PRE-ROLL CONE PACKING AND FOLDING DEVICES, SYSTEMS, AND METHODS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/674,145, filed Jul. 22, 2024, which is incorporated by reference herein in its entirety.

FIELD

The present disclosure relates to systems, apparatus, and methods for compression of pre-roll cones supported in a cone holder assembly, such as systems, apparatus, and methods for compression of filler material within pre-roll cones and/or folding of open-end portions of pre-roll cones.

BACKGROUND

A pre-roll cone is a shell (e.g., a paper shell) for a cigarette-type product that has not yet been folded, but which has been formed into a hollow tube or roll. A pre-roll cone can be filled with filler product (e.g. tobacco, herbs, etc.). An open-end portion of a pre-roll cone can be folded to retain the filler product within the cone and form a finished product (i.e., a filled and closed cone). Conventional techniques for forming a filled and closed cone include filling the pre-roll cone and folding the open end by hand.

SUMMARY

Described herein are 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 and/or packing 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 and/or compressing open-end portions of pre-roll cones supported in a holder assembly and having a filler material disposed therein. In some examples, the multi-axis positioning system can control a position of a carriage having a plunger attached thereto relative to a platform via one or more actuators.

In some examples, a cone holder assembly including a plurality of cavities each configured to receive and/or support a pre-roll cone can be coupled to the platform. A loader assembly can be utilized to fill each of the cones with filler material. In some examples, a folder assembly including a plurality of folders can be coupled to the cone holder assembly such that each of the folders is aligned with one of the cavities (having a filled pre-roll cone disposed therein). In some examples, a computerized control can control the multi-axis positioning system to selectively perform packing, folding, and/or packing and folding of the pre-roll cones supported in the cone holder assembly. In some examples, a packing operation can be performed based on one or more packing criteria, such as a selected compression pressure or a selected compression depth for compressing filler material within a cone. In some examples, a folding operation can be performed based on one or more folding criteria, such as a selected compression pressure or a selected compression depth for folding an open-end portion of a pre-roll cone.

In one representative example, a pre-roll cone packing and/or folding system includes: 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.

In another representative example, a pre-roll cone packing and/or folding system includes: 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.

In another representative example, a pre-roll cone packing and/or folding system includes: 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.

The foregoing and other objects, features, and advantages of the disclosure will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are front and rear perspective views of an exemplary packing and/or folding multi-axis positioning system.

FIGS. 1C-1F are front, side, rear, and top views of the exemplary packing and/or folding multi-axis positioning system of FIGS. 1A and 1B.

FIGS. 2A-2C are detailed rear views of an exemplary Y-axis actuator for the system of FIGS. 1A-1F.

FIG. 2D-2F are detailed perspective views of exemplary connector assemblies and an exemplary X-axis stage for the system of FIGS. 1A-1F.

FIGS. 3A and 3B are detailed rear views of an exemplary carriage and plunger coupled to the X-axis stage for the system of FIGS. 1A-1F.

FIG. 3C is a side view of an exemplary X-axis actuator to drive movement of the carriage and plunger along the X-axis stage.

FIG. 3D and 3E are front perspective views of the X-axis actuator and the carriage and plunger along.

FIGS. 3F and 3G are perspective views of an exemplary packer plunger for the system of FIGS. 1A-1F.

FIGS. 3H and 3I are perspective views of an exemplary folder plunger for the system of FIGS. 1A-1F.

FIGS. 4A and 4B are top perspective view of an exemplary platform, Z-axis stages, and Z-axis actuator for the system of FIGS. 1A-1F.

FIG. 4C is a rear view of the platform, Z-axis stages, and Z-axis actuator.

FIGS. 5A and 5B are rear and side views of an exemplary on-board display and/or user input device for the system of FIGS. 1A-1F.

FIG. 6A and 6B are perspective views of an exemplary pre-roll cone holder assembly for use with the system of FIGS. 1A-1F.

FIG. 6C is a perspective view of an exemplary pre-roll cone that can be supported in the holder assembly of FIGS. 6A and 6B.

FIG. 6D is a cross-sectional view of an exemplary pre-roll cone holder for in the holder assembly of FIGS. 6A and 6B.

FIGS. 6E and 6F are top perspective views of a loader assembly for use with the holder assembly of FIGS. 6A and 6B.

FIG. 6G is a top perspective view of the holder assembly of FIGS. 6A and 6B supporting a plurality of pre-roll cones having a filler material disposed therein.

