Abstract:
A drum elevator and method of elevating cigarettes, the apparatus including a series of rotatable cigarette transferring drums including a first plurality of horizontally disposed drums at a first elevation and a second plurality of vertically disposed drums extending to a second elevation, the second plurality of vertically disposed drums receiving output from the first plurality of drums, the series of drums adapted to receive a procession of cigarettes at the first elevation and to elevate the cigarettes along a transfer path to the second elevation while maintaining the cigarettes arranged substantially in the procession; a rejection station at a location along the transfer path; a controller operative to selectively actuate the rejection station; and a stack former at the second elevation, the stack former receiving output of the second plurality of vertically disposed drums.

Description:
This application is a div. of Ser. No. 09/154,775 Sep. 17, 1998 now U.S. Pat. No. 6,123,201. 
    
    
     FIELD OF INVENTION 
     The present invention relates to machines used in the manufacture of cigarettes, and more particularly to mass-flow elevators for transporting the output of cigarette makers to cigarette packing machines. 
     BACKGROUND OF INVENTION 
     In a typical filter tipping machine, two-up tobacco rods are transferred along a series of drums for the execution of manufacturing steps which ultimately create, near the exit of the tipping machine, a succession of individual, filter tipped cigarettes that are discharged from a final, exit drum. Usually a stack-former apparatus is placed adjacent the exit drum of the tipping machine to initiate the formation of a moving, multi-layered mass of cigarettes. The stacked mass of cigarettes is then directed through a mass-flow elevator to the accumulator and/or a tray filler, which interfaces with a cigarette packer. Downstream of the stack-former, tracking of individual cigarettes is usually not possible. 
     Mass flow elevators of the prior art commonly comprise a pair of mutually opposing, vertically oriented endless belts which vertically transport the stacked (multi-layered) mass of cigarettes to a height that is conducive to feeding cigarettes to the packer and/or an accumulator or tray filler. It has been found that when one of the belts fall, the elevator may still continue to vertically transport cigarettes, but in a manner that increases the risk of skewed cigarettes, product degradation (e.g., flatten “D” shaped cigarettes) and machine jams downstream of the elevator. 
     Tipping machines of the prior art have included one or more quality inspection stations at a location along the cigarette stream when the individual cigarettes have been fully formed and separated from one another. Typically, these devices inspect the cigarettes for loose ends, proper rod density, missing filters and other quality-indicative features. Because cigarettes are not fully constructed until close to the exit station of the tipping machine, there is but little room and opportunity for the placement and operation of the inspection devices and for effecting rejection of unacceptable cigarettes (i.e., cigarettes which have failed to pass one or more of the aforementioned quality inspection tests). There is also little or no room nor time for confirmation of a detector&#39;s initial reading. 
     Because cigarettes were heretofore mixed amongst each other soon after the exit of the tipping machine, all rejections of unacceptable cigarettes had been effected within the tipping machine, typically at a single rejection station at a fixed location along a single drum (usually the exit drum or a dedicated rejection drum just upstream of the exit drum). At the rejection station, a blast of compressed gas would be communicated to an underside of a passing flute known to carry an unacceptable cigarette by the flute tracking system of tipping machine controller. The blast is gauged to be sufficient to overcome the vacuum retention system of drum so as to blow the cigarette off the respective drum flute. Because the blast has to be complete and so immediate in so little space and time, the ejection process often rips or otherwise further damages the rejected cigarettes. The additional damage also tends to mask the true condition of the cigarette as it appeared at the inspection station, hampering resolution and correction of the casual problem at the cigarette maker. 
     Also, prior ejection systems heightened the risk of jams, because all ejections, for whatever reason out of a multiple of reasons, had to be undertaken at the exit station amongst a host of high speed, complicated rotating machinery. Additionally, if a consecutive series of cigarettes failed inspection, the repetitious operation of the rejection system would degrade its performance and/or tend to interfere with the vacuum retention system of the machine. 
     Heretofore, sampling of good cigarettes included the practice of a machine operator manually scooping a sample of cigarettes from the stacked mass. The scooping action has been found to occasionally skew cigarettes along the stack and to sometimes damage product. 
     OBJECTS AND SUMMARY OF THE INVENTION 
     Accordingly, an object of the present invention is to provide a cigarette elevator arrangement for transferring the output of a cigarette making module without the aforementioned problems of the prior art. 
