CIGARETTE FILLING MACHINE WITH CASING FEED MECHANISM

Abstract

A cigarette filling machine includes several novel features, including a first mechanism for delivering empty casings to a tobacco outlet, a second mechanism that drives tobacco cutting, spoon insertion, and a casing clamp using a single motor, a novel sprocket array for processing tobacco, and related components. The machine can be used to perform new methods for filling empty cigarette casings with tobacco.

Claims

1. An apparatus for filling cigarette casings, comprising: a casing hopper for holding empty cigarette casings; a dispensing chute coupled to the casing hopper and movable between a dispensing position and a non-dispensing position; a first sensor positioned to sense a position of the dispensing chute; a tobacco hopper coupled to the casing hopper, configured for directing loose tobacco to a tubular channel coupled to the tobacco hopper, wherein the tubular channel has receiving end configured for receiving tobacco coupled via a tube to an outlet outside the tobacco hopper oriented towards the dispensing chute; a casing trolley positioned under the dispensing chute, moveable between a pickup position for receiving a casing from the dispensing chute and a drop-off position for placing an open end of the casing over an outlet of the dispensing tube; and a circuit configured to activate motion of the casing trolley based on a signal from the first sensor.

2. The apparatus of claim 1, wherein the casing hopper comprises a oscillating member positioned at a floor thereof for ensuring movement of empty casings towards the dispensing chute.

3. The apparatus of claim 2, wherein the oscillating member comprises a pivoting plate coupled to a mechanical oscillator driven by a first motor.

4. The apparatus of claim 3, wherein the mechanical oscillator comprises a linear cam interposed between the oscillating member and a cam follower.

5. The apparatus of claim 4, wherein the cam follower is coupled to a reciprocating truck configured for back-and-forth motion driven by the motor.

6. The apparatus of claim 5, wherein the casing trolley is coupled to the reciprocating truck.

7. The apparatus of claim 1, further comprising a second sensor positioned to sense presence of a cigarette casing on the outlet of the tubular channel.

8. The apparatus of claim 7, wherein the tubular channel comprises an electrically conductive material, and the second sensor comprises an electrically conductive pad coupled to an actuator configured for moving the pad from a clamped position in contact with the outlet of the tubular channel, and an unclamped position spaced apart from the tubular channel.

9. The apparatus of claim 8, wherein the circuit is further configured to coordinate action of the actuator with the casing trolley such that the second sensor moves to the clamped position immediately after the casing trolley moves to its drop-off position, and then moves to the unclamped position immediately after dispensing tobacco from the tubular channel is completed.

10. The apparatus of claim 1, wherein the circuit comprises a processor coupled to a memory, the memory holding instructions that when executed by the processor cause the apparatus, based on the signal from the first sensor, to activate motion of the casing trolley from the pickup position to the drop-off position if the dispensing chute is in the dispensing position and then to activate dispensing of tobacco from the outlet of the tubular channel, and if the dispensing chute is not in the dispensing position to wait for further input before activating the dispensing of tobacco from the outlet.

11. The apparatus of claim 10, further comprising a second sensor positioned to sense presence of a cigarette casing on the outlet of the tubular channel, wherein the memory holds further instructions, that when executed by the processor, prevents dispensing of tobacco from the outlet until the presence of a cigarette casing is detected by the second sensor.

12. The apparatus of claim 11, wherein the memory holds further instructions, that when executed by the processor, causes the apparatus to wait for user input after the second sensor detects that no casing is present on the outlet tube, and after receiving the user input, dispensing tobacco from the outlet if the second sensor detects the presence of a cigarette casing on the outlet.

13. An apparatus for filling cigarette casings, comprising: a tobacco hopper configured for directing loose tobacco to a tubular channel coupled to the tobacco hopper, wherein the tubular channel has a receiving end configured for receiving shredded tobacco coupled via a tube to an outlet outside the tobacco hopper; a sprocket array mounted in a pass-through between the hopper and a compaction chamber below the tobacco hopper, wherein the sprocket array comprises a plurality of sprockets spaced apart along a shaft, wherein each of the sprockets is characterized by teeth each having an arcuate concave forward profile and a rearward profile beveled towards its distal tip; a motor coupled to the sprocket array, wherein the activation of the motor causes the sprocket array to rotate; and a controller for controlling operation of the motor.

14. The apparatus of claim 13, further comprising a slotted plate mounted around the sprocket array having slots aligned parallel and adjacent to one or more corresponding sprockets of the sprocket array for tobacco to pass through into the compression chamber.

15. The apparatus of claim 14, wherein the slots are in the range of 3.5 to 6 mm wide.

16. The apparatus of claim 13, wherein the controller causes the sprocket array to reverse its rotation once substantially one rotation after rotating forwards substantially four rotations, repeatedly.

17. A method for operating an apparatus for filling cigarette casings, the method comprising: detecting, by at least one processor of the apparatus and at least one first sensor, whether a dispensing chute for empty casings is in a dispensing position; if the dispensing chute is in the dispensing position, activating, by the at least one processor, a dispensing mechanism for an empty casing, wherein the dispensing mechanism is configured to position the empty casing over an outlet of a tobacco dispensing mechanism; and if the dispensing chute is not in the dispensing position, preventing by the at least one processor operation of the dispensing mechanism while waiting for user input.