FIG. 6H is a front perspective view of the system of FIGS. 1A-1F performing an exemplary packing operation.

FIGS. 7A and 7B are top perspective and detailed view of an exemplary folder assembly for use with the system of FIGS. 1A-1F.

FIGS. 7C and 7D are perspective and cross-sectional views of the holder and folder assemblies.

FIG. 7E is a front perspective view of the system of FIGS. 1A-1F performing an exemplary folding operation.

FIG. 8 is a schematic illustration of an exemplary packing and/or folding multi-axis positioning system, in accordance with the examples of the disclosure, and an exemplary computerized controller.

FIGS. 9-12 are logical flow diagrams of exemplary methods that can be executed by a computerized controller apparatus for controlling the exemplary packing and/or folding multi- axis positioning systems.

FIGS. 13A-13E are exemplary graphical user interfaces (GUIs) for the exemplary packing and/or folding multi-axis positioning systems.

DETAILED DESCRIPTION

General Considerations

For purposes of this description, certain aspects, advantages, and novel features of examples of this disclosure are described herein. The disclosed methods, apparatus, and systems should not be construed as being limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed examples, alone and in various combinations and sub-combinations with one another. The methods, apparatus, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed examples require that any one or more specific advantages be present or problems be solved.

Although the operations of some of the disclosed examples are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language set forth below. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. Additionally, the description sometimes uses terms like “provide” or “achieve” to describe the disclosed methods. These terms are high-level abstractions of the actual operations that are performed. The actual operations that correspond to these terms may vary depending on the particular implementation and are readily discernible by one of ordinary skill in the art.

As used in this application and in the claims, the singular forms “a,” “an,” and “the” include the plural forms unless the context clearly dictates otherwise. Additionally, the term “includes” means “comprises.” Further, the term “coupled” generally means physically, mechanically, chemically, magnetically, and/or electrically coupled or linked and does not exclude the presence of intermediate elements between the coupled or associated items absent specific contrary language.

Overview

As discussed above, conventional techniques for forming a filled and closed cone include filling the pre-roll cone and folding the open end of the cone by hand, which can be challenging to stabilize a position of the cone for filling and folding, therefore making process time consuming and difficult to produce multiple filled and closed cones. Further, conventional techniques can result in significant loss of filler material, irregular, inconsistent and/or insufficient consistency or density of the filler material within the cone, and/or irregular, inconsistent and/or insufficient folding of the open end of the cone.

The systems, apparatus, and methods disclosed here address one or more of the foregoing issues with conventional pre-roll techniques. In some examples, a loading and folding system can include a multi-axis positioning system including a carriage having a plunger extending from a bottom surface of the carriage. The multi-axis positioning system can be in communication with a computerized controller for controlling movement of the carriage and/or a platform for supporting a plurality of pre-roll cones. In some examples, the pre-roll cones can be supported in an upright position where the open end of the cone is oriented upward. Each of the cones can be filled with a filler material. In some examples, the computerized controller can be configured for controlling a position of the carriage relative to the platform along three axes (e.g., X, Y, and Z axes). In some examples, the computerized controller can be configured for controlling a position of the carriage relative to the platform along two axes (e.g., X and Y axes or Y and Z axes).

In some examples, a plurality or pre-roll cones can be loaded into cavities within a pre-roll cone holder assembly (which can also be referred to as a “holder assembly” or a “cone holder assembly”) that can be mounted on and/or coupled to the platform. In some examples, the cavities can have a sloped-shape (i.e., a shape complementary to the shape of a pre-roll cone) for supporting the cones in a position where the (larger) open-ends are oriented upward and opposing (smaller) ends are oriented downward. In some examples, each of the cavities can be referred to a “holder.” In some examples, a folder assembly can be coupled to the holder assembly and can be configured to enable folding of the open-end portions of the cones. For example, the folder assembly can include recesses each having a folder (e.g., a body having a slot, such as, for example, a star-shaped opening and/or slot) therein. The folders can be aligned with open-end portions of the cones supported within the holder assembly. A plunger having a cross-section complementary to a shape of the folder (e.g., a shaft having a star-shaped cross-section) can be inserted through the folder to cause folding of the open-end portion of the pre-roll cone. Exemplary holder assemblies and exemplary folder assemblies for folding pre-roll cones that can be utilized with the systems and methods described herein are disclosed in U.S. Pat. No. 11,766,069, which is incorporated by reference herein.