     It is another object of the present invention to provide such a cigarette elevator, which has the additional capacity to reject cigarettes outside of the tipping machine so as promote a more efficient and reliable cigarette ejection system. 
     It is yet another object of the present invention to provide a cigarette elevator having the capacity to preserve order amongst a procession of cigarettes beyond a cigarette maker and/or its tipping machine so as to facilitate further and/or confirmatory inspection of the cigarettes. 
     It is another object of the present invention to provide a cigarette elevator module which facilitates additional inspection of the cigarettes without imposing significant changes to the layout of the cigarette manufacturing module. 
     It is yet another object of the present invention to provide a cigarette elevator such that repetitive rejection of cigarettes can be undertaken without disruption of acceptable cigarettes and with less risk of causing machine jams. 
     Still another object of the present invention is to provide an arrangement for confirmatory inspection of finished cigarettes such that false rejection of acceptable cigarettes is minimized. 
     Another object of the present invention is to provide a drum elevator having provision for gentle, damage-free sampling of cigarettes at the moment of their production. 
     Yet another object of the present invention is to gently transport the output of a cigarette maker to a cigarette packer and/or accumulator such that deformation of good cigarettes is minimized and the rejection of unacceptable cigarettes is as complete and accurate as possible. 
     These and other objects are achieved with the present invention which provides a drum elevator and method of elevating cigarettes, wherein the apparatus comprises a series of rotatable cigarette transferring drums that includes a first plurality of horizontally disposed drums at a first elevation and a second plurality of vertically disposed drums extending to a second, desired elevation. The second plurality of vertically disposed drums receive the output of the first plurality of drums, and the first and second pluralities of drums being adapted to receive a procession of cigarettes at the first elevation and to elevate the cigarettes to the second elevation while maintaining the cigarettes arranged in the procession. The drum elevator further comprises a rejection station at a location along the transfer path; a controller operative to selectively actuate the rejection station; and a stack former at the second elevation which receives the output of the second plurality of vertically disposed drums. 
     Another aspect of the present invention includes provision of a soft ejection station comprising a nip defined between a pair of adjacent cigarette conveying drums, with the upstream drum including a second vacuum plenum at the nip between the drums and an arrangement for selectively evacuating and venting the second plenum. Accordingly, the second vacuum plenum is arranged both to draw cigarettes onto the upstream drum upon evacuation and to gently release cigarettes from between the drums upon venting. Such action avoids damaging the sampled cigarettes during the ejection process so that they may be reclaimed, and it is not intrusive upon adjacent portions of the cigarette procession. 
     Yet another aspect of the present invention includes provision of a stack former comprising a counter arranged to generate a signal indicative of a rate of cigarettes entering the stack former, a substantially stationary element at a location along a pathway of the cigarettes such that cigarettes are discharged beyond the element as a stacked mass; and a conveyor controller configured to adjust an adjustable conveyor drive mechanism responsively to the signal indicative of cigarette rate so that the stacked mass of cigarettes is maintainable at a predetermined height. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING 
     These and other objects and advantages novel features of the present invention will become apparent from the following detailed description of the preferred embodiments when considered in conjunction the drawing, wherein: 
     FIG. 1 is a perspective view of a cigarette manufacturing system of the prior art; 
     FIG. 2 is a detailed cross-sectional diagram of exit station of a typical tipping machine of the prior art; 
     FIG. 3 is a drum elevator system constructed in accordance with a preferred embodiment of the present invention, together with adjacent details of a tipping machine that has been modified to cooperate therewith; 
     FIG. 4 is a cross-sectional side view of a soft ejection station included within the drum elevator system of FIG. 3; 
     FIG. 5 is a cross-sectional side view of a valve of the soft ejection station shown in FIG. 4; and 
     FIG. 6 is a diagram of an alternate, preferred embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION 
     Referring now to FIG. 1 (prior art) a filter cigarette maker module  2  comprises a tobacco rod making machine  4  coupled with a tipping machine  6 , the latter typically being arranged to interpose two-up filter plugs between spaced apart pairs of tobacco rods, securing same with tipping paper, and severing it to produce individual cigarettes. Referring now also to FIG. 2 (prior art), at the exit of the tipping machine  6  a stack former  8  is operative to transform the output of the tipping machine  6  into a mass of cigarettes  10  which are carried along a conveyor  12  to a mass flow elevator  14 . 
     At the mass flow elevator  14  of the prior art, the stacked mass of cigarettes  10  are directed beneath a pair of opposing endless belts  16  and  18  which carry the stack of cigarettes  10  to a high elevation  19 . 