18. The method of claim 17, further comprising detecting, by the at least one processor of the apparatus and at least one second sensor, whether the empty casing is positioned over the outlet of the tobacco dispensing mechanism; if the empty casing is not positioned over the outlet of the tobacco dispensing mechanism, preventing by the at least one processor operation of the dispensing mechanism until presence of the empty casing over the outlet is detected by the second sensor.

19. The method of claim 18, wherein the apparatus further comprises a casing hopper, and activating the dispensing mechanism comprises activating, by the at least one processor, a motor coupled to an oscillation mechanism configured for oscillating a member positioned at a floor of the casing hopper for ensuring movement of empty casings towards the dispensing chute.

20. An apparatus for filling cigarette casings, comprising: a tobacco hopper configured for directing loose tobacco to a tubular channel coupled to the tobacco hopper, wherein the tubular channel has a receiving end configured for receiving shredded tobacco coupled via a tube to an outlet; coupled to the tubular channel, a mechanism configured for cutting the shredded tobacco by a sliding cutter after the tobacco is received in the tubular channel, inserting a tobacco carrying spoon through the tube and into a cigarette casing coupled to the outlet, and retracting the tobacco carrying spoon; and a motor coupled to the mechanism, wherein activation of the motor causes the cutting, inserting, and retracting by the mechanism until the motor is deactivated.

21. The apparatus of claim 20, wherein the mechanism comprises a frame plate, a drive pin rotating around an input shaft driven by the motor on a first side of the frame plate, the drive pin contained in a linear slot along a first leg of an L-shaped link, a second leg of the L-shaped link coupled to a linear cam connected to the tobacco carrying spoon via a slot in the frame plate, wherein rotation of the drive pin causes reciprocating motion of the linear cam along a first axis of motion, and the motion of the linear cam actuates a pivoting actuator that drives a sliding cutter driver coupled to the cutter along a second axis transverse to the first axis driving the cutting in coordination with the inserting and retracting.

22. The apparatus of claim 21, wherein the sliding cutter driver is coupled to the cutter by a channeled coupler on a second side of the frame plate, the channeled coupler coupled to a link at a proximal portion thereof and to a rotating arm coupled to an axle causing the proximal portion of the link to rotate back-and-forth around the axle, whereby a distal portion of the link coupled to the cutter causes the cutter to slide back-and-forth in a channel.

23. The apparatus of claim 20, wherein the mechanism is further configured for clamping the cigarette casing to the outlet prior to the inserting of the tobacco carrying spoon and unclamping the cigarette casing after the retracting of the tobacco carrying spoon.

24. The apparatus of claim 21, wherein the mechanism is further configured for clamping the cigarette casing to the outlet prior to the inserting of the tobacco carrying spoon and unclamping the cigarette casing after the retracting of the tobacco carrying spoon, and the mechanism further comprises a second pivoting link acted upon by the linear cam to actuate the clamping and unclamping in coordination with the inserting and retracting.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The features, nature, and advantages of the present disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the drawings in which like reference characters identify like elements correspondingly throughout the specification and drawings.

[0026] FIG. 1 is a perspective view of a cigarette filling machine.

[0027] FIG. 2A is a perspective view of the cigarette filling machine with casings in its casing hopper.

[0028] FIG. 2B is a partial perspective view of the cigarette filling machine with the casing dispensing chute in an open position.

[0029] FIG. 3 is a top view of the cigarette filling machine.

[0030] FIG. 4 is a detail top view of the tobacco hopper and sprocket array of the cigarette filling machine.

[0031] FIG. 5 is a front view of the cigarette filling machine.

[0032] FIG. 6 is a left side view of the cigarette filling machine.

[0033] FIG. 7 is a rear perspective view of the cigarette filling machine illustration sections.

[0034] FIG. 8 is a section view of the cigarette filling machine through A-A of FIG. 7.

[0035] FIG. 9 is a section view of the cigarette filling machine through B-B of FIG. 7.

[0036] FIG. 10 is a section view of the cigarette filling machine through C-C of FIG. 7.

[0037] FIG. 11 is a section view of the cigarette filling machine through D-D of FIG. 7.

[0038] FIG. 12A is a top view of the cigarette filling machine with the upper housing hidden.

[0039] FIG. 12B is a top view of the sprocket array and slotted plate assembly.

[0040] FIG. 12C is a side view of the sprocket array and slotted plate assembly.

[0041] FIG. 12D is a profile dimensioned view of a sprocket array sprocket.

[0042] FIGS. 13A-D show corresponding elevation views of the cutter-inserter mechanism during an operating sequence.

[0043] FIGS. 13E-F are various views showing certain additional structural details of the cutter-inserter mechanism behind the frame plate.

[0044] FIG. 14 is a conceptual block diagram illustrating components of an apparatus or system for cigarette filling.

[0045] FIG. 15 is a flow chart illustrating aspects of a method performed by the cigarette filling machine.

[0046] FIG. 16 is a flow chart illustrating further aspects of a method performed by the cigarette filling machine.

DETAILED DESCRIPTION

[0047] Various aspects are now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of one or more aspects. It may be evident, however, that the various aspects may be practiced without these specific details. In other instances, well-known structures and devices are represented in block diagram form to facilitate focus on novel aspects of the present disclosure.