In some examples, the computerized controller can be configured to control a Y-axis actuator for controlling insertion of the plunger (along a Y-axis of the system) into each of the pre-roll cones for compressing and/or packing filler material within each of the cones. In some examples, compression of the filler material within the cones and/or folding of the open-end portions of the cones can be precisely controlled or limited to enable consistent and/or regular density of the filler material within the cone based on one or more control parameters. In some examples, the computerized controller can be configured to control a Y-axis actuator for controlling insertion of the plunger (along a Y-axis of the system) into each of the pre-roll cones based on one or more compression criteria. For example, the system can include a pressure sensor in communication with the computerized controller, and the computerized controller can determine when a pre-set maximum or threshold pressure is met. In another example, the system can include a position sensor in communication with the computerized controller, and the computerized controller can determine when a pre-set maximum or threshold depth is met. Upon determination that the pressure threshold or the threshold depth is met, the computerized controller can stop movement of the plunger and cause retraction of the plunger in an opposing direction. In some examples, the system can be selectively operated based on either of a threshold pressure or a threshold depth. In some examples, when the system is operated based on a selected one of a threshold pressure or a threshold depth, the other of the threshold pressure or the threshold depth can act as a safety or a back-up control parameter.

In some examples, the plunger is a packer plunger configured for insertion through the open-end portion for compression of filler material within the pre-roll cones. In some examples, the plunger can be a folder plunger configured for insertion through the folder of the lid for folding of the open-end portions of the cones.

In some examples, the computerized controller can control relative positioning of the platform and the carriage relative to one another. In some examples, the computerized controller can control a Z-axis actuator for controlling movement of the platform along an Z-axis of the system. In some examples, the computerized controller can control an X-axis actuator for controlling movement of the carriage along an X-axis of the system. In another example, the platform can be stationary and the computerized controller can control one or more of an X-axis actuator and a Z-axis actuator for controlling movement of the carriage. Control of the relative positioning of the carriage and the platform relative to one another can enable repositioning of the plunger and iterative packing and/or folding of each of the pre-roll cones in a holder. For example, the computerized controller can control positioning of the carriage and the platform relative to one another based on pre-programmed data or information related to dimensions of the holder, positions of the cavities within the holder, a number of cavities in each row, and/or a map of the holder. In some examples, the computerized controller can control positioning of the carriage and the platform relative to one another based on position sensor data (e.g., optical sensor data, rotary encoder data, and/or other position data).

Examples of the Disclosed Technology

FIGS. 1A-1E illustrate an exemplary packing and/or folding multi-axis positioning system 100 (which can also be referred to as a “pre-roll cone system”) in accordance with the present disclosure. In some examples, the packing and/or folding multi-axis positioning system 100 can be an XYZ multi-axis positioning system that can enable and/or allow for controlled movement and positioning of a carriage 102 and a platform 104 relative to each other in a three-dimensional space (i.e., along three perpendicular axes: X (horizontal), Y (vertical), and Z (depth)). In a multi-axis positioning system, an X-axis typically refers to the horizontal axis that runs left and right along the width of the workspace, the Y-axis is typically the vertical axis that moves up and down along the height of the workspace, and the Z-axis is the axis that represents depth or movement along the third dimension, perpendicular to both the X-axis (horizontal axis) and the Y-axis (vertical axis). The exemplary systems, apparatus, and methods disclosed herein are described according to this typical XYZ orientation; however, it will be appreciated that the X, Y, and Z axes disclosed herein can be given other designations. For example, the X-axis shown in FIGS. 1A and 1B can be a Z-axis, and the Z-axis shown in FIGS. 1A and 1B can be an X-axis, etc.

The multi-axis positioning system 100 includes a plurality of linear stages 106 (which can also be referred to as “guides” or “guide members” or “rails”) that can enable smooth and precise linear motion along each axis. Movement along the stages can be driven by various types of actuators, such as, for example, stepper motors, servo motors, solenoids, and/or piezoelectric motors, coupled to a drive mechanism, such as, for example, a belt, a lead screw, a shaft, and/or one or more gears. The stages can be fabricated from a metallic material, such as, for example, anodized aluminum or stainless steel, which can provide durability and stability of the stages to maintain movement and/or positioning accuracy over time.