     At the higher elevation  19 , the stack of cigarettes  10  is typically directed along another conveyor  20  to a cigarette packing machine  22  and/or an accumulator  24 . At the cigarette packer  22 , the cigarettes are bundled and package into individual cigarette packs. 
     Referring to FIG. 2 (prior art), upstream of its exit, the cigarette tipping machine  6  typically includes a turning drum  30  having a plurality of vacuum actuated, cigarette retaining flutes  33 . The turning drum  30  establishes a procession of individual cigarettes which are thereafter transferred onto an inspection drum  32  about which are situated one or more cigarette inspection stations  34   a,    34   b  and  34   c.  Such is typical of the Max tipping machine manufactured by Hauni Machinenbauag of Hamburg, Germany. 
     By the time cigarettes  40  reach the inspection drum  32 , the fabrication of the individual cigarettes  11  is complete. Conventionally, the finished cigarettes are transferred one after another onto the inspection drum  32 . The inspection drum  32  itself has a plurality of circumferentially spaced, axially extending flutes  36  along its outer surface, each flute  36  having a longitudinal axis parallel to the rotational axis of the drum  32 . Each flute  36  receives one cigarette  11  and the cigarette is held in the flute by reduced pressure (“vacuum”) which is communicated to the flute by passageways  35  extending radially to the flute  36  from a vacuum plenum  37  disposed along the interior of the drum  32 . Such vacuum is typically communicated only along the arcuate portion of the drum  32  along which the cigarettes are to be held as the drum  32  rotates to convey the cigarettes  11 . When a cigarette ladened flute arrives at an angular location at which the cigarette  11  is to be transferred to the next, downstream drum (here, a rejection drum  42 ), vacuum to the flute of the upstream drum (here, drum  32 ) is interrupted at or preferably just upstream of the angular location of transfer so that the next downstream drum (here, the rejection drum  42 ) can pick up the cigarette  11  with little or no interference from the upstream drum (e.g., the inspection drum  32 ). 
     While the cigarettes are rotated about the inspection drum  32 , they are inspected in the conventional way by inspection apparatus  34   a - 34   c  as is typically provided in the aforementioned Hauni Max machine. For example, its inspection station  34   a  may execute a “dilution check” to make sure that the cigarette has proper resistance to draw. The inspection station  34   b  may be arranged to execute an inspection of the tobacco rod density. Another station  34 C might execute an inspection for missing filters. These inspections are mentioned only for purposes of example, and others might be undertaken either in substitution for or in addition to the ones specifically mentioned here. 
     Typically, any output signal from the inspection stations  34   a - 34   c  indicating the presence of an unacceptable cigarette on one of the flutes  36  of the drum  32  is communicated to the controller  50 , which also receives signals from the drum drive train  55  of the tipping machine  6 . With such input, the controller  50  tracks the whereabouts of unacceptable cigarettes as they transfer from the inspection drum  32  to the rejection drum  42 . 
     As the procession of cigarettes  11  are rotated about the rejection drum  42 , they pass beneath a rejection station  44  whose operation is subject to the tracking and control of the controller  50 . The rejection station  44  typically comprises one or more valved, air jets  46  that are communicated with a source of pressurized air  48 . Because of the limited confines within the tipping machine, the Max tipping machine will typically have only one of such rejection stations  44  such that all unacceptable cigarettes are discharged at this singular station and collected together in a bin  49  located adjacent the rejection drum  42 . 
     Also, because of the extreme machine speeds of the tipping machine and because the output of the rejection jet  46  must overcome the retention action of the drum vacuum system, the discharge from the jet  46  must be immediate and forceful so as to assure complete removal as the unacceptable cigarette arrives at the rejection station  44 . 
     Typically, those cigarettes  11  which pass inspection (i.e., acceptable cigarettes) are transferred from the rejection drum  42  onto the exit drum  60 ; then through a stack former  8  located adjacent the exit of the tipping machine  6 ; and onto the conveyor  12  whose speed is controlled by a controlled drive mechanism  70 . The stack former  8  includes a rotatable deflector plate  65  which is angularly deflected about a pivot  67  by the stream of cigarettes coming off the exit drum  60 . Deflection of the plate  65  adjusts a rheostat, which in turn causes the controller  70  to adjust the speed of the conveyor  12  and thereby adjust the height of the stack  10 . If a great number of cigarettes are discharged against the deflector plate  65 , it is upwardly displaced, which motion causes a signal to the controller  70  to increase the speed of the conveyor  12  so that the stack of cigarettes  10  remains at a desired height. If fewer cigarettes arrive at the stack former  8 , the deflector plate  65  drops, sending a signal which causes the controller  70  of the conveyor  12  to slow the conveyor speed to maintain the height of the stack  10 . 
