High speed object inserter and related methods

Abstract

An apparatus for inserting one or more objects into a filter component of a tobacco rod. The apparatus includes: a storage apparatus that stores a plurality of the objects; an inserter wheel that inserts the objects into a band of filter material; and an acceleration chamber that transfers the objects from the storage apparatus to the inserter wheel. The acceleration chamber includes: a vortex chamber defining a periphery and an opening in the periphery; a source of air that accelerates the objects around the periphery of the vortex chamber; and a metering drum that rotates around the vortex chamber, the metering drum having metering holes movable into alignment with the opening in the periphery of the vortex chamber. The metering holes receive the objects through the opening in the periphery of the vortex chamber, and transfer the objects to the inserter wheel.

1 . An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:
 a storage apparatus that stores a plurality of the objects;   an inserter wheel that inserts the objects into a band of filter material; and   an acceleration chamber that transfers the objects from the storage apparatus to the inserter wheel, wherein the acceleration chamber includes:
 a vortex chamber defining a periphery and an opening in the periphery; 
 a source of air that accelerates the objects around the periphery of the vortex chamber; and 
 a metering drum that rotates around the vortex chamber, the metering drum having metering holes movable into alignment with the opening in the periphery of the vortex chamber; 
   wherein the metering holes receive the objects through the opening in the periphery of the vortex chamber, and transfer the objects to the inserter wheel.   
     
     
         2 . The apparatus of  claim 1 , further comprising:
 an outer guide ring and an inner guide ring, wherein the opening in the periphery of the vortex chamber is located between the outer guide ring and the inner guide ring.   
     
     
         3 . The apparatus of  claim 2 , further comprising:
 a shield that covers the opening between the outer guide ring and the inner guide ring for a portion of the periphery of the vortex chamber.   
     
     
         4 . The apparatus of  claim 2 , wherein at least one of the outer guide ring and the inner guide ring defines a chamfer inclined toward the metering holes in the metering drum. 
     
     
         5 . The apparatus of  claim 2 , wherein the outer guide ring and the inner guide ring define a chicane in the transfer region, wherein the chicane is aligned with the metering holes in the metering drum. 
     
     
         6 . The apparatus of  claim 5 , further comprising at least one air jet proximate the chicane, the at least one air jet adapted to redirect the objects toward the inserter wheel. 
     
     
         7 . The apparatus of  claim 1 , further comprising a guide that extends around a portion of the metering drum and covers the metering holes, wherein the guide retains the objects in the metering holes. 
     
     
         8 . The apparatus of  claim 7 , wherein the metering drum defines an outer diameter and the guide defines an inner diameter located at a distance from the outer diameter of the metering drum, wherein the guide includes a ramped portion having an increased inner diameter that increases the distance between the outer diameter of the metering drum and the ramped portion. 
     
     
         9 . The apparatus of  claim 7 , wherein the metering holes define a metering hole diameter, and a portion of the guide overlaying the metering holes defines a guide width, wherein the guide width is less than the metering hole diameter. 
     
     
         10 . The apparatus of  claim 1 , further comprising a feed tube extending from the storage apparatus to the vortex chamber, wherein the feed tube defines a chamfered opening into the vortex chamber, and the chamfered opening is inclined with respect to the vortex chamber to direct the objects in substantially the same trajectory as the source of air flowing in the vortex chamber. 
     
     
         11 . The apparatus of  claim 1 , further comprising at least one pneumatic cylinder adapted to raise the inserter wheel into a position out of contact with the band of the filter material. 
     
     
         12 . The apparatus of  claim 1 , wherein the inserter wheel includes a plurality of pockets, and each pocket is adapted to support one of the objects with between about one quarter and one half of the volume of the object received in the pocket, and the remainder of the volume of the object protruding from the pocket. 
     
     
         13 . The apparatus of  claim 12 , further comprising a fluted portion in communication with each pocket, wherein the fluted portion defines a substantially cross-shaped cross section. 
     
     
         14 . The apparatus of  claim 1 , further comprising:
 a first tongue that compresses the band of filter material into a substantially cylindrical shape, wherein the inserter wheel inserts the objects into the band of filter material;   a second tongue that compresses a second band of filter material into a substantially cylindrical shape, the first tongue and the second tongue adapted to guide the first and second bands of filter material along substantially parallel paths; and   a second inserter wheel that receives objects from a second acceleration chamber and inserts the objects into the second band of filter material.   
     
     
         15 . An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:
 a storage apparatus that stores a plurality of the objects;   an inserter wheel that inserts the objects into a band of filter material;   a tow guide located upstream of the inserter wheel, wherein the band of filter material passes through the tow guide; and   a plow located at least partially within the tow guide, the plow defining a downstream end proximate to the inserter wheel, and an upstream end opposite to the downstream end;   wherein the plow is tapered from a first cross-section at the upstream end to a second cross-section at the downstream end, and the first cross-section is larger than the second cross-section.   
     
     
         16 . The apparatus of  claim 15 , wherein the inserter wheel has an outer periphery defining a width, and the second cross-section of the plow is substantially equal to the width of the outer periphery of the inserter wheel. 
     
     
         17 . The apparatus of  claim 15 , wherein the inserter wheel has an outer periphery, and the downstream end of the tow guide is tapered in a direction generally tangential to the outer periphery. 
     
     
         18 . An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:
 a storage apparatus that stores a plurality of the objects;   an inserter wheel that inserts the objects into a band of filter material, the inserter wheel defining an outer periphery with a plurality of pockets distributed evenly around the outer periphery, each pocket adapted to support one of the objects;   a drive motor adapted to rotate the inserter wheel; and   a controller that controls rotation of the drive motor, wherein the controller is adapted to vary the speed of rotation of the inserter wheel to insert the objects into the filter material at asymmetrical distances from one another.   
     
     
         19 . The apparatus of  claim 18 , further comprising:
 a cutter head adapted to cut the band of filter material, the cutter head located downstream from the inserter wheel;   a position sensor associated with the inserter wheel; and   a controller in communication with the cutter head and the position sensor, wherein the controller synchronizes operation of the cutter head with the position of the inserter wheel.   
     
     
         20 . The apparatus of  claim 19 , wherein the position sensor comprises a proximity sensor or a light sensor. 
     
     
         21 . The apparatus of  claim 19 , wherein the position sensor comprises a shaft encoder associated with the inserter wheel.