In some examples, the multi-axis positioning system 100 can be configured for packing applications (e.g., packing or compressing filler material with pre-roll cones). In some examples, the multi-axis positioning system 100 can be configured for folding applications (e.g., folding or compressing open-end portions of pre-roll cones having filler material disposed therein). In some examples, the multi-axis positioning system 100 is configured for both packing and folding applications. For example, the multi-axis positioning system 100 can selectively perform a packing application or a folding application (e.g., based on a user selection of either packing or folding). In another example, the multi-axis positioning system 100 can perform a packing application, and, based on a determination that the packing application is complete, switch to a folding application.

In the present example, the XYZ multi-axis positioning system 100 can include two Y-axis stages 108a, 108b, an X-axis stage 110, and two Z-axis stages 112a, 112b. The Z-axis stages 112a, 112b can be attached to and extend over a surface of a base 120 and can be in a parallel orientation relative to the base 120. A lower end portion of each of the Y-axis stages 108a, 108b can be attached to the base 120 so that the Y-axis stages 108a, 108b are in a vertical orientation relative to the base 120. A top frame member 122 can be coupled to and extend between the upper end portions of the Y-axis stages 108a, 108b. A display device 124 (which can be, for example, an on-board computerized controller including a display screen or a display screen in communication with an off-device computerized controller) can be coupled to the top frame member 122. An X-axis actuator 114 can be configured to drive movement (e.g., leftward and rightward translation) of the carriage 102 along the X-axis stage 110. A Y-axis actuator 116 can be configured to drive movement (e.g., upward and downward translation) of the X-axis stage 110 along the Y-axis stages 108a, 108b, thereby driving movement (e.g., upward and downward translation) of the carriage 102. A Z-axis actuator 118 can be configured to drive movement (e.g., forward and rearward translation) of the platform 104 along the Z-axis stages 112a, 112b.

In some examples, the multi-axis positioning system can include two (or more) of Y-axis and X-axis positioning sub-systems (e.g., a first set of two Y-axis stages 108a, 108b and Y-axis actuator 116 and an X-axis stage 110 and X-axis actuator 114, and a second set of two Y-axis stages 108a, 108b and Y-axis actuator 116 and an X-axis stage 110 and X-axis actuator 114) coupled to a base 120 having the two Z-axis stages 112a, 112b and the Z-axis actuator 118. In such examples, the platform 104 can be moveable along the Z-axis stages 112a, 112b so that it can be positioned under the first XY sub-system for performing packing applications and can be positioned under the second XY sub-system for performing folding applications. For example, the platform 104 can be positioned under the first XY sub-system for a packing application, and after it is determined that the packing application is complete, the platform 104 can be repositioned under the second XY system for a folding application.

In other exemplary packing and/or folding multi-axis positioning systems in accordance with present disclosure, a Z-axis actuator can be configured to drive movement (e.g., forward and rearward translation) of the Y-axis stages 108a, 108b, thereby driving movement (e.g., forward and rearward translation) of the carriage 102. In such examples, the platform 104 can be stationary or can be excluded. In another example, a Y-axis actuator can be coupled to the platform such that the platform is moveable along the Y-axis and the Z-axis. In such examples, the system can be configured for X-axis movement of the carriage/plunger and the X-axis stage can be stationary.

In other exemplary packing and/or folding multi-axis positioning systems in accordance with present disclosure, the system can be configured for movement along two axes, such as the X-axis and Y-axis or the Z-axis and Y-axis. For example, a system can include the X-axis actuator 114 configured to drive movement (e.g., leftward and rightward translation) of the carriage 102 along the X-axis stage 110, and the Y-axis actuator 116 configured to drive movement (e.g., upward and downward translation) of the X-axis stage 110 along the Y-axis stages 108a, 108b. In another example, a system can include the Y-axis actuator 116 configured to drive movement (e.g., upward and downward translation) of the X-axis stage 110 along the Y-axis stages 108a, 108b, and can include the Z-axis actuator 118 configured to drive movement (e.g., forward and rearward translation) of the platform 104 along the Z-axis stages 112a, 112b. In some examples, the Z-axis stage can be a single member or can include additional members. In some examples, the Z-axis stages and actuator can be replaced by another translational movement mechanism, such as, for example, a conveyor belt.

Returning to the present example, the Y-axis actuator 116 can include a motor 126 that drives a lead screw 128 (which can also be referred to as a “lead screw sub-system” or “lead screw mechanism”) that translates rotational motion of the lead screw 128 into linear motion of the X-axis stage 110 and the carriage 102 coupled thereto. FIGS. 2A-2C respectively show detailed views of a lower portion, a center portion, and a top portion of an exemplary configuration for the Y-axis actuator 116. As can be seen therein, in some examples, the motor 126 can be coupled to the base 120 and/or the Y-axis stage 108a. In some examples, the motor 126 can be a stepper motor, a servo motor, or another type of rotational motion motor. The motor's shaft (not shown) can be connected to the lead screw 128, for driving the rotation thereof. The lead screw 128 can be a threaded member having helical thread that runs along its length. The lead screw 128 can extend through and/or be engaged with a nut 130 that is fixedly coupled to a connector assembly 132. The nut 130 can include matching internal threads fitted onto the lead screw 128. As the motor 126 turns the lead screw 128, the engaged helical threads convert the rotational motion of the lead screw into linear motion of the connector assembly 132 along the length of the lead screw 128. In some examples, the lead screw 128 can include one or more stop members for acting as a hard stop to prevent further movement of the lead screw 128 in an upward direction and/or a downward direction.

The connector assembly 132 can be movably coupled to the Y-axis stage 108a and can include a pair of plates having a plurality of wheels (for example, three, wheels, four wheels, etc.) rotatably coupled thereto and disposed therebetween. The wheels of the connector assembly 132 can engage with tracks or grooves on opposing sides of the Y-axis stage 108a (FIG. 2E). The connector assembly 132 can be further coupled with a first end portion of the X-axis stage 110 for guiding movement of the X-axis stage 110 along the Y-axis stage 108a as a linear force is actively applied to the connector assembly 132 by the Y-axis actuator 116. Another connector assembly 134 (including a plate and a plurality of wheels engaged with tracks on opposing sides of the Y-axis stage 108b) can movably couple a second end portion of the X-axis stage 110 to the Y-axis stage 108b (FIG. 2F). The connector assembly 134 can passively guide movement of the X-axis stage 110 along the Y-axis stage 108b.

FIGS. 3A-3I illustrate exemplary configurations for the X-axis actuator 114 and the carriage 102. As can be seen in FIGS. 3A and 3B, in some examples, the X-axis actuator 114 can be coupled to a front face of the connector assembly 132. In some examples, the X-axis actuator 114 can include a motor 140 and a belt 142 (e.g., a toothed belt) attached to a connector assembly 136. The motor 140 can be a stepper motor, a servo motor, or another type of rotational motion motor. The motor's shaft (not shown) can be connected to and drive rotation of a gear (not shown). The connector assembly 136 can be configured to moveably couple the carriage 102 to the X-axis stage 110. In some examples, the connector assembly 136 can include a plate and a plurality of wheels (e.g., three wheels, four wheels, etc.) rotatably coupled to the plate. A housing 138 of the carriage 102 can be coupled to the plate of the connector assembly 136. The wheels of the connector assembly 136 can engage with tracks or grooves on opposing upper and lower sides of the X-axis stage 110. The connector assembly 136 can guide movement of the carriage 102 along the X-axis stage 110 when a force is applied thereto by the X-axis actuator 114. In some examples, the teeth on the belt 142 can mesh with the teeth on the gear of the motor 140 and enable precise control of side-to-side movement of the carriage 102 along the X-axis stage 110.

As can be seen in FIGS. 3A-3E, the housing 138 of the carriage 102 can be enclosed on all sides and a plunger 144 (which can also be referred to as a “shaft” or a “rod”). FIGS. 3F and 3H show the carriage 102 with a front plate or wall of the housing 138 removed to show an interior of the carriage 102. As can be seen therein, the plunger 144 can extend through an aperture 146 in a bottom plate or wall 153 of the housing 138. A support plate or wall 148 can extend laterally across interior space of the housing 138 and can be attached to (e.g., bolted to) opposing side plates or walls of the housing 138. The plunger 144 can extend through a linear bearing 149 that is attached to (e.g., bolted to) the support plate 148 and can extend below the support plate 148 within the housing. In some examples, the plunger 144 is coupled to the bottom plate 153.