     In the above-described system of the prior art, all unacceptable cigarettes are rejected together and commingled, in a manner with oftentimes leads to damage of the rejectable cigarette, all which factors frustrate statistical analysis of types and reasons for cigarettes to fail inspection. The system also loses tracking of unacceptable cigarettes at the stack former where all cigarettes are bunched together as a massed stack of cigarettes  10 . 
     Also, if a repetitive stream of unacceptable cigarettes pass through the system, the rejection station  44  must operate repetitively at high machine speeds such that operation of the jets  46  may disrupt proper operation of the vacuum retention system on the rejection drum  42  such that good cigarettes are unintentionally rejected and, worse still, cigarettes become jammed at or about the inspection drum  42  and/or the exit drum  60 . 
     Referring now to FIG. 3, a preferred embodiment of the present invention provides a drum elevator system  100  for an improved and orderly handling of the output of a tipping machine  506  for delivery to an elevated conveyor  520  (or other system for delivering cigarettes to an automated cigarette packer). The elevator system  100  preferably comprises a vertical series of drums  102  at the top of which a stack former  104  operates to form a stack  510  of cigarettes at a location which is adjacent the conveyor  520  and distal of the exit of the tipping machine  506 . A horizontal series of drums  106  operatively link the vertical series of drums  103  with the exit of the tipping machine  506  and includes a link-up gear box assembly  108  such that at least the first several of the horizontal drums  106  are driven by the tipping machine  506 . 
     In the preferred embodiment the horizontal series of drums  106  preferably comprise the first five drums ( 120 , 130 , 140 , 148 , 150 ) and the vertical series of drums  102  preferably comprise the next three drums ( 160 ,  170 , 180 ) together with the drums immediately preceding the stack former  104  (drums  194 , 196 , 200 ). It is contemplated that one of ordinary skill upon a reading and understanding of this entire disclosure might employ greater or lesser numbers of drums amongst the vertical and horizontal series of drums  102 ,  106  in the practice of the present invention. 
     Preferably, the link-up gear box  108  includes the first three drums ( 120 ,  130 , 140 ) of the drum elevator system  100 . Preferably, each drum of the drum elevator system  100  is provided about its periphery a plurality of axially directed, circumferentially spaced-apart flutes which receive and releasably retain individual cigarettes under the action of a vacuum retention system as previously explained for drums such as found on the tipping machine  6  and  506 . Other similarly functioning mechanisms might be employed to effect a releasable retention of cigarettes  11  on the drums of the drum elevator system  100 . 
     Referring to FIG. 3, the transfer and retention of cigarettes from drum to drum along the drum elevator system  100  is represented by arcuate arrows at each drum (such as arrows a and b at the first and second drums  120  and  130 , respectively) which indicate generally the preferred angular location along each drum where cigarettes are received by a drum and the preferred angular location where cigarettes are released from the respective drum and transferred to the next. For example, in the link-up gear box  108 , the first drum of  120  receives cigarettes from the rejection drum  42 ′ of the tipping machine  506  at approximately at a 4 o&#39;clock position and transports it approximately 1800 in a counter-clockwise direction to a 10 o&#39;clock position where the cigarettes are transferred to the second drum  130  of the link-up gear box  108 . In turn, the second drum  130  delivers cigarettes to the third drum  140  of the link-up gear box  108 . 
     The first drum  120  of the link-up gear box  108  is preferably a replica of the original or standard exit drum  60  of the tipping machine  506  (and tipping machine  6 ′ from which the former is adapted), except that the first drum  120  is rotatably mounted to the link-up gear box  108  and is drivingly linked with the second and third drums  130 ,  140  of the link-up gear box  108  by belts and/or drive chains, such that rotation of the first drum  120  causes synchronous rotation of the second and third drums  130 ,  140 . The first drum  120  is also connected with the portion of drive train  555  of the tipping machine  506  that is otherwise available to drive the exit drum  60  of the tipping machine. Accordingly, as the drive train  555  of the tipping machine  506  causes the drums  30 ′ and  42 ′ to rotate under the command of the controller  50 ′ of the tipping machine  506 , the first drum  120  of the gear box link  108  is also caused to rotate, together with the second and third drums  130 ,  140 . By such arrangement, the first three drums ( 120 , 130  and  140 ) of the elevator  100  are caused to rotate synchronously with the drums within the tipping machine  506  as commanded by the controller  50 ′ of the tipping machine  506 . 
