Patent Publication Number: US-8991587-B2

Title: Method of setting reciprocal position of filter segments on a carrier element of a grouping unit in a process of manufacturing multi-segment filters

Description:
The object of the invention is a method of setting reciprocal position of individual segments occurring in the multi-segment filter which are fed onto a carrier element of a grouping unit from the modules of the machine used in the tobacco industry in the process of manufacturing multi-segment filters for cigarettes. 
     In the tobacco industry, there is a demand for multi-segment filters used in the production of cigarettes which consist of at least two types of segments made of different filtration materials; such segments may be soft, filled for example with unwoven cloth, paper, cellulose acetate, or hard, filled with granulate, sintered elements or hollow cylinders. The created series of segments is then divided appropriately into filters used for manufacturing cigarettes. One known method of making multi-segment filters is an end-wise method whose operating principle was presented several times in patent descriptions owned by the British company MOLINS Ltd. For example, British patent description No. GB 1.146.259 shows a method of manufacturing filters consisting of at least three different segments and a machine enabling the use of such method, consisting of three modules. Segments are formed by cutting, with circular cutters, filter rods moving peripherally on three different drums, and the cut sets of segments are removed from each flute of the drum with a chain conveyor provided with pushers, working always in a vertical plane inclined by a slight angle from the axis of the cutting drum. Segments are then removed by ejectors from the chain conveyor onto a rotating intermediate disc mounted horizontally, whose pushers, situated on the perimeter, transfer segments endwise along the horizontal track of the grouping tape to a worm drum regulating the movement of the segments, while earlier, segments of another type obtained by cutting filter rods on drums in the other modules, are fed in a similar manner into the empty spaces between the segments onto the grouping tape. In the presented structure the intermediate disc of the central module has pushers making additionally reciprocating motion when encountering resistance of defined strength, caused by wedging of filter segments. Said transfer is possible by using a ball clutch, which protects the pushers against damage in case of malfunction of the device. Another British patent description filed by the same company, No. GB 2.151.901, presents a device in which rods filled with tobacco are fed onto the horizontal track of the grouping tape by a set of discs mounted horizontally, while the filter segments cut on the drum are inserted respectively into the empty spaces between the rods by means of rotating discs situated vertically above the tape track. The problem of mechanical setting of reciprocal position of filter segments on the grouping tape for two or three types of segments was solved in the description of the British patent of the said company No. GB 1.053.547, where a wheel provided with two peripheral flutes situated above a roller guiding the perforated tape delivering the segments was used. Each flute of the wheel is provided with suitable sets of suction opening groups, where five openings in each group were shown, and the groups are evenly spaced on the circumference of the wheel. The suction opening groups which are connected with one flute are offset circumferentially from suction opening groups which are connected with the second flute. The said openings have a connection to the atmosphere through suitable adjacent wheel surfaces, whereas each adjacent surface near the lowest part of the circumference of the wheel is provided with a suction chamber which is connected with the source of vacuum through a tube, and the suction openings come into contact with the said chamber. The wheel is rotated with the rotational speed higher than the linear velocity of filter rollers so that the movement of one type of segments with the rotational speed of the wheel is forced by sucking them into the appropriate flute in the time when the group of openings connected with it joins to the chamber. So successive segments are axially separated from each other to a distance greater than the length of segments of the second type, and this spacing is maintained on the perforated tape whose speed is equal to the peripheral speed of the wheel. Successive segments of the second type are likewise axially separated from each other by holding by means of vacuum in the appropriate flute of the wheel, and, as the groups of both kinds of openings are offset on the circumference of the wheel, the separated segments of one type are linearly shifted in relation to separated segments of the second type. In the known state of the art, no easy in practice and reliable method of setting the reciprocal position of any required number of filter segments on the grouping tape in the course of preparation of the production line for the start-up was presented. 