FIGS. 3G and 3I illustrate exemplary configurations for plungers 144 (i.e., plungers 144a and 144b) that can be utilized with the system 100. FIG. 3G illustrates an exemplary packer plunger 144a including a head 154a and a shaft 156a. In some examples, the head 154a can be coupled to the support plate 148 of the carriage 102. In some examples, the shaft 156a includes a proximal shaft portion 158 and a distal shaft portion 160. The distal shaft portion 160 can have a smaller diameter than the proximal shaft portion 158 thereby forming an annular shoulder 161 at an intersection of the proximal and distal shaft portions. In some examples, the packer plunger 144a is formed from (or includes an exterior coating formed from) a metallic material, such as stainless steel or anodized aluminum. In some examples, the metallic material can be resistant to adhesion of filler material thereto. In some examples, the packer plunger is made from another material, such as a polymeric material. As discussed further below, the packer plunger 144a can be configured for compressing filler material within pre-roll cones that are supported in a holder assembly (such as, for example, the exemplary holder assembly 184 shown in FIGS. 6A-6B, 6E-6H, and 7C and described below). In some examples, the shaft 156a can be inserted into a pre-roll cone to compress filler material therein via downward translation of the carriage 102 and the plunger 144a along the Y-axis of the system, and can then be retracted from the pre-roll cone via upward translation of the of the carriage 102 and the plunger 144a along the Y-axis of the system.

FIG. 3I illustrates an exemplary folder plunger 144b including a head 154b and a shaft 156b. The shaft 156b can include a shaper portion 162. The shaper portion 162 may be defined by an end of the shaft 156b opposite the head 154b. The shaft 156b including the shaper portion 162 can be sized and shaped to fit through a slot of the pre-roll cone folder assembly (such as, for example, a slot of the exemplary folder assembly 208 shown in FIGS. 7A-7E and described below) for engagement by the shaper portion 162 with an open-end portion of a pre-roll cone disposed within the holder assembly.

In some examples, the shaper portion 162 is a shape at the end of shaft 156b. In some examples, the shaper portion 162 is a shape corresponding to a cross-section of the shaft 156b. In some examples, the shaper portion 162 can be shaped as a 6-pointed cross or star. In some examples, the shaper portion can have an angular cross-section. In some examples, the shaper portion can be shaped as a five-pointed cross, a square, a triangle, a circle, or other shape. In some examples, the folder plunger 144b is formed from (or includes an exterior coating formed from) polymeric material, such as, for example nylon, rubber, or plastic. In some examples, the polymeric material can be lower cost and/or can be easily molded to form the angular shape of the folder plunger. In some examples, the folder plunger 144b is made from another material, for example, a metallic material. As discussed further below, the folder plunger 114b can be configured for folding open-end portions of pre-roll cones that are supported in a holder assembly having a folder assembly coupled to the holder assembly. In some examples, the shaft 156b can be inserted through openings in a folder within the folder assembly for folding the open-end portions of the pre-roll cones via downward translation of the carriage 102 and the plunger 144b along the Y-axis of the system, and can then be retracted from the opening via upward translation of the of the carriage 102 and the plunger 144b along the Y-axis of the system.

In some examples, a plunger 144 (e.g., one of the plungers 144a, 144b) can be permanently attached to a carriage 102. In some examples, a carriage 102 can be permanently attached, and the system 100 can be a dedicated packing system or a dedicated folding system. In some examples, the system 100 can be adapted to perform both packing and folding operations. For example, a first carriage 102 including one type of plunger (e.g., the packer plunger 144a) can be detachable from the connector assembly 136 and can be switched out for (i.e., interchangeable with) another carriage 102 including another plunger type (e.g., the folder plunger 144b) depending on a selected packing or folding application of the system 100. In some examples, the plungers 144a, 144b can be detachable from the carriage and can be selectively switched out depending on a selected packing or folding application of the system 100. In other words, the plungers 144a, 144b can be interchangeably connected to the carriage 102. For example, each of the plungers 144a, 144b can be attached to a bottom plate 153 that is releasably coupled to one or more sidewalls or plates of the housing 138. The bottom plate 153 and the lower portion of side walls of the housing 138 can include couplers (for example, a latches) for attaching and detaching the bottom plate. In this way, a selected one of the plungers 144a, 144b can be coupled to the carriage depending on the selected packing or folding application for the system.

In some examples, a carriage (having a similar configuration to the carriage 102) can include a first type of plunger (e.g., the packer plunger 144a) extending from one wall of the housing (e.g., the bottom plate) and a second type of plunger (e.g., the folder plunger 144b) extending from another wall of the housing (e.g., an opposing, upper plate, or one of the side plates). In such examples, the carriage can be rotatably attached to a connector assembly and can be rotated to switch the orientation of the plungers (e.g., by rotating the carriage 180° or 90°) depending on a selected application (e.g., packing or folding) of the system 100. In some examples, the rotation mechanism of the carriage can be manually rotatable. In some examples, the rotation mechanism and orientation of the carriage can be controlled by a computerized controller in communication with the rotation mechanism and can be rotated to a selected orientation based on whether a packing application or a folding application is being performed.