[0048] Referring to FIGS. 1-6, exterior features of the cigarette filling machine 100 are depicted in various views. The machine 100 may be generally encased and framed by an upper housing 102 and a lower housing 105. The housings 102, 104 may be formed of a structural plastic and assembled using machine screws. A tobacco hopper 106 covered by a pivoting lid 120 is in fluid communication with an exterior of the machine 100 via a top surface of the upper housing 102, for receiving shredded tobacco for incorporation into cigarettes. The tobacco hopper 106 may be configured for directing loose tobacco to the tubular channel 126 coupled to the tobacco hopper. The tubular channel 126 may have a receiving portion configured for receiving tobacco from a packing chamber 127 (shown in FIG. 10) under the hopper 106. The tubular channel 126 may be coupled via a tube to an outlet outside the tobacco hopper oriented towards the dispensing chute 130.

[0049] A rotatable sprocket array 108 may be positioned in a lower portion of the tobacco hopper 106, between the hopper and the tobacco packing chamber 127 underneath. When configured and operated as described herein, the sprocket array 108 readies shredded tobacco for packing into the tubular channel 126 and subsequent delivery into a cigarette casing clamped around an exterior of the channel 126 by a casing clamp 128. The casing clamp 128 forms a part of a sensor for detecting the presence of a casing on the tubular channel, described herein below.

[0050] On a side of the machine 100 adjacent to the tubular channel 126, the machine may include a casing hopper 110 for holding a plurality of empty cigarette casings 124 as shown in FIG. 2A. An oscillating member 112 is provided in a floor of the casing hopper 110, in the depicted embodiment configured as a pivoting plate. Using a mechanism described herein below, the oscillating member 112 is oscillated gently around a hinge line, which assists in urging the very lightweight paper empty casings 124 to the casing dispensing chute 130. The tobacco hopper 106 may be coupled to the casing hopper 110.

[0051] The casing dispensing chute 130 is shaped to guide one empty casing at a time to a casing trolley 114, which delivers each casing to the tubular channel 126. In an aspect, the dispensing chute 130 is coupled to the casing hopper and is movable between a dispensing position (shown) and a non-dispensing position (FIG. 2B), wherein the dispensing chute 130 is pivoted upwards. The open end of the empty casing fits around the outlet of the tubular channel 126 and is automatically clamped in place by the casing clamp 128 during operation of the machine, which will be described in more detail later. Completed cigarettes filled with packed tobacco drop into the output hopper 116 when the casing clamp 128 is automatically unclamped at the end of an insertion cycle. FIG. 2B shows the casing dispensing chute 130 in an open position, pivoted upwards. The filling machine 100 includes a sensor configured to detect the position of the dispensing chute 130. The sensor 190 is described in connection with FIG. 9 below.

[0052] The top exterior surface of the housing 102 may reveal a user interface screen 118 for displaying messages to the user from a control processor of the machine. A start button 122 may also be provided here for toggling the machine 122 between an operating state and a static waiting state. Referring to FIG. 3, a rear of the machine 100 may include a power switch 132 and power port 134 for connecting a DC power supply.

[0053] Referring to FIG. 4, the sprocket array 108 may include a plurality of sprockets 109 fixed to a shaft at a hub 111, spaced by a spacer 107 and fitted into a slotted plate 136 that separates the tobacco hopper 106 from a compaction chamber underneath the slotted plate 136.

[0054] Referring to FIGS. 5 and 6, alignment of the dispensing chute 130 and casing trolley 114 with the tubular channel 126 is shown. The casing clamp 128 may be configured as a sensor positioned to sense presence of a cigarette casing on the outlet of the tubular channel 126. The tubular channel may be made of an electrically conductive material, and the sensor may include an electrically conductive pad 138 coupled via a metallic arm 140 to an actuator 142 configured for moving the pad 138 from a clamped position in contact with the outlet of the tubular channel 126, and an unclamped position spaced apart from the tubular channel. When a casing is present on the tubular channel, electrical resistance between the conducting pad and the tubular channel greatly increases. This increase in electrical resistance while the casing clamp 128 is in a clamped position may be detected using any suitable circuit connected to the actuator 142 and tubular channel 126, and interpreted as an indication that a casing is present. Conversely, a low electrical resistance between the actuator 142 and tubular channel 126 when the casing clamp 128 is in a clamped position indicates that no casing is present, interrupting operation of the tobacco insertion cycle. A mechanism for actuating the actuator 142 is described in more detail herein below.

[0055] Referring to FIGS. 7-12A, interior details of the machine 100 are shown in various sectional views. The section planes for each sectional view shown in FIGS. 8-11 are indicated in FIG. 7. FIG. 12A shows an upper perspective view of the machine 100 with the upper housing and other covering components hidden to reveal interior components.

[0056] FIG. 8 shows a section through the casing hopper 110 of the filling machine 100, revealing details of mechanical oscillator 156 under the casing hopper. The oscillator mechanism 156 is configured to perform dual functions: a first function of oscillating the member 112 forming the floor of the casing hopper, and a second function of controlling movement of the casing trolley 114 that receives individual casings from the dispensing chute 130 and delivers them to the outlet of the tubular channel 126. The oscillator 156 may be driven by a DC motor 144 that via a rack-and-pinion, belt drive, or other mechanism (not shown) transforms the rotational output of the motor 144 to back-and-forth motion of a reciprocating truck 150 configured to slide along a pair of rails 148. The casing trolley 114 may be coupled to the reciprocating truck 114 by a sliding coupling. As the truck 150 is driven back-and-forth, it carries a cam 152 along a linear toothed cam follower 154 fixed to the oscillating member 112, imparting a gentle up-and-down motion.

