higher precision. Further, in some exemplary embodiments, digital high speed module  204  can also include a processor or processing capabilities that may allow it to compare any signals which may be inputted into digital high speed module  204 . Further, digital high speed module  204  can compare any inputted signals from any sensors, such as sensors  314  to a known or predetermined signal or pattern. The known signal or pattern may be a signal generated from or a pattern of a known type or brand of cigarette filter and which may be stored in PLC  210 , as described below. Further, the known signal or pattern may be of a filter that is fulfills a predetermined or desired constitution, construction, composition or quality criteria. Following any comparison made by digital high speed module  204  of incoming signals against a known signal or pattern, an output may be produced. The output may indicate that a filter segment whose composition, construction, geometrical shape, quality criteria or any is appropriate or desired, resulting in a “good” output or signal otherwise indicating that the filter segment is acceptable and the filter segment may continue through any further components of machine  100 . However, in situations where the filter segment does not comply with a desired construction, composition or any quality criteria indicated by the known signal or pattern, a “bad” output or signal otherwise indicating the filter segment is bad. The filter segment may then be removed by ejector  110 , for example after it is cut by cutting device  108 . 
         [0022]    Known signals or patterns can be stored in a memory, for example a memory associated with PLC  210 . The memory in PLC  210  may be referred to as a brand manager. The brand manager in PLC  210  may store known signals or patterns that have the desired parameters for filters or filter segments, such as those described previously. Further, data provided by digital high speed module  204  may be converted into a desired format by converter  208  so that it may be compared to the stored data in PLC  210 . 
         [0023]    The desired parameters for filters stored in PLC  210  can include the best or most demanded parameters for each or any sensor. While known signals or parameters may be stored on PLC  210  in any desired manner, an interface, such as human machine interface (HMI)  212  may be utilized or otherwise associated with PLC  210 . HMI  212  may allow for a computer operator to enter any desired data, such as known signals or patters, add, edit or change any desired data. System  200  may also, in some exemplary embodiments, include a self learning mode which can act to improve or otherwise optimize any sensor performance parameters during otherwise routine operation. Further, any new or additional known signals or patterns or other parameters may also inputted into system  200  through HMI  212  through the use of physical products and a sensory examination thereof. Also, as system  200  is working to produce products, a mathematical model of the sensitivity and working parameters of the sensors may be adjusted either automatically or manually through HMI  212  as desired, for example in real time. Additionally, various settings and pre-sets of any programmable sensors can be stored, for example, in a “sensor library” of the PLC  210 . When any type of filter is chosen from the brand manager, the PLC  210  can send hardware settings to an appropriate sensor (for example sensor  314 ). Thus the sensor may be automatically programmed or set-up for an appropriate type of filter being produced. 
         [0024]    In some further exemplary embodiments, PLC  210  may also record, tabulate and/or store any statistical data regarding products of system  200 , for example filter segments. Exemplary data can include the number of “good” filter segments compared to the number of “bad” filter segments. Additionally, as described previously, upon the receipt of a “bad” signal, digital high speed module  204  may send a signal to ejector  110  which can act to remove the undesired filter segment from system  200  without any interruption of or effect on further production. 
         [0025]    In another exemplary embodiment, the components of system  200  may be synchronized. For example, encoder  206  may act to determine when any sensors, for examples sensors in modules  302  through  310 , perform a measurement or otherwise perform a sensing action. The encoder  206  may make these determinations and then synchronize the sensors with the speed of rod  104  of system  200 . 
         [0026]    In yet a further exemplary embodiment, system  200  may synchronize any data received from any sensors with the cutting device  108 , which may be a cutting head device. Cutting device  108  may function to cut rod  104  at any desired interval or intervals. For example, cutting device  108  may cut rod  104  at precisely determined intervals so as to form filters having a desired length. Additionally cutting device  108  may cut rod  104  at desired or precise intervals so as to maintain a desired distance between a filter segment and/or capsule in a filter from a beginning of a filter. 
         [0027]    In still further exemplary embodiments, system  200  may be a stand alone system. Therefore, as desired, system  200  may be integrated into or incorporated with any other known system so as to improve a desired manufacturing process. For example, the system  200  can be connected to another control system  220  through a standard communication interface  218 . Thus the system  200  can exchange information with other systems, any networked or internet-accessible system or machine or any other hardware or software as desired. 
         [0028]    The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art. 
         [0029]    Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims.