Pre-roll cone packing and folding devices, systems, and methods

Abstract

Systems, apparatus, and methods for compression of pre-roll cones supported in a cone holder assembly. In some examples, a multi-axis positioning system can be configured for compressing a filler material within pre-roll cones supported in a cone holder assembly. In some examples, a multi-axis positioning system can be configured for folding open-end portions of pre-roll cones supported in a cone holder assembly and having a filler material disposed therein. In some examples, a computerized controller can operate the multi-axis positioning system to control relative positioning of a carriage having a plunger attached thereto and a platform via one or more actuators, such as X-axis, -axis, and/or Z-axis actuators. In some examples, the computerized controller can control movement of a carriage and/or a platform based on one or more compression criteria.

We claim: 
     
         1 . A pre-roll cone system comprising: 
       a multi-axis positioning system comprising:
 an X-axis stage; 
 a carriage movably coupled to the X-axis stage, the carriage comprising a housing and a plunger, the plunger extending from a first surface of the housing; 
 an X-axis actuator configured to drive movement of the carriage along an X-axis of the multi-axis positioning system; 
 a pair of Y-axis stages, a first end of the X-axis stage movably coupled to a first one of the Y-axis stages and a second end of the X-axis stage movably coupled to a second one of the Y-axis stages; 
 a Y-axis actuator configured to drive movement of the X-axis stage along a Y-axis of the multi-axis positioning system; 
 
       a cone holder assembly comprising a first body having a plurality of cavities formed therein, each cavity having an opening on a top surface the first body, wherein each cavity is configured to receive a pre-roll cone and a filler material therein such that the filler material is disposed within the pre-roll cone and an open-end portion of the pre-roll cone extends above the top surface of the first body; 
       one or more sensors comprising at least one of a pressure sensor or a position sensor; and 
       a computerized controller configured for communication with each of the X-axis actuator, the Y-axis actuator, and the one or more sensors, wherein the computerized controller comprises one or more processors and one or more non-transitory computer-readable storage media having a plurality of computer-executable instructions stored thereon, the plurality of computer-executable instructions configured to, when executed by the one or more processors, cause the computerized controller to:
 cause positioning of the carriage to a first position such that the plunger is aligned with a cavity of the plurality of cavities of the cone holder assembly; 
 cause the carriage to move in a downward direction along the Y-axis toward the cavity, thereby causing the plunger to contact at least one of the pre-roll cone or the filler material within the pre-roll cone received within the cavity; 
 determine whether one or more compression criteria are met based on one or more sensor signals generated based on the contact between the plunger and the at least one of the pre-roll cone or the filler material within the pre-roll cone, the one or more compression criteria comprising one or more of a threshold compression depth or a threshold compression pressure; 
 based on a determination that one or more compression criteria are met, cause the carriage to move in an upward direction along the Y-axis thereby causing retraction of the plunger away from the cavity; and 
 cause repositioning of the carriage along the X-axis to a second position such that the plunger is aligned with an adjacent cavity of the plurality of cavities of the cone holder assembly. 
 
     
     
         2 . The pre-roll cone system of  claim 1 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       iteratively perform, for each of the cavities in the cone holder assembly, the steps of causing the carriage to move in the downward direction along the Y-axis, determining that the one or more compression criteria are met, causing the carriage to move in the upward direction along the Y-axis, and causing repositioning of the carriage. 
     
     
         3 . The pre-roll cone system of  claim 2 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       based at least on the determination that one or more compression criteria are met, add one to a total count of compressions; 
       determine that the total count is equal to a threshold count, the threshold count corresponding to a number of cavities in the cone holder assembly; and 
       based at least on the determination that the total count being equal to the threshold count, stop the iterative performance of the steps. 
     
     
         4 . The pre-roll cone system of  claim 1 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       receive data indicative of primary compression criteria, the primary compression criteria being a user-selected one of the threshold compression depth or the threshold compression pressure; and 
       based at least on the primary compression criteria, designate a non-selected one of the threshold compression depth or the threshold compression pressure as secondary compression criteria. 
     
     
         5 . The pre-roll cone system of  claim 4 , wherein the determination that one or more compression criteria are met comprises determination that the primary compression criteria is met, and wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       based on a determination that the primary compression criteria is not met, determine whether the secondary compression criteria; and 
       based on a determination that the secondary compression criteria is met, cause the carriage to move in an upward direction along the Y-axis thereby causing retraction of the plunger away from the cavity. 
     
     
         6 . The pre-roll cone system of  claim 1 , wherein the plunger is a packer plunger comprising a proximal shaft portion and a distal shaft portion, wherein the distal shaft portion has a smaller diameter than the proximal shaft portion, wherein an annular shoulder is disposed at an intersection between the distal shaft portion and the proximal shaft portion, wherein the annular shoulder is configured to compress the filler material within the pre-roll cone supported in the cone holder assembly. 
     