[0057] Meanwhile, as the truck 150 moves towards the tobacco hopper 106, the casing trolley 114 being free to slide within a range of motion perpendicularly to motion of the truck 150 is urged against a flange (not shown), causing the trolley to carry the casing away from the dispensing chute 130 and towards the outlet of the tubular channel 126. After the casing is filled, the truck reverses direction, carrying the truck 140 and casing trolley 114 back to the dispensing chute 130. Once the casing trolley 114 is free of the flange, a return spring (not shown) urges it away from the tobacco outlet and back under the dispensing chute 130 to receive the next available casing. A circuit and processor of the filling machine 100 coordinate action of the oscillator 156 and a dispensing mechanism that dispenses tobacco from the tobacco hopper described herein below. Thus, by action of the mechanism 156, the casing trolley 114 is positioned under the dispensing chute 130 at the beginning of a cycle, and moveable between a pickup position for receiving a casing from the dispensing chute and a drop-off position for placing an open end of the casing over an outlet of the dispensing tube.

[0058] Additionally, when a sensor 190 detects the dispensing chute 130 is in the position shown in FIG. 8, the oscillator and trolley mechanism 156 is activated. Conversely, referring to FIG. 9, when the sensor 190 positioned to sense a position of the dispensing chute 130 detects that the chute 130 it rotated around the hinge pin 131 (one of a pair shown) so that the lower portion of the chute 130 is lifted away from the sensor as shown in FIG. 2B, the oscillator and trolley mechanism 156 is deactivated by the control processor of the machine 100.

[0059] The sensor 190 may include an electrical connector 192 coupled to a circuit board 194 attached to an interior of the upper housing 102. The circuit board 194 may be coupled to a sensor 196, for example an optical or magnetic sensor, for example, a Hall effect sensor, configured to sense the presence of a detectable feature 188 mounted to the dispensing chute 130 when placed directly over the sensor 196. If the sensor is magnetic, the detectable feature 188 may be a magnet. If the sensor is optical, the detectable feature 188 may be an opaque or reflective object that rests over a window in the upper housing 102. Other combinations of sensors and detectable features may also be suitable. When the dispensing chute 130 is pivoted around the pivot 131 away from the casing hopper 110, the detectable feature 188 is no longer detected by the sensor 196, which via the board 194 and connector 192 signals a system control processor, which in turn deactivates the motor 144, stopping operation of the oscillator mechanism 156.

[0060] Referring to FIG. 10, a section C-C (FIG. 7) shows certain details of the tobacco hopper 106. The sprocket array 108 and slotted plate 136 are interposed between an upper portion of the hopper in which loose shredded tobacco is loaded by the user, and a packing chamber 127 where tobacco that passes through the sprocket array 108 and slotted plate 136 is packed into a packing channel 158 and spoon 160. Once packed in place, a slug of packed tobacco for insertion into an empty casing is cut by upward movement of the cutter 162. Packing of tobacco is done by a tamping plate 164 of a pusher assembly 160 actuated by a drive train 170 and DC motor 168 via a gearbox 172. The pusher assembly 160 and drive train 170 may be configured and operated as described in U.S. Pat. No. 10,701,965 (see tobacco packer module) by the inventor hereof, which is incorporated herein by reference in its entirety. Certain other features of the tobacco hopper 106 may also be as described in the '965 Patent. However, the sprocket array 108 as described herein is new, not present in prior cigarette filing machines, and is described in more detail herein below. The sprocket array 108 may be fixed to a drive shaft 105 and driven by a dedicated DC motor 174 via a gearbox 176 (shown in FIG. 11) under control of the machine's 100 central processor. The shape, configuration, and action of the spoon 160 are known in the art, being described in the referenced U.S. Pat. Nos. 10,701,965, and 8,261,752 by the inventor hereof, likewise incorporated herein in its entirety by reference.

[0061] Referring to FIG. 11, section D-D shows additional interior components of the cigarette filling machine 100, including the motor 174 and gearbox 176 coupled to the driveshaft 105 of the sprocket array 108, and another DC motor 180 coupled via a gearbox 182 and output shaft 228 to a triple-action actuator mechanism 184. The actuator mechanism 184 is configured to provide three separate but correlated actions: the movement of the tobacco insertion spoon 160, the cutter 162, and the casing clamp 128. This mechanism 184 is described in more detail below in connection with FIGS. 13A-E. A main circuit board 178 holds a central processor for controlling operation of the machine 100 and user interface 118, motor driver controllers for the four motors used in the machine 100, and components conventional in circuit boards of this type. Elements of the circuit board 178, program instructions, and methods for operating the machine 100 under control of the central processor are described in connection with FIGS. 14-16 below.