Returning to FIGS. 3F and 3H, one or more sensors 150 can be coupled to the plunger 144 and/or an interior of a top plate or wall 151 of the housing 138. The one or more sensors 150 can be in communication with a computerized controller and/or receive power via one or more wires 152. In some examples, one or more of the sensors can be in wireless communication with a computerized controller. In some examples, the plunger 144 can be positioned relative to be in communication with the one or more sensors 150 such that the one or more sensors can generate signals, for example, pressure signals based on a force, a pressure, and/or a resistance applied to and/or by the plunger, and/or position signals based on a position (e.g., depth) of the plunger relative to the platform or an object positioned on the platform (such as, for example, a pre-roll cone or a pre-roll cone holder).

In some examples, the one or more sensors can include a pressure sensor coupled to the housing 138 and/or the plunger 144 that can measure the pressure exerted on or by the plunger 144, and/or the sensor can detect changes in pressure at the plunger 144 and convert these changes into an electrical signal and/or a pressure reading. In some examples, the pressure sensor can be a resistive pressure sensor or a piezoresistive pressure sensor. The pressure sensor can be coupled to the plunger in such a way that it can accurately measure the pressure without hindering the plunger's function. In some examples, the pressure sensor can be directly coupled to the plunger. In some examples, the pressure sensor can be coupled to the plunger via an adaptor that transmits the pressure from the shaft to the sensor. The electrical signals produced by the pressure sensor can be communicated to the computerized controller, which then processes and/or interprets the signals as pressure values. The pressure values (which can also be referred to as “pressure data”) can be used for monitoring or controlling the plunger 144, as discussed in detail below.

In some examples, the one or more sensors can include one or more position sensors that can measure a current position of the plunger, a distance travelled by the plunger, and/or a distance between the plunger and another object, such as, for example, a distance between a tip of the plunger and the platform or an object positioned on the platform. The position sensors can provide signals and feedback to a computerized controller for generating position data, such as, for example, a depth of the plunger within a pre-roll cone. In some examples, a position sensor can be included in the one or more sensors 150 coupled to the plunger 144 and/or the carriage 102. In some examples, one or more sensors 150′ (FIG. 8) can be coupled to other (off-carriage) portions of the system 100, for example, at the actuators, the connector assemblies, the base, the top frame member, and/or the stages.

In some examples, a position sensor can be an optical sensor or a system of optical sensors, which can detect the position of the plunger 144 in three-dimensional space. In some examples, optical sensors can emit beams of light, which can be interrupted or reflected by moving parts of the system (such as, for example, the plunger, the carriage, and/or the X-axis stage). The optical sensors can detect the changes and convert them into electrical signals that the computerized controller uses to determine position values for the plunger 144 and/or the carriage 102 (which can also be referred to as “plunger/carriage position data”). In some examples, other or additional types of sensors can be used to generate position data, such as rotary encoders, motor encoders, and/or optical encoders coupled to the one or more of the actuators and/or the connector assemblies, inertial measurement units, linear positioning sensors (e.g., linear variable differential transformers), potentiometers, and/or ultrasonic sensors. The plunger/carriage position data can be used for monitoring or controlling the carriage 102 and the plunger 144, as discussed in detail below.

In some examples, the system 100 can additionally include one or more end stop switches 155 (FIG. 8) for limiting and/or controlling movement of the carriage 102 and/or the X-axis stage 110. For example, the carriage 102, the X-axis stage 110, and/or the Y-axis stages 108a, 108b can include end stop switches comprising, for example, mechanical levers or buttons. When the carriage 102 and/or the X-axis stage 110 reaches an end range of movement, it can press against the lever or button, thereby causing it to actuate and/or close an electrical circuit. When the switch is triggered or activated, it can send a signal to a computerized controller to indicate that the carriage 102 and/or the X-axis stage 110 has reached its limit along one or more of the axes (e.g., X or Y). Once the controller receives the signal, it will identify or generate a “stop” command for the respective axis. The controller can then instruct the system's actuators to halt and/or reverse direction, preventing the carriage 102 and/or the X-axis stage 110 from impacting other components of the system.