     Preferably, drums beginning with the fourth drum  148  and all upstream drums thereafter (drums  150 , 160 , 170 , 180 , 194 , 196 , 200 ) are linked together by gearing or more preferably, a system of belts to rotate synchronously together. In the preferred embodiment, only the sixth drum  160  of that group is driven by the drive mechanism  145  of the elevator system  100 , although another drum or drums of the group might be selected. 
     The drum elevator system includes its own controller  110  for executing operator commands and maintaining desired drum speeds of the fourth drum  148  and all upstream drums thereafter (drums  150 , 160 , 170 ,  180 , 194 , 196 , 200 ). Preferably, a shaft-speed encoder  142  is operatively located at the third drum  140 . The shaft encoder  142  provides a signal to the controller  110  indicative of the rotational speed of the third drum  140  of the link-up gear box  108 . For production operation, the controller  110  is configured to control, responsively to the signal generated from the shaft-speed encoder  142 , the speed at which the drive mechanism  145  drives the sixth drum  160 , so that the sixth drum  160 , together with all the other drums linked with it, are synchronized with the rotation of the third drum  140 . At other times, such as when the machine operator enters a command at the controller  50 ′ to stop operations (shut-down), the controller  110  is preferably configured to continue rotation of the remainder of drums of the elevator system  100  independent of the first, second and third drums ( 120 ,  130 , 140 ) for a time sufficient to clear product from the elevator system  100 . 
     Although the preferred embodiment utilizes a reading of drum speed of the third drum  140 , another drum of the link-up gear box  108  could be used instead. 
     Between the third drum  140  and the fourth drum  148  is established a “soft” ejection station  146  which is operable at the command of the controller  110  to interrupt transfer of cigarettes between the third and fourth drums (drums  140 ,  148 ) so as to gently remove cigarettes from the stream of cigarettes and to direct them instead through chute a  148  to a sampling draw or bin  149  for collection and inspection. 
     Referring now to FIG. 4, the soft ejection station  147  preferably comprises modifications to the fourth drum  148  such that it includes a second vacuum plenum  310  adjacent the nip  311  established between the third and fourth drums (drums  140 ,  148 ) and a plenum control system  320  which is operable to selectively communicate a vacuum or alternatively a vent to the second vacuum plenum  310  responsively to signals preferably from the controller  110  of the drum elevator system  100 . 
     The third drum  140  preferably comprises a rotatable outer drum portion  330  having a plurality of spaced-apart flutes  332  that are sized to receive a cigarette  11 . Each flute is communicated with the interior of the drum  140  through one or more, preferably at least two, vacuum ports  336 . The outer drum portion  330  rotates about a fixed inner drum body  338  which includes air control flanges that establish, in cooperation with the outer drum portion  330 , a vacuum plenum  340 , a vacuum relief plenum  342  and first and second vacuum closure portions  344  and  346 . The vacuum plenum  340  extends circumferentially about the drum interior from a first angular position  348  just upstream of the nip  411  between the second and third drums  130 , 140  to a second angular position  350  just upstream of the nip  311  between the third and fourth drums  140 , 148 . The vacuum plenum  340  is communicated with a vacuum source  350  through a vacuum duct  352 . 
     By such arrangement, the vacuum plenum  340  is operative to pick up a cigarette  11   a  from the preceding second drum  120  and to retain the cigarette  11   a  upon the respective flute  332   a  as the outer drum portion  330  rotates toward the second angular position  350 . Thereat, the first vacuum closure portion  344  of the fixed drum body  338  obstructs communication of vacuum to the vacuum ports  336  of the flute so as to facilitate transfer of the cigarette  11  to the next (fourth) drum  148 . The vacuum release plenum  342  is provide just downstream of the nip between the third and fourth drums  140 , 148  which serves to vent the vacuum ports  336  to the surrounding environment at an angular location just downstream of the nip  311  to minimize any tendency for a cigarette  11  to remain drawn to the flute  332  of the third drum  140 . The second vacuum closure portion  346  maintains closure of vacuum ports  336  until a respective flute  332  arrives again at the first angular location  348 . 