     
         7 . The pre-roll cone system of  claim 6 , wherein at least an outer surface of the packer plunger is formed from a metallic material. 
     
     
         8 . The pre-roll cone system of  claim 1 , further comprising a folder assembly comprising a second body having a plurality of openings each having a folder including a slot disposed therein, wherein a bottom surface of the second body is configured to engage the top surface of the first body of the cone holder assembly such that each folder is aligned with one of the cavities in the cone holder assembly, wherein the plunger is a folder plunger comprising a shaper shaft having an angular-shaped cross-section, wherein the shaper shaft is sized and shaped to be inserted into the slot of the folder in the folder assembly to cause folding of the open-end portion of the pre-roll cone. 
     
     
         9 . The pre-roll cone system of  claim 8 , wherein the folder plunger is comprised of a polymeric material. 
     
     
         10 . The pre-roll cone system of  claim 1 , wherein the plunger is a packer plunger and the system further comprises a folder plunger, wherein the packer plunger and the folder plunger are configured to be interchangeably coupled to the carriage. 
     
     
         11 . The pre-roll cone system of  claim 1 , wherein the plunger is a packer plunger and the system further comprises a folder plunger extending from a second surface of the housing, wherein the carriage is rotatable between a first orientation and a second orientation, wherein, in the first orientation, the first surface of the housing and the packer plunger oriented downward, and wherein, in the second orientation, the second surface of the housing and the folder plunger are oriented downward. 
     
     
         12 . The pre-roll cone system of  claim 1 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       cause positioning of the carriage to an initial position such that the plunger is not aligned with the cavities of the cone holder assembly; 
       cause the carriage to move in a downward direction along the Y-axis thereby causing the plunger to contact a top surface of the cone holder assembly; 
       determine a height of the cone holder assembly based on one or more sensor signals generated based on the contact between the plunger and the top surface of the cone holder assembly; and 
       select the one or more compression criteria from a plurality of stored compression criteria based at least on the determined height of the cone holder assembly. 
     
     
         13 . The pre-roll cone system of  claim 1 , further comprising:
 a pair of Z-axis stages;   a platform movably coupled to the Z-axis stages, wherein the platform includes one or more couplers for coupling the cone holder assembly to the platform, wherein the plurality of cavities in the cone holder assembly are arranged in a plurality of rows of cavities;   a Z-axis actuator configured to drive movement of the platform along a Z-axis of the multi-axis positioning system;   wherein the computerized controller is configured for communication with the Z- axis actuator, wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to:
 cause positioning of the platform at a first platform position such that the plunger is aligned with a row of the plurality of rows of cavities of the cone holder assembly coupled to the platform; 
 determine that the carriage has reached an end position of the row; and 
 based at least on the determination that the carriage has reached the end position, cause repositioning the platform along the Z-axis to a second platform position such that the plunger is aligned with an adjacent row of the plurality of rows of cavities in the cone holder assembly. 
   
     
     
         14 . A system comprising: 
       a multi-axis positioning system comprising:
 a plurality of stages; 
 a carriage movably coupled to at least a first one of the plurality of stages; 
 a plunger extending from a bottom surface of a housing of the carriage, wherein the plunger comprises a proximal shaft portion and a distal shaft portion, the proximal shaft portion having a greater diameter than the distal shaft portion, wherein an annular shoulder is disposed at an intersection between the distal shaft portion and the proximal shaft portion; 
 a platform movably coupled to at least a second one of the plurality of stages; 
 a plurality of actuators, the plurality of actuators configured to control, along X, Y, and Z-axes of the multi-axis positioning system, relative positioning between the carriage and the platform; 
 
       a cone holder assembly comprising a first body having a plurality of cavities formed therein, the plurality of cavities arranged in a plurality of rows, each cavity having an opening on a top surface the first body, wherein each cavity is configured to receive a pre-roll cone and a filler material disposed within the pre-roll cone, wherein the platform comprises a coupler for coupling the cone holder assembly thereto; 
       one or more sensors comprising at least one of a pressure sensor or a position sensor; and 
       a computerized controller configured for communication with each of the actuators and the one or more sensors, wherein the computerized controller comprises one or more processors and one or more non-transitory computer-readable storage media having a plurality of computer-executable instructions stored thereon, the plurality of computer-executable instructions configured to, when executed by the one or more processors, cause the computerized controller to:
 cause relative positioning of the carriage and the cone holder assembly to a first position such that the plunger is aligned with a cavity of the plurality of cavities of the cone holder assembly; 
 cause the carriage to move in a downward direction along the Y-axis toward the cavity, thereby causing the plunger to contact the filler material within the pre-roll cone received within the cavity; 
 determine that one or more compression criteria are met based on one or more sensor signals, the one or more compression criteria comprising one or more of a threshold compression depth or a threshold compression pressure; 
 based on the determination that one or more compression criteria are met, cause the carriage to move in an upward direction along the Y-axis thereby causing retraction of the plunger away from the cavity; and 
 cause relative repositioning of the carriage and the cone holder assembly to a second position such that the plunger is aligned with an adjacent cavity of the plurality of cavities of the cone holder assembly. 
 
     
     
         15 . The system of  claim 14 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       determine that the carriage has reached an end position of a row of cavities in the cone holder assembly; and 
       based at least on the determination that the carriage has reached the end position, cause relative repositioning of the carriage or the platform such that the plunger is aligned with an adjacent row of the plurality of rows of cavities in the cone holder assembly. 
     
     
         16 . The system of  claim 15 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       receive data indicative of a user selection of primary compression criteria, the primary compression criteria being one of the threshold compression depth or the threshold compression pressure, wherein the determination that one or more compression criteria are met comprises determination that the primary compression criteria is met; and 
       based at least on the data indicative of the user selection of the primary compression criteria, designate a non-user-selected one of the threshold compression depth or the threshold compression pressure as secondary compression criteria. 
     
     
         17 . The system of  claim 16 , wherein the plurality of computer-executable instructions are further configured to, when executed by the one or more processors, cause the computerized controller to: 
       based on a determination that the primary compression criteria is not met, determine whether the secondary compression criteria is met; and 
       based on a determination that the secondary compression criteria is met, cause the carriage to move in an upward direction along the Y-axis thereby causing retraction of the plunger away from the cavity. 
     
     
         18 . A system comprising: 
       a multi-axis positioning system comprising:
 a plurality of stages; 
 a carriage movably coupled to at least a first one of the plurality of stages; 
 one or more plungers configured to be coupled to the carriage; 
 a platform movably coupled to at least a second one of the plurality of stages; 
 a plurality of actuators, the plurality of actuators configured to control, along X, Y, and Z-axes of the multi-axis positioning system, relative positioning between the carriage and the platform; 
 
       a cone holder assembly comprising a first body having a plurality of cavities formed therein, the plurality of cavities arranged in a plurality of rows, each cavity having an opening on a top surface the first body, wherein each cavity is configured to receive a pre-roll cone and a filler material therein such that the filler material is disposed within the pre-roll cone and an open-end portion of the pre-roll cone extends above the top surface of the first body, wherein the platform comprises a coupler for coupling the cone holder assembly thereto; 
       a folder assembly comprising a second body having a plurality of openings each having a folder including a slot disposed therein, a bottom surface of the second body configured to engage the top surface of the first body of the cone holder assembly such that each folder is aligned with one of the cavities; 
       one or more sensors comprising at least one of a pressure sensor or a position sensor; and 
       a computerized controller configured for communication with each of the plurality of actuators and the one or more sensors, wherein the computerized controller comprises one or more processors and one or more non-transitory computer-readable storage media having a plurality of computer-executable instructions stored thereon, the plurality of computer-executable instructions configured to, when executed by the one or more processors, cause the computerized controller to:
 cause relative positioning of the carriage and the cone holder assembly to a first position such that a plunger of the one or more plungers is aligned with a cavity of the plurality of cavities of the cone holder assembly; 
 cause the carriage to move in a downward direction along the Y-axis toward the cavity, thereby causing the plunger to contact at least one of the pre-roll cone or the filler material within the pre-roll cone received within the cavity; 
 determine whether one or more compression criteria are met based on one or more sensor signals generated based on the contact between the plunger and the at least one of the pre-roll cone or the filler material within the pre-roll cone, the one or more compression criteria comprising one or more of a threshold compression depth or a threshold compression pressure; 
 based on the determination that one or more compression criteria are met, cause the carriage to move in an upward direction along the Y-axis thereby causing retraction of the plunger away from the cavity; and 
 cause relative repositioning of the carriage and the cone holder assembly to a second position such that the plunger is aligned with an adjacent cavity of the plurality of cavities of the cone holder assembly. 
 
     
     
         19 . The system of  claim 18 , wherein the one or more plungers comprise a packer plunger, the packer plunger comprising a proximal shaft portion and a distal shaft portion, wherein the distal shaft portion has a smaller diameter than the proximal shaft portion, wherein an annular shoulder is disposed at an intersection between the distal shaft portion and the proximal shaft portion, wherein the annular shoulder is configured to compress the filler material within the pre-roll cone supported in the cone holder assembly. 
     
     
         20 . The system of  claim 18 , wherein the one or more plungers comprise a folder plunger, the folder plunger comprising a shaper shaft having an angular-shaped cross-section, wherein the shaper shaft is sized and shaped to be inserted into the slot of the folder in the folder assembly to cause folding of the open-end portion of the pre-roll cone.