Cigarette package coding system and associated method

• US 10,160,559 B2
• Filed: 08/04/2014
• Issued: 12/25/2018
• Est. Priority Date: 10/17/2011
• Status: Active Grant

• Current Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco)
• Original Assignee: R J Reynolds Tobacco Company (R. J. Reynolds Tobacco)
• Inventors: Gates, Hugh, Phan, Hung, Campbell, Chris, Hall, David, Wood, Gary, Thomas, Reggie, Brantley, Frank
• Primary Examiner(s): Shechtman, Sean
• Application Number:
  US14/451,066
• Publication Number:
  US 20150013269A1
• Time in Patent Office: 1,604 Days
• Field of Search: None
• CPC Class Codes: B65B 19/30 responsive to presence of faulty articles, e.g. incorrectly filled cigarettes
• CPC Class Codes: B65B 19/32 responsive to incorrect grouping of articles or to incorrect filling of packages
• CPC Class Codes: B65B 61/26 for marking or coding completed packages
• CPC Class Codes: B65G 47/261 Accumulating articles
• CPC Class Codes: G05B 19/41875 characterised by quality surveillance of production
• CPC Class Codes: G05B 23/0294 Optimizing process, e.g. process efficiency, product quality
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A package coding system for a cigarette manufacturing process is provided. An imprinting device imprints an alphanumeric code on each of a series of cigarette packages. A conveyor device conveys the cigarette packages in a feed direction. An inspection device is operably engaged with the conveyor device and inspects the alphanumeric code imprinted on each cigarette package conveyed by the conveyor device to determine whether any of the cigarette packages includes a defect in the imprinted alphanumeric code, and thus comprises a defective cigarette package. A removal device is operably engaged with the conveyor device and is configured to be in communication with the inspection device. The removal device is configured to remove the defective cigarette package from the series of cigarette packages conveyed by the conveyor device in response to identification thereof by the inspection device. An associated method is also provided.

Claims

1. A package coding system implemented in a cigarette manufacturing process, said system comprising:

an imprinting device configured to imprint an alphanumeric code on each of a series of discrete cigarette packages;

a conveyor device configured to convey the discrete cigarette packages, adjacent to and unspaced with respect to each other to form a continuous series and in a feed direction;

a removal device operably engaged with the conveyor device, the removal device being further configured to remove a defective cigarette package from the continuous series of discrete cigarette packages conveyed by the conveyor device in response to identification thereof; and

an inspection device operably engaged with the conveyor device and the removal device, and configured to inspect the alphanumeric code imprinted on each cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device to determine whether any of the cigarette packages includes a defect in the imprinted alphanumeric code, any one of the cigarette packages including the defect being the defective cigarette package, the inspection device being further configured to compare the alphanumeric code imprinted on each cigarette package with a model alphanumeric code to determine whether any of the cigarette packages includes the defect in the imprinted alphanumeric code.

2. The system according to claim 1, further comprising a synchronization device operably engaged with the inspection device, the conveyor device, and the removal device, the synchronization device being configured to determine a position of the defective cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device, in response to the determination thereof by the inspection device, and to communicate the position of the defective cigarette package in the continuous series of discrete cigarette packages to the removal device so as to notify the removal device of the defective cigarette package being in registration therewith.

3. The system according to claim 2, wherein the inspection device is configured to identify the defective cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device, and to direct the removal device to interact with the defective cigarette package, when the defective cigarette package is in registration therewith, to remove the defective cigarette package from the continuous series of discrete cigarette packages conveyed by the conveyor device.

4. The system according to claim 1, wherein the removal device is configured to direct a pressurized air charge substantially perpendicularly to the feed direction of the conveyor device, the pressurized air charge being configured to interact with the defective cigarette package, so as to direct the defective cigarette package out of the continuous series of discrete cigarette packages, without interacting with the cigarette packages preceding and subsequent to the defective cigarette package, and adjacent to and unspaced therewith, in the continuous series of discrete cigarette packages.

5. The system according to claim 4, further comprising a collection device operably engaged with the removal device and the conveyor device and configured to collect the defective cigarette package removed from the continuous series of discrete cigarette packages.

6. The system according to claim 1, wherein the inspection device includes a processor configured to execute an image processing procedure configured to compare an image of the imprinted alphanumeric code on each of the discrete cigarette packages to the model alphanumeric code to determine whether any of the cigarette packages includes the defect in the imprinted alphanumeric code.