     Preferably, all of the other drums of the drum elevator system  100 , except fourth drum  148 , are constructed like the arrangement of the third drum  140  with a vacuum plenum is provided along the angular path extending from just upstream of where the drum first receives a cigarette to just upstream of where the drum is to release a cigarette to a subsequent drum. 
     As previously mentioned, establishment of soft ejection station  147  includes modifications of the fourth drum  148  to include an independently operable, second vacuum plenum  310 . 
     In particular, the fourth drum  148  includes a fixed drum body  338   x  and a rotatable drum portion  330   x  like those of the third drum  140 , except that the fixed drum body  338   x  is extended to include a third body portion  410  which receives a fixture  412  that encloses the second vacuum plenum  310 . Preferably, the second plenum originates at an angular position slightly upstream of the nip  311  between the fourth and third drums  148 , 140  as viewed in the direction of movement of the rotatable drum portion  330   x  of the fourth drum  148 . Preferably, the second plenum  310  initiates approximately 50 to 100 upstream of the nip  311 , more preferably approximately 70, and extends approximately 300 to 500 beyond the nip  311 , more preferably approximately 420. At the terminus  414  of the second vacuum plenum  310 , the fixture  412  and/or the third portion  410  of the fixed drum body  338   x  provide a seal with the rotatable drum portion  330   x  so as to isolate the second vacuum plenum  310  from the first vacuum plenum  340   x.  The first vacuum plenum  340   x  is constructed like the vacuum plenum  340  of the third drum  140 , except that it accommodates a clockwise drum rotation instead of a counter-clockwise one and is angularly shorter because of its partial displacement by the second vacuum plenum  310 . A vacuum line  352   x  communicates the first vacuum plenum  340   x  with a source of vacuum  350  though a port  353   x  as is arranged in the third drum plenum  340 . 
     Preferably, the plenum fixture  412  is provided with a vacuum port  416 , which is connected to a valve  430  of the plenum controller system  320  through a first conduit  418 . The valve  430  preferably includes a vent port  432  and is also connected to a vacuum line  422 , which leads to the source of vacuum  350 , either directly or more preferably through a connection with the vacuum line  352   x.    
     Preferably, the second plenum has an arc distance approximating the distance of two flutes lengths along the fourth drum  148 . Accordingly, upon venting of the second plenum  310 , a cigarette  11   b  at or about the nip  311  and another cigarette  11   c  mid-way across the arc distance of the second plenum  310  will be released. A third cigarette  11   d  at or near the end of the arc distance of the second plenum  310  is retained upon the fourth drum  148 , because of the residual vacuum retention at that flute. 
     Preferably, the first and second plenums  310 , 340   x,   340  are provided at minimum with 65 millibars of underpressure, preferably 100 to 110. With such, the drum elevator system  100  is capable of sending a lone cigarette  11 , with all other flutes empty, along the entire length of the drum elevator at a rate of 8,000 cigarettes per minute. 
     Referring now also to FIG. 5, the valve  430  preferably includes a valve body or slider  434  that is movable from a retracted position (as shown in FIG. 5) and a venting position. While in the retracted position, the valve  430  permits communication between the conduit  420  and the vacuum line  422  so that the vacuum source  350  may draw a vacuum from the second vacuum plenum  310 . At the venting position, the vacuum line  422  is closed by a valve flange  436 , and the conduit  420  is communicated with the vent  434  through an orifice  438  in the valve body  434  so that any vacuum in the second plenum is relieved. Accordingly, a vacuum cannot be reestablished in the second plenum  310  until communication between the second plenum and the vacuum source  350  is reestablished upon return of the valve body  434  to its retracted position. 
     Preferably, the valve  430  is actuated through a hydraulic or electrical actuator  440  that is operable from receipt of signals from the controller  110  of the drum elevator system  100 . In the alternative, the valve actuator  440  may comprise a manually operable, spring loaded plunger  442 . With all actuators, it is preferred that the actuator biases the valve body  434  toward its retracted position. 