[0062] FIG. 12A shows a top view perspective of the filling machine 100 with the top cover and other obscuring components hidden to reveal interior components. Many of the components are already described and are indicated in FIG. 12A only to show relative positions within the machine 100. However, a spoon insertor trolley 186 and guide rail 187 for the trolley 186 are best seen in this view. The insertion spoon 160 is coupled to the trolley 186 and moves back-and-forth by operation of the actuator mechanism 184 driven by the motor 180.

[0063] FIG. 12B shows a top view of the sprocket array 108 and slotted plate 136 assembly. FIG. 12C shows a side view the same, and FIG. 12D shows a profile and dimensions in millimeters of a representative sprocket 109, of which seven or other suitable number of identical sprockets may be provided in the sprocket array 108. As noted above, the sprocket array 108 is mounted in a pass-through between the tobacco input hopper 106 and the compaction chamber 127 below the tobacco hopper. The sprocket array 108 may include a plurality of sprockets like the sprocket 109 spaced apart along a shaft 105 (FIG. 10). As shown in FIG. 12D, each of the sprockets 109 may be characterized by teeth each having an arcuate concave forward profile (indicated at R5) and a rearward profile beveled towards its distal tip. The bevel as depicted is 15, wherein a root portion of the backwards-facing tooth profile is 31 from a radius line drawn from the root to the center of the sprocket 109, and a tip portion of the backwards-facing tooth profile is 46 from the radius line. The indicated shape and configuration of the sprocket 109 represent an embodiment, other geometries may also be useful. The sprocket 109, slotted plate 136, and other components of the array 108 may be formed of mild steel, stainless steel, or other durable structural material.

[0064] The filling machine 100 may include a slotted plate 136 mounted around the sprocket array 108, having slots 115, 117 aligned parallel and adjacent to one or more corresponding sprockets of the sprocket array 108 for tobacco to pass through into the compression chamber. The slots may be in the range of 3.5 to 6 mm wide, for example, slots 115 at 4.2 mm and slots 117 at 4.9 mm are depicted. Other geometries may also be suitable.

[0065] The filling machine 100 may include a motor 174 coupled to the sprocket array 108, wherein the activation of the motor 174 causes the sprocket array to rotate, and a controller 202 for controlling operation of the motor 174. In an aspect, the controller causes the motor to reverse rotation of the sprocket array for substantially one rotation after rotating the array forwards for substantially four rotations, and to repeat this alternating cycle of four forward rotations followed by one reverse rotation during operation of the motor. Other reciprocating motion patterns may also be useful. It is believed that the combination of the mechanical configuration of the sprocket array 108 and the method for controlling its motion provide more reliable and superior packing and filling of cigarette casings for a wider variety of input tobacco types, as compared to prior designs which lack a sprocket array 108 or comparable component.

[0066] As described herein above, the apparatus 100 for filling cigarette casings may include a tobacco hopper 106 configured for directing loose tobacco to a tubular channel 126 coupled to the tobacco hopper, wherein the tubular channel 126 has a receiving end configured for receiving shredded tobacco coupled via a tube to an outlet for receiving an empty casing to be filled. Referring to FIGS. 13A-F, the apparatus 100 may further include, coupled to the tubular channel 126, a mechanism 184 configured for cutting the shredded tobacco by a sliding cutter 162 after the tobacco is received in the tubular channel 162, inserting a tobacco carrying spoon 160 through the tubular channel 162 and into a cigarette casing coupled to the outlet, and retracting the tobacco carrying spoon 160. The apparatus may further include a motor 180 coupled to the mechanism 184, wherein activation of the motor causes the cutting, inserting, and retracting by the mechanism 184 until the motor 180 is deactivated.

[0067] The mechanism 184 may include a frame plate 256, a drive pin 228 rotating around an input shaft 224 driven by the motor 180 on a first side of the frame plate 256, the drive pin 228 contained in a linear slot along a first leg of an L-shaped link 230, a second leg of the L-shaped link 230 coupled to a linear cam 234 connected to the tobacco carrying spoon 160 via a slot through the frame plate 256, wherein rotation of the drive pin 228 causes reciprocating motion of the linear cam 234 along a first axis of motion aligned with the slot though the frame plate 256, and the motion of the linear cam 234 actuates a pivoting actuator 238 that drives a sliding cutter driver 242 coupled to the cutter along a second axis transverse to the first axis. The motion of the cutter driver 242 along the second axis drives the cutting in coordination with the inserting and retracting.

[0068] Referring to FIGS. 13E and 13F, the sliding cutter driver 242 may be coupled to the cutter 162 by a channeled coupler 248 on a second side of the frame plate 256. The channeled coupler 248 may be coupled by a drive rod 246 to a link 244 at a proximal portion thereof and to one or more rotating arms 250, 250 coupled to an axle 252. Back-and-forth rotation of the arms 250, 250 causes the proximal portion of the link 244 to rotate back-and-forth around the axle 252, whereby a distal portion of the link 244 coupled by a pin 254 to the cutter causes the cutter 162 to slide back-and-forth in a channel. When the cutter 162 is at the top of its range of motion, it both trims off any excess of tobacco compressed inside the spoon 160 into a cylindrical form and holds it in place until the spoon is inserted into the casing.