7. The system according to claim 6, wherein the image processing procedure is further configured to analyze one of a location of the imprinted alphanumeric code on each of the discrete cigarette packages, a print quality of the imprinted alphanumeric code on each of the discrete cigarette packages, and a substantive content of the imprinted alphanumeric code on each of the discrete cigarette packages.

8. The system according to claim 1, wherein the inspection device further comprises a machine vision system.

9. The system according to claim 1, further comprising an analysis device operably engaged with the inspection device, the analysis device being configured to analyze the defective cigarette packages determined by the inspection device to determine one of a defect type associated with the defect and a cause of the defect.

10. The system according to claim 9, wherein the analysis device is further configured to classify each defect in one of a plurality of defect types, and to halt the cigarette manufacturing process upon one of the plurality of defect types attaining a threshold amount of defects.

11. The system according to claim 10, further comprising a handling device operably engaged with the conveyor device downstream of the removal device, the handling device being configured to manipulate the discrete cigarette packages remaining on the conveyor device downstream of the removal device so as to eliminate any open spaces therebetween due to removal of defective cigarette packages by the removal device.

12. A method of verifying package coding in a cigarette manufacturing process, said method comprising:

imprinting an alphanumeric code on each of a series of discrete cigarette packages using an imprinting device;

conveying the discrete cigarette packages, adjacent to and unspaced with respect to each other to form a continuous series and in a feed direction using a conveyor device;

inspecting the alphanumeric code imprinted on each cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device, using an inspection device operably engaged therewith, by comparing the alphanumeric code imprinted on each cigarette package with a model alphanumeric code, to determine whether any of the cigarette packages includes a defect in the imprinted alphanumeric code, any of the cigarette packages including the defect being a defective cigarette package; and

removing the defective cigarette package from the continuous series of discrete cigarette packages conveyed by the conveyor device, using a removal device operably engaged with the conveyor device and configured to be in communication with the inspection device, in response to identification thereof by the inspection device.

13. The method according to claim 12, further comprising determining a position of the defective cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device, using a synchronization device and in response to the determination of the defective cigarette package by the inspection device, and communicating the position of the defective cigarette package in the continuous series of discrete cigarette packages to the removal device so as to notify the removal device of the defective cigarette package being in registration therewith.

14. The method according to claim 13, identifying the defective cigarette package in the continuous series of discrete cigarette packages conveyed by the conveyor device, using the inspection device, and directing the removal device to interact with the defective cigarette package, when the defective cigarette package is in registration therewith, to remove the defective cigarette package from the continuous series of discrete cigarette packages conveyed by the conveyor device.

15. The method according to claim 12, further comprising directing a pressurized air charge substantially perpendicularly to the feed direction of the conveyor device, using the removal device, the pressurized air charge being configured to interact with the defective cigarette package, so as to direct the defective cigarette package out of the continuous series of discrete cigarette packages, without interacting with the cigarette packages preceding and subsequent to the defective cigarette package, and adjacent to and unspaced therewith, in the continuous series of discrete cigarette packages.

16. The method according to claim 15, further comprising collecting the defective cigarette package removed from the continuous series of discrete cigarette packages using a collection device operably engaged with the removal device and the conveyor device.

17. The method according to claim 12, further comprising executing an image processing procedure, using a processor associated with the inspection device, to compare an image of the imprinted alphanumeric code on each of the discrete cigarette packages to the model alphanumeric code to determine whether any of the cigarette packages includes the defect in the imprinted alphanumeric code.

18. The method according to claim 17, wherein executing an image processing procedure further comprises analyzing one of a location of the imprinted alphanumeric code on each of the discrete cigarette packages, a print quality of the imprinted alphanumeric code on each of the discrete cigarette packages, and a substantive content of the imprinted alphanumeric code on each of the discrete cigarette packages.

19. The method according to claim 12, wherein inspecting the alphanumeric code further comprises inspecting the alphanumeric code imprinted on each discrete cigarette package, using an inspection device comprising a machine vision system.

20. The method according to claim 12, further comprising analyzing the defective cigarette packages determined by the inspection device, using an analysis device operably engaged with the inspection device, to determine one of a defect type associated with the defect and a cause of the defect.

21. The method according to claim 20, further comprising classifying each defect in one of a plurality of defect types, and halting the cigarette manufacturing process, using the analysis device, upon one of the plurality of defect types attaining a threshold amount of defects.

22. The method according to claim 12, further comprising manipulating the cigarette packages remaining on the conveyor device downstream of the removal device, using a handling device operably engaged with the conveyor device downstream of the removal device, so as to eliminate any open spaces therebetween due to removal of defective cigarette packages by the removal device.