     In operation, as acceptable cigarettes  11  are carried about the third drum  140  into the nip between the third and fourth drums  140 , 148 , the controller  110  keeps the valve  430  at its retracted position so that a vacuum is established in the second vacuum plenum  310 . As acceptable cigarettes  11  are carried by the third drum  140  into the nip between the third and fourth drums  140 , 148 , the vacuum retention action of the third drum  140  is interrupted just upstream of the nip while simultaneously vacuum of the second plenum  310  is communicated to an adjacent flute  332   x  of the fourth drum  148  as it too enters the nip. As a result, the cigarette  11  (such as the cigarette  11   b  in FIG. 4) is drawn toward the adjacent flute  332   x  of the fourth drum  148  and is retained upon the fourth drum  148  by the vacuum retention action of the second and first vacuum plenums  310 , 340   x,  whereupon it is released to the fifth drum  150 . 
     If the cigarette  11   b  is unacceptable acceptable (e.g., one of the inspection stations  34   a - 34   c  of the Max tipping machine  506  had indicated that the cigarette  11   b  is unacceptable), or if a signal is received from the controller  110  that a sampling of cigarettes is to be undertaken, the controller  110  will cause the valve  340  to vent the second vacuum plenum  310  so as to prevent the transfer of the cigarette  11   b  from the third drum  140  to the fourth drum  148  and to allow instead for the cigarette to fall from between the drums  148 , 140  into the chute  149  leading to a collection the bin (drawer)  151 . This soft ejection action may be continued for given number of additional cigarettes and/or for a predetermined amount of time as established by the controller  110  when using the soft ejection station  147  for sampling. Thereafter, or alternatively, after the single rejection of the cigarette  11   b,  the valve  430  is preferably returned to its retracted position to thereby reestablish a vacuum in the second plenum  310 . 
     It is to be realized that the soft ejection station  147  effects removal of cigarettes without imposing a potentially damaging blast of pressurized air or the like upon the cigarette. Accordingly, a set of sampled, yet acceptable cigarettes can be returned to the stream of cigarettes being fed into the packing machine; and if the sampled cigarettes are unacceptable, their true condition is not masked by any further damage from the sampling process. 
     Alternatively, the soft rejection station  147  may be constructed utilizing the principles and arrangements taught in U.S. Pat. No. 5,232,079. Optionally, a rail may be imposed at an angular position along the third drum  140  downstream of nip  311  so as to assure removal of any clinging, untransferred cigarettes from the third drum  140 . 
     Referring back to FIG. 3, at the sixth drum  160 , the procession of cigarettes is preferably carried 2700 about the drum to enter the remainder of the vertical series of drums  102  of the drum system  100 . Preferably, rejection ports are  164 ,  166  are provided at approximately the 6 o&#39;clock and 8 o&#39;clock angular positions, respectively, about the drum  160 . These rejection ports  164 ,  166  preferably comprise a type like those employed at the rejection drum  92 ′ of the tipping machine  506 . These rejection ports  164 ,  166  are adapted to pneumatically discharge unacceptable cigarettes from the sixth drum  160  upon command from the controller  110  so as to discharge cigarettes into the bins  165 ,  167 , respectively. 
     Cigarettes are then transferred about the next seventh drum  170  wherefrom they are transferred to an eighth drum  180  of the vertical series of drum  102 . Preferably, the eighth drum  180  includes rejection ports  182 ,  184  at its 8:00 o&#39;clock and 7:00 positions, which are adapted to discharge cigarettes at the command of the controller  110  into bins  183  and  185 , respectively. 
     The procession of cigarettes at the eighth drum  180  are transferred to the convertible drum assembly  190 , which in this preferred embodiment comprises a ninth and tenth drums,  194 ,  196 . These ninth and tenth drums deliver cigarettes to the eleventh drum  200  such that cigarettes are delivered to the stack former  104  in the desired direction which, in this embodiment, is toward the right as viewed in FIG. 3 so that cigarettes throughout their travel from the first drum  120  to the eleventh drum  200  have traveled a C-shaped path. 
     Referring now to FIG. 6, in an alternate embodiment, the convertible drum assembly  190 ′ comprises a single drum  195  instead of the pair of drums  194  and  196  of the previous embodiment. The stack former  104 ′ and the eleventh drum  200 ′ are essentially the same systems as in the prior embodiment, but turned around so as to discharge cigarettes to the left as viewed in FIGS. 3 and 6. Accordingly, the vertical set of drums  102 ′ and the horizontal set of drums  106 ′ of the alternate embodiment define a Z-shaped pathway for the cigarettes. 