[0069] Referring again to FIGS. 13A-13D, the mechanism 184 may be further configured for clamping a cigarette casing to the outlet of the tubular channel 126 prior to the inserting of the tobacco carrying spoon 160 and unclamping the cigarette casing after the retracting of the tobacco carrying spoon. For example, the mechanism 184 may further include a second pivoting actuator 236 acted upon by the linear cam 234 to actuate the clamping and unclamping in coordination with the inserting and retracting. The pivoting actuator 236 may be integrated with the actuator 142 shown in FIG. 6.

[0070] FIGS. 13A-13D show an operating sequence of the mechanism 184 in elevation views of the outward-facing side of the frame plate 256. Referring to FIG. 13A, the drive arm which rotates clockwise around the drive shaft 223 one revolution per cycle is at this moment of the cycle located just past top dead center (twelve o'clock position), with the cylindrical drive pin 228 engaged in an intermediate position in the slot through one leg of the L-shaped link 230. The other leg of the L-shaped link 230 is coupled through a straight link 232 to the linear cam 234, pulling the cam 234 to the right end of the horizontal slot on the frame plate 256. At this point of the cycle, the cutter driver 242 is at the lower end of its range of motion, as the linear cam 234 is positioned in a slot in the pivoting actuator 238, which allows the left end of the actuator to drop, pulling the cutter driver 242 downwards by the link 240. A different portion of the linear cam 234 pushes a right end of the second pivoting actuator downwards, causing the left end of the second pivoting actuator to rise, lifting the casing clamp 128 off the outlet of the tubular channel 126 so that the machine 100 is ready to receive an empty casing over the outlet. The linear cam 234 is coupled to a trolley 186 which is free to move back-and-forth along a tubular rail 187, shown in FIG. 12A. However, the motive force for back-and-forth motion of the linear cam 234 is supplied by the mechanism 184 and motor 180.

[0071] Referring to FIG. 13B, the drive arm 226 has rotated to the three o'clock position, causing the drive pin 228 to move towards the right end of the slot in the L-shaped link 230, which in turn causes the link 230 to begin pushing the linear cam towards the left. In this position, the first pivoting actuator 238 pushes the cutter driver 242 to the top of its range. In this position, via the linkage on backside of the frame plate 256 described herein above, the cutter 162 is moved up to its cutting position, compressing the tobacco into the packing channel 158 and spoon 160 while trimming it to form a plug of tobacco for insertion into the cigarette casing. Meanwhile, the controller of the machine 100 coordinates operation of the casing dispensing mechanism such that an empty casing has been placed over the outlet. The leftward motion of the linear cam 234 has allowed the right end of the second pivoting actuator 236 to move up under a spring force. In turn, the left end of the second actuator 256 moves downward, causing the casing clamp 128 to clamp the installed casing (not shown in FIGS. 13A-D) to the tubular channel 126, ready for insertion of the tobacco.

[0072] Referring to FIG. 13C, the drive arm 226 has rotated to the five o'clock position, moving the drive pin to the right end of the slot in the L-shaped link 230. The cutter driver 260 remains at the top of its range. Accordingly, the cutter 162 remains in its cutting position, containing the tobacco in the packing channel 158 and spoon 160. The casing clamp 128 remains in a clamped position. Further rightward movement of the linear cam 234 pulls its coupled trolley 186 and the spoon 160 which is coupled to the trolley 186 to the right. The tip of the spoon 160 is seen beginning to extend past the outlet of the tubular channel 126. During an actual cycle, the spoon 126 would be beginning to carry the cut plug of tobacco into an empty casing clamped to the outlet.

[0073] Referring to FIG. 13D, the drive arm 226 has rotated to the eight o-clock position, causing the L-shaped link 230 to push the linear cam 234 to its leftmost position. Accordingly, the spoon 160 is fully extended from the tubular channel 126. The cutter driver 260 has begun to move downward, as all the tobacco in the tubular channel has been carried into the casing at this point. The casing clamp 128 is unclamped. Thus, after the spoon is fully retracted and the drive arm 226 returns towards the twelve o'clock position, the filled cigarette is released and falls into the output hopper 116. The cycle continues for so long as enough tobacco remains in the packing chamber 127 and casings remain in the casing hopper 110, or until interrupted by the user.

[0074] Referring to FIG. 14, operation of the cigarette filling machine 100 may be controlled by a circuit 200 located in the main circuit board 178. The circuit 200 may include a processor 202 coupled to a memory 204. The memory 204 may hold program instructions, that when executed by the processor 202, cause the machine 100 to perform operations of methods described herein. As part of executing these instructions, the processor may receive inputs from sensors and user input devices and based on these inputs, independently control the operation of the four motors included in the machine. Examples of input devices and the four motors in the circuit 200 are illustrated in conceptual block form. The circuit 200 may include other input devices and components as disclosed herein, or as are known in the art of DC motor control.

[0075] The memory 204 may hold instructions for powering a motorized portion of the circuit 200 on in response to the start button sensor 206 detecting that the user has depressed the start button 122 (FIG. 3) while the motorized portion of the circuit is powered off, and powering the motorized portion of the circuit 200 off in response to the start button sensor 206 detecting that the user has depressed the start button 122 while the motorized portion of the circuit is powered on. Thus, the user can activate and inactivate all motor operations simply by pressing the start button 122. The circuit 200 may also include a power switch 132 (FIG. 3) to power the entire circuit on and off.

[0076] Once the circuit 200 is powered on and the start button 122 is depressed, the processor 202 executing instructions in the memory 204 may check the status of various sensors and control the four motors accordingly.