     According to the invention, the method of setting reciprocal position of filter segments on the carrier element of the grouping unit in the process of manufacturing multi-segment filters used in the tobacco industry for cigarettes, wherein the segments from multiple modules of the machine for manufacturing filters are delivered Onto the carrier element of the grouping unit and arranged in a sequence corresponding to the structure of the cigarette filter, and the designation of the sequence of said modules was adopted in the direction corresponding to the direction of movement of segments on the carrier element, consist in registering, with the process of manufacturing filters stopped, the position and length of the segment from each module on the carrier element of the grouping unit, and then setting the reciprocal position of segments and the distance between segments. For this purpose, segments from successive modules are fed separately onto the moving carrier element of the grouping unit and moved to the area of operation of a sensor registering the position and the length of segments, after which, by means of the sensor, the length of fed segment and its position relative to the carrier element of the grouping unit is registered and the registered results are stored in the control system of the machine for manufacturing filters and, after storing the registered information with regard to segments delivered from all modules, the required sequence of segments and the distance between segments are set virtually in the said control system, with the position of mechanisms of individual modules being adjusted by means of the control system so as to enable obtaining the virtually set sequence of segments on the carrier element of the grouping unit. The length and position of the segments may be registered by means of one sensor, common for all modules and situated behind the last module or by means of separate sensors, each of which is situated behind the respective module, wherein the sensor may constitute an optical element operating in the range of visible radiation or invisible radiation, or constitute an ultrasonic element. In another embodiment of the method according to the invention, the segments from the last module are fed onto the carrier element of the grouping unit, after which said carrier element is stopped in such reference position that the fed segments are behind the last module and the position of the segment is marked on the registering element situated next to the carrier element, and then the segments are removed from the carrier element. Then the segments from the next to last module are fed onto the carrier element of the grouping unit, after which the carrier element is stopped in such reference position that the fed segments are next to the said registering element, the position of the fed segment is marked on that registering element and the segments are removed from the carrier element, and then the marked position of the segment fed from the next to last module is compared to the previously marked position of the segment from the last module and the position of mechanisms of the next to last module is adjusted so as to obtain the expected position of the segment from the next to last module in relation the segment from the last module, after which the next to last module is restarted for the purpose of comparison and control of the position of fed segments in the reference position of the carrier element with the position registered previously at the registering element. The procedure as for the segments from the next to last module is carried out for segments from successive modules, until the first module. In yet another embodiment of the method according to the invention, the segments from the last module are fed onto the carrier element of the grouping unit, after which the position of the segment is marked on the registering element situated next to the carrier element using a stroboscopic device, and then the segments are removed from the carrier element. Then the segments from the next to last module are fed onto the carrier element of the grouping unit, after which the position of the fed segment is marked on the registering element using the stroboscopic device and the segments are removed from the carrier element, and then the marked position of the segment fed from the next to last module is compared with the previously marked position of the segment from the last module and the position of mechanisms of the next to last module is adjusted so as to obtain the expected position of the segment from the next to last module in relation to the segment from the last module, after which the next to last module is restarted for the purpose of comparison and control of the position of fed segments from the next to last module with the position of segments from the last module registered on the registering elements. The procedure as for the segments from the next to last module is carried out for segments from successive modules, until the first module. In another embodiment of the method according to the invention, the segments from the first module are fed onto the carrier element of the grouping unit and the segments are moved so that the first fed segment is in the feeding area of segments from the second module onto the carrier element, after which the position of the device feeding the segments form the second module is set taking into consideration the position of the segment from the first module on the carrier element of the grouping unit and the set position of the feeding device of the second module is stored, and the control system adjusts the arrangement of the remaining mechanisms of the module. Afterwards, the segments from the first and second modules arranged in a defined sequence on the carrier element are moved so that the said segments are in the feeding area of segments from the third module, after which the position of the device feeding segments from the third module is set taking into consideration the position of segments from the second and first modules on the carrier element of the grouping unit and the set position of the feeding device of the third module is stored, and the control system adjusts the arrangement of the remaining mechanisms of the module. The procedure as for the segment of the third module is carried out for segments from successive modules, until the last module. The application of the method according to the invention allows considerable time saving, especially during the change of the structure of manufactured filter, and reduces the loss of material when setting the position of filter segments on the carrier element of the grouping unit. 