     Referring back to FIG. 3, as cigarettes  11  are transferred from the eleventh drum  200  into the stack former  104 , they are directed through a single row stacker  205  before accumulating into a cigarette stack  510  in cooperation with the fixed, deflection plate  208 . The stack  510  is moved toward a cigarette packing machine and/or accumulating system situated at a downstream location along the conveyor  520  whose speed is controlled by a controlled drive mechanism  71  that is controllably linked to the controller  110  of the drum elevator system  110 . As an optional part of the drum elevator system  100 , an improved stack former  104  includes a fixed deflector plate  208  and a modified drive and controller arrangement for the conveyor  520  wherein the motor speed of the conveyor  520  is determined from at least one of the outputs of photo-cell counters  210  and  212  preferably located at the sixth drum  160  and a photo-cell counter  214  preferably located adjacent the fixed deflector plate  208 . 
     Preferably, the first photo cell  200  at the drum  160  is configured to count all flutes  332 ′ of the sixth drum  160  as they pass by the photo sensor  200  so as to establish a 100% baseline signal. The second photo cell  210  at the sixth drum  160  counts the number of cigarettes  11  actually passing the photo cell  210 . The third photo cell  214  at the deflector plate  208  counts the actual number of cigarettes  11  entering the stack former  204 . From these signals, the actual cigarette count and the drum elevator speed are established and used for controlling the speed of the conveyor  520  such that conveyor speed and stack height are controlled with digital precision and minimum intermittent lunches. 
     With the drum elevator system as described, damaged-free sampling of cigarettes may be undertaken using the soft ejection port  146  as previously described. 
     Additionally, should the tipping machine  506  shut down, the controller  110  may be configured to continue the drive mechanism  145  for a predetermined period of time to clear those cigarettes which have transferred upon the fourth drum  148  and those situated beyond. 
     Furthermore, one or more rejection ports of a given drum, such as those at the sixth drum  160 , can be dedicated to the removal of cigarettes having a predetermined type of unacceptability. For instance, the inspection station  34   b  might be arranged to detect missing filters. In such case, interaction between the controller  50 ′ of the tipping machine and controller  110  of the drum elevator system  100  might be arranged such that the rejection port  164  of the sixth drum will undertake removal of those cigarettes found to be unacceptable for missing filters by the inspection station  34   b.  Accordingly, those rejections would be undertaken only at the sixth drum of the elevator  100  instead of at the rejection drum  142 ′ of the tipping machine. The other rejection stations, such as the other rejection port  166  of the sixth drum  160  and those of the eighth drum  180  might be dedicated to other forms of unacceptability. Such arrangements provide an opportunity to separate unacceptable cigarettes according to type of imperfection amongst the several bins (e.g.,  183 ,  185  adjacent the eighth drum  180  and the bins  165  and  166  of the sixth drum  160 ). 
     Additionally, or in the alternative, if repetitive rejections need to be undertaken for a long procession of the unacceptable cigarettes, the controller  50 ′ of the tipping machine  506  and the controller  110  of the drum elevator system  100  may be configured to have the consecutive rejections undertaken at one or more of the drums such as those at drums  160  and/or  180  to alternate the execution of rejections amongst the rejection ports. Accordingly, the situation of having a single rejection port execute a long series consecutive rejection operations is avoided and the risk of depleting the vacuum retention system of any given drum is avoided. 
     Additionally, the drum elevator system  100  provides space for placement of additional inspection stations, such as detectors  290 , 292  at the fifth and third drums  150 , 140 , respectively, that may be dedicated to execute confirmatory inspections of cigarettes  11  such that in order for a cigarette to be subjected to a rejection, it must fail an initial inspection, for instance at the inspection station  34   a′  with within the tipping machine  506 , and fail the same type of test as conducted at another inspection station along the drum elevator  100 , for instance at the inspection station  292  adjacent the third drum  140 . By such arrangement, false rejection of good product is minimized and production efficiency is enhanced. 
     It is to be understood that present invention may be embodied and other specific forms doubt departing from the spirit or essential characteristics of the present invention. For example, interaction between the controllers, the inspection stations and the rejection stations amongst the various drums might be configured differently from that explained in connection with the deferred embodiment. The number and size of drum might be altered to meet certain space requirements at a manufacturing facility. Additionally, the preferred embodiment is described with reference to a cigarette maker module that is configured to produce filter cigarettes. The invention is readily adaptable for use in conjunction with a cigarette maker module that is configured to produce non-filter cigarettes. The scope of the invention is indicated by the dependent claims rather than by the foregoing descriptions and all the changes and variations which fall within the meaning and range of the claims are intended to be embrace therein.