[0077] The casing chute sensor 214 (e.g., the optical sensor 196 shown in FIG. 9) detects whether the casing dispensing chute 130 is in its dispensing position. If so, the processor activates the oscillator motor 144, which drives the mechanical oscillator 156 described herein above, which so long as casings are loaded into the casing hopper 110 delivers a casing to the tubular channel 126. If the chute 130 is not in a dispensing position, the processor does not activate the motor 144.

[0078] Regardless of whether the sensor 214 indicates that the dispensing chute 130 is in its dispensing position, the executed instructions cause the processor to determine based on the sensor 216 (e.g., casing clamp/sensor 128 shown in FIG. 6) input whether an empty casing is placed over the tubular channel 126. If the sensor 216 indicates that no casing is present, the processor will not activate the spoon and cutter motor 180 that drives the cutter and spoon actuator 184 even if other conditions for activating the motor 180 are satisfied. Thus, the processor 202 prevents the machine 100 from ejecting tobacco from the tubular channel 126 when a casing is not clamped in place to receive the tobacco.

[0079] The circuit 200 may be further configured to coordinate action of the spoon and cutter actuator 184 with the casing trolley 114 such that the casing clamp 128 moves to the clamped position immediately after the casing trolley 114 moves to its drop-off position, and then moves to the unclamped position immediately after dispensing tobacco from the tubular channel 126 is completed. The circuit 200 may include a memory 204 holding further instructions, that when executed by the processor 202, prevents dispensing of tobacco from the outlet of the tubular channel 126 until the presence of a cigarette casing is detected by the casing clamp sensor 128. Additionally, the memory 204 may hold further instructions that when executed by the processor, causes the apparatus to wait for user input after the casing clamp sensor 128 detects that no casing is present on the outlet tube 126, and after receiving the user input, dispensing tobacco from the outlet if the casing clamp sensor 128 detects the presence of a cigarette casing on the outlet.

[0080] The circuit 200 may control operation of the sprocket array motor 174 in response to a lid sensor 212 that detects whether the lid 120 of the tobacco hopper 106 is closed. If the sensor 212 indicates the lid 120 is open, the processor 202 prevents operation of motor 172 so that the sprocket array 108 does not turn until the lid 120 is closed.

[0081] The circuit 200 may control operation of the pusher motor 168 that drives the pusher actuator 166 in response to several sensors, including a push motor sensor 218, push tray position sensor 220, and compression sensors 222. Depending on the position of the pusher assembly 166 and deflection of the tamping plates 164, the processor determines whether to rotate the motor forwards, backwards, or to hold in place. If sensors 218, 220, and 222 taken together indicate the presence of packed tobacco in the packing channel 150, the processor can determine that a cutting and inserting cycle can be initiated, and after that cycle is completed to reverse the motor direction to begin another packing cycle.

[0082] The circuit may control operation of the spoon and cutter motor 180 based on data from multiple sensors. The circuit may use the spoon sensor 210 to move the spoon and cutter to the proper initial position for a cutting and inserting cycle by controlling the motor 180 driving the cutter and spoon actuator mechanism 180 described above. Then, if the sensor 216 indicates that a casing is clamped to the tubular channel 126, and the packing sensors 218, 220 and 222 indicate that packed tobacco is ready to be inserted, the processor may activate the motor 180 to drive the actuator 184 through one cycle of operation.

[0083] Referring to FIG. 15, a method 300 for performing by a cigarette filling machine 100 may include at 302, starting operation in response to a user input, for example, detecting that the user has pressed the start button 122. The method 300 may further include, at 304, determining whether a lid 120 of a tobacco hopper 106 is closed, and if not to wait 306 for the lid to be closed. The method 300 may further include at 308, determining whether tobacco is compressed into a packing channel 158 using one or more compression sensors. 122, and if not, activating 310 a sprocket array 108 to move tobacco into a packing chamber 127 and then activating 312 a pusher mechanism to pack tobacco in the packing chamber 127 into a packing channel 158. If compression cannot be achieved after a threshold number of push cycles (e.g., ten cycles), the processor may stop the pusher motor and display an alert on the user interface screen 118.

[0084] The method 300 may further include at 314 detecting, by at least one processor of the apparatus and at least one first sensor, whether a dispensing chute 130 for empty casings is in a dispensing position. The method 300 may further include, based on determining that the dispensing chute is in the dispensing position, activating 316, by the at least one processor, a dispensing mechanism for an empty casing, wherein the dispensing mechanism is configured to position the empty casing over an outlet of a tobacco dispensing mechanism. In an aspect of the method 300, the apparatus may further include a casing hopper 110, and activating the dispensing mechanism may include activating, by the at least one processor, a motor coupled to an oscillation mechanism 156 configured for oscillating a member 112 positioned at a floor of the casing hopper for ensuring movement of empty casings towards the dispensing chute.

[0085] The method 300 may further include, based on determining that the dispensing chute is not in the dispensing position, preventing by the at least one processor operation of the dispensing mechanism while waiting for user input.

[0086] The method 300 may further include at 318 detecting, by the at least one processor of the apparatus and at least one casing sensor, whether the empty casing is positioned over the outlet of the tobacco dispensing mechanism, and if the empty casing is not positioned over the outlet of the tobacco dispensing mechanism, reversing the spoon and cutter mechanism to its initial position and preventing 320 by the at least one processor operation of the dispensing mechanism until presence of the empty casing over the outlet is detected by the casing sensor.