    
    
     
       For the purpose of better understanding, the object of the invention was illustrated in embodiments in the figure in which 
         FIG. 1  generally shows a fragment of the machine used in the tobacco industry for manufacturing multi-segment filters, provided with four modules, each of which feeds segments of appropriate type onto the carrier element of the grouping unit by means of the feeding device, and the position of the segments is registered by means of a common sensor situated behind the last module, which constitutes the embodiment I, wherein  FIG. 1   a  illustrates setting of segments fed by the fourth, last module,  FIG. 1   b —setting of segments fed by the third, next to last module,  FIG. 1   c —setting of segments fed by the second module,  FIG. 1   d —setting of segments fed by the first module and  FIG. 1   e —a fragment of the machine during normal operation with the sensor switched off, 
         FIG. 2  generally shows the interface console of the control system representing graphically the segments fed from four modules and their position on the carrier element as in embodiment I, wherein  FIG. 2   a —illustrates the state before the beginning of setting the position of the segments, whereas  FIG. 2   b —the state after setting the optimal position of the segments, 
         FIG. 3   a —the interrelation of the units of the machine with the control system when using one, common sensor,  FIG. 3   b —the interrelation of the units of the machine with the control system when using separate sensors for each module, which constitutes a modification of embodiment I, 
         FIG. 4  generally shows a fragment of the machine as in  FIG. 1  where the position of segments is registered by means of a registering element situated next to the carrier element behind the last module, which constitutes the embodiment II, wherein  FIG. 4   a  illustrates setting of segments fed by the fourth, last module,  FIG. 4   b —setting of segments fed by the third, next to last module,  FIG. 4   c —setting of segments fed by the second module and  FIG. 4   d —setting of segments fed by the first module, 
         FIG. 5  generally shows a fragment of the machine as in  FIG. 4  where the position of the segments is registered by means of a registering element situated next to the carrier element behind the last module using the stroboscopic device, which constitutes the embodiment III, wherein  FIG. 5   a  illustrates setting of the segments fed by the fourth, last module,  FIG. 5   b —setting of segments fed by the third, next to last module,  FIG. 5   c —setting of segments fed by the second module and  FIG. 5   d —setting of the segments fed by the first module, whereas 
         FIG. 6  generally shows a fragment of the machine used in the tobacco industry for manufacturing multi-segment filters, provided with four modules, each of which feeds segments of the respective type onto the carrier element of the grouping unit by means of the feeding device, where the position of the segments is set by reciprocal adjustment of feeding devices of adjacent modules, which constitutes the embodiment IV, wherein  FIG. 6   a  illustrates setting of segments fed from the first module,  FIG. 6   b —setting of segments fed from the second module,  FIG. 6   c —setting of segments fed from the third, next to last module and  FIG. 6   d —setting of segments fed from the fourth, last module. 
     
    
    
     Embodiment I. A machine for manufacturing multi-segment filters shown in a fragment in  FIG. 1  consists of four similar modules  1 , designated successively A, B, C, D, in the direction corresponding to the movement of a carrier element  2  of a grouping unit. Each of the modules  1  delivers, through a feeding device  6  onto the carrier element  2  respectively segments  3 A,  3 B,  3 C,  3 D which may differ in length and content. Behind the last module  1 D, near the carrier element  2 , is situated a sensor  4  registering the position and length of segments  3  on the carrier element  2  taking into consideration the reference point  5 , which is the cutting line of a ready multi-segment rod, where the sensor  4  transmits the results of measurements to the control system of the machine. For the purpose of setting the reciprocal position of the segments  3  on the carrier element  2  at first the last module  1 D is started which by means of the feeding device  6 D conveys the segments  3 D to the moving carrier element  2 , where its length and position in relation to the reference point  5  is registered by the sensor  4 , and the result of the measurement transmitted to the memory of the control system. Afterwards, the segments  3 D are removed from the carrier element  2 , whereas the feeding device  6 D, not fed with segments  3 D, remains switched on, which is necessary when setting the position of the next segment  3 C ( FIG. 1   a ). Then the next to last module  1 C is started which by means of the feeding device  6 C conveys the segments  3 C onto the moving carrier element  2 , and its length and position relative to the reference point  5 , taking into consideration the distance from the segment  3 D, is registered by the sensor  4 , and the result of the measurement is transmitted to the memory of the control system ( FIG. 1   b ). Similar activities are carried out in order to set the position of segments  3 B ( FIG. 1   c ) and segments  3 A ( FIG. 1   d ). A manual change of the reciprocal position of the segments  3  stored in the control system is carried out by means of the display field  7  of the control system interface ( FIG. 2   a  and  FIG. 3   a ) in which the segments  3 D,  3 C,  3 B,  3 A, fed respectively from the modules  1 D,  1 C,  1 B,  1 A, have been represented graphically in independent lines  8 D,  8 C,  8 B,  8 A where the registered arrangement of segments  3  on the carrier element  2  is presented in the display field  7  by means of the line  9 . In the example shown, the distance between segments  3  requires regulation. After pressing one of the keys A, B, C, D in the panel  10 , corresponding to the segments  3 A,  3 B,  3 C,  3 D, the position of the segment  3  in relation the reference point  5  and in relation to other segments  3  may be set manually by means of the control buttons  11 , taking into consideration respective distances between the segments  3 , which will be stored in the control system and represented graphically on the line  9 . The sequence of segments  3  encoded in the control system will be mapped during normal operation of the machine, which is shown in  FIG. 1   e.    