FIGS. 4A-4C illustrate exemplary configurations for the Z-axis actuator 118 and the platform 104. As can be seen therein, the platform 104 can include a planar upper surface 164 having a plurality of connectors 166 (which attach connector assemblies to a bottom surface of the platform). The platform 104 can further include couplers 168 on opposing sides of the platform 104 that extend upward from the surface 164. Each of the couplers 168 can include depressions or receptacles 170 that are configured to receive complementary couplers on an object (e.g., a holder assembly) for releasably coupling the object to the platform. A connector assembly 172 can be coupled to a lower surface of the platform 104 (opposing the upper surface 164) (FIG. 4C). In some examples, the connector assembly 172 can have a configuration similar to the configuration of to the connector assemblies 132, 134, 136. For example, the connector assembly 172 can be movably coupled to the Z-axis stage 112a and can include a plate or a pair of plates having a plurality of wheels (for example, three, wheels, four wheels, etc.) rotatably coupled thereto. The wheels of the connector assembly 172 can engage with tracks or grooves on opposing sides of the Z-axis stage 112a. Although not shown, another connector assembly having a similar configuration can couple the platform 104 to the Z-axis stage 112b. The connector assemblies can guide movement of the platform 104 along the Z-axis stages 112a, 112b when a force is applied thereto by the Z-axis actuator 118. In some examples, the Z-axis actuator 118 can include a motor 174 and a belt 176 (e.g., a toothed belt) attached to or engaged with a structure on the lower side of the platform 104. The motor 174 can be a stepper motor, a servo motor, or another type of rotational motion motor. The motor's shaft (not shown) can be connected to and drive rotation of a gear (not shown). In some examples, the teeth on the belt 176 can mesh with the teeth on the gear of the motor 174 and enable precise control of forward and backward movement of the platform 104 along the Z-axis stages 112a, 112b. It will be appreciated that, in examples where the platform is moveable along a Z-axis of a multi-axis positioning system, such as in the system 100, one or more of the foregoing position sensors can be utilized to generate platform position data and/or control movement of the platform. Further, the platform and/or the Z-axis stages can include one or more of the end stop switched described above for limiting and/or controlling movement of the platform.

FIG. 4C additionally illustrates an exemplary configuration of the base 120. As can be seen therein, the base 120 can include a power receptacle 178 and a main power switch 180 for providing power to electrical components, such as the actuators, the sensors, and/or the display device 124. FIGS. 5A and 5B a display mount 182 for mounting the display device 124 to the top frame member 122.

It will be appreciated that the various actuators discussed above can alternatively have one or more features of others of the actuators. For example, the Y-axis actuator can be a belt-driven actuator. In another example, one or more of the Z-axis actuator or the X-axis actuator can be driven by a lead screw.

Turing to FIGS. 6A-6H, exemplary apparatus for use with the multi-axis positioning system 100 are shown and described. Referencing FIG. 6A, a pre-roll cone holder assembly 184 is shown with its pre-roll cone holders 186 empty. Holes 188 are shown in the pre-roll cone holder assembly 184 and can be configured to receive guideposts extending from a bottom surface of a folder assembly (such as, for example, the folder assembly 208 shown in FIGS. 7A-7E and described below) for coupling the folder assembly to the holder assembly. FIG. 6B shows the pre-roll cone holder assembly 184 bearing a plurality of pre-roll cones 190 in its plurality of pre-roll cone holders 186 with a plurality of top, open-end portions of the of pre-roll cones 190 protruding above an upper surface of the pre-roll cone holder assembly 184.

FIG. 6C illustrates an exemplary configuration of one of the pre-roll cones 190 (unfilled and removed from the holder assembly 184). The pre-roll cones 190 can be made in various sizes, for example, a smaller size for holding approximately a half-gram of filler material and a larger size for receiving approximately one gram of filler material. The pre-roll cone holder assembly 184 can be manufactured in corresponding sized. For example, a larger pre-roll cone holder having a greater height can be configured to receive the larger pre-roll cones, while a smaller pre-roll cone holder having a lesser height can be configured to receive the smaller pre-roll cones.

FIGS. 6D shows a cross section of one of the holders or cavities 186 of the holder assembly 184. As can be seen therein, a holder 186 includes one or more supporting walls 192 that define a sloped cavity 194 configured for receiving and supporting a pre-roll cone 190 for folding. The sloped cavity 194 may