[0087] The method 300 may further include in response to determining 318 that a casing is placed over a tobacco dispensing outlet, operating 322 a spoon and cutter mechanism 184 to insert a plug of packed tobacco into the casing. The method 300 may further include determining 324 whether input is received that requires stopping 326 operation of the filling machine 100, and if not, continuing operation of the machine.

[0088] Referring to FIG. 16, a method 310 may be performed as part of method 300 by a cigarette filling machine 100, in conjunction with block 308. In addition, or in the alternative, the method 310 may be performed independently by any cigarette filling machine with a sprocket array or equivalent mechanism disposed to process tobacco passing from an input hopper to a compaction chamber. The method 310 may be controlled using a circuit 200 as described. At 330, the circuit activates a sprocket array motor to drive the sprocket array in a forward direction until determining, at 332, that a forward limit is reached. Then, at 334, the circuit activates the sprocket array motor in a reverse direction until, at 336, a reverse limit is reached. At 338, the circuit determines whether the operation cycle and continues looping through the method 310 until finished. In the illustrated embodiment of the cigarette filling machine 100, a cycle with a four-to-one (4:1) ratio of forward revolutions to reverse revolutions is used, but other ratios may also be useful.

[0089] The methods 300, 310 may include any one or more additional operations as described herein. Each of these additional operations is not necessarily performed in every embodiment of the method, and the presence of any one of the operations does not necessarily require that any other of these additional operations also be performed.

[0090] The various illustrative logical blocks, modules, circuits, and algorithm steps described in connection with the aspects disclosed herein may be implemented as electronic hardware, computer software, or combinations of both. To clearly illustrate this interchangeability of hardware and software, various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends upon the application and design constraints imposed on the overall system. Skilled artisans may implement the described functionality in varying ways for each application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present disclosure.

[0091] As used in this application, the terms component, module, system, and the like are intended to refer to a computer-related entity, either hardware, a combination of hardware and software, software, or software in execution. For example, a component may be, but is not limited to being, a process running on a processor, a processor, an object, an executable, a thread of execution, a program, and/or a computer or system of cooperating computers. By way of illustration, both an application running on a server and the server can be a component. One or more components may reside within a process and/or thread of execution and a component may be localized on one computer and/or distributed between two or more computers.

[0092] Program instructions may be written in any suitable high-level language, for example, C, C++, C #, JavaScript, or Go, and compiled to produce machine-language code for execution by the processor. Program instructions may be grouped into functional modules, to facilitate coding efficiency and comprehensibility. It should be appreciated that such modules, even if discernable as divisions or grouping in source code, are not necessarily distinguishable as separate code blocks in machine-level coding. Code bundles directed toward a specific function may be considered to comprise a module, regardless of whether machine code on the bundle can be executed independently of other machine code. In other words, the modules may be high-level modules only.

[0093] Various aspects will be presented in terms of systems that may include several components, modules, and the like. It is to be understood and appreciated that the various systems may include additional components, modules, etc. and/or may not include all the components, modules, etc. discussed in connection with the figures. A combination of these approaches may also be used.

[0094] In addition, the various illustrative logical blocks, modules, and circuits described in connection with the aspects disclosed herein may be implemented or performed with a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general-purpose processor may be a microprocessor, but in the alternative, the processor may be any conventional processor, controller, microcontroller, or state machine. A processor may also be implemented as a combination of computing devices, e.g., a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. As used herein, a processor encompasses any one or functional combination of the foregoing examples.

[0095] Operational aspects disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of the two. A software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, a removable disk, a CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to the processor such the processor can read information from, and write information to, the storage medium. In the alternative, the storage medium may be integral to the processor. The processor and the storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In the alternative, the processor and the storage medium may reside as discrete components in a user terminal.

[0096] Furthermore, the one or more versions may be implemented as a method, apparatus, or article of manufacture using standard programming and/or engineering techniques to produce software, firmware, hardware, or any combination thereof to control a computer to implement the disclosed aspects. Non-transitory computer readable media can include but are not limited to magnetic storage devices (e.g., hard disk, floppy disk, magnetic strips . . . ), optical disks (e.g., compact disk (CD), digital versatile disk (DVD), BluRay . . . ), smart cards, solid-state devices (SSDs), and flash memory devices (e.g., card, stick). Those skilled in the art will recognize many modifications may be made to this configuration without departing from the scope of the disclosed aspects.

[0097] In view of the exemplary systems described supra, methodologies that may be implemented in accordance with the disclosed subject matter have been described with reference to several flow diagrams. While for purposes of simplicity of explanation, the methodologies are shown and described as a series of blocks, it is to be understood and appreciated that the claimed subject matter is not limited by the order of the blocks, as some blocks may occur in different orders and/or concurrently with other blocks from what is depicted and described herein. Moreover, not all illustrated blocks may be required to implement the methodologies described herein. Additionally, it should be further appreciated that the methodologies disclosed herein are capable of being stored on an article of manufacture to facilitate transporting and transferring such methodologies to computers.

[0098] The previous description of the disclosed aspects is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these aspects will be clear to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.