     Alternatively, the method of setting the segments  3  may include the use of four sensors  4 , respectively one situated behind each feeding device  6 , which is shown in  FIG. 3   b.    
     Embodiment II. In  FIG. 4 , the machine as in embodiment I also in a fragment is shown, wherein the length and the position of segments  3  on the carrier element  2  is registered by means of the registering element  12  situated behind the last module  1 A next to the carrier element  2 . For the purpose of setting the reciprocal position of the segments  3  on the carrier element  2 , at first the last module  1 D is started which by means of the feeding device  6 D conveys the segments  3 D onto the carrier element  2  moving in slow motion, where the element  2  is stopped at the moment when the respective reference position is reached, and the position of the first segment  3 D is marked on the registering element  12 , after which the segments  3 D are removed ( FIG. 4   a ). Afterwards, similar activities are carried out for the segments  3 C fed from the module  1 C and the position and length of the segment  3 C marked on the registering element  12  are compared with the previously marked position of the segment  3 D and then, in case of improper arrangement of the segment  3 C in relation to the segment  3 D, the mechanisms of the module  1 C are adjusted so as to obtain the expected position of the segment  3 C in relation to the segment  3 D by referring to the position of the segments  3 D and  3 C marked on the registering element  12 . At the end, the module  1 C is restarted in order to compare and control the position of fed segments  3 C in the reference position of the carrier element  2  with previously registered position of the segment  3 C on the registering element  12 , and then the segments  3 C are removed from the carrier element  2  ( FIG. 4   b ). Similar activities are carried out for the purpose of setting the position of the segments  3 B ( FIG. 4   c ) and the segments  3 A ( FIG. 4   d ). 
     Embodiment III. In  FIG. 5   a ,  FIG. 5   b ,  FIG. 5   c  and  FIG. 5   d , the machine as in embodiment II is shown, wherein the position of the segments  3  on the registering element  12  situated next to the carrier element  2  is marked by means of the stroboscopic device  13 , which does not require stopping the carrier element  2  each time after the segment  3  being set has reached the reference position. All other operations in this embodiment are carried out in an identical way as in embodiment II. 
     Embodiment IV. In  FIG. 6 , the machine as in embodiments I, II and III is shown, but with a considerably simplified control system. For the purpose of setting the reciprocal position of the segments  3  on the carrier element  2 , with the machine switched off, at first the module  1 A is started which, by means of the feeding device  6 A, conveys the segments  3 A onto the carrier element  2  moving in slow motion, whereas the element  2  is stopped at the moment when the first segment  3 A is placed in the feeding area of the segments  3 B from the module  1 B onto the carrier element  2  ( FIG. 6   a ). Afterwards, the position of the feeding device  6 B from the module  1 B is set and stored taking into consideration the position of the segment  3 A, and the control system adjusts the arrangement of the remaining mechanisms of the module  1 B ( FIG. 6   b ). In turn, the segments  3 B and  3 A set in a defined sequence on the carrier element  2  are moved so that the segment  3 B is in the feeding area of the segments  3 C from the module  1 C and the position of the feeding device  6 C from the module  1 C is set and stored taking into consideration the position of the segments  3 B and  3 A, and the control system adjusts the arrangement of the remaining mechanisms of the module  1 C ( FIG. 6   c ). Similar operations are carried out for the segments  3 D from the module  1 D ( FIG. 6   d ). 
     All procedures presented above refer to a situation when manufacturing of a new filter type is started or it was necessary to change the structure of the manufactured filter by changing the sequence of the segments  3  in the filter, changing one of the segments  3  to another or removing one of the segments  3 . Setting of the segments  3  is carried out before the start or after interrupting the production of filters. After setting on the carrier element  2 , during normal operation of the machine, the segments  3  are moved to further units in which they are pushed close to each other, wrapped in the cigarette paper, and then, by cutting the so formed continuous filter string, multi-segment filter rods are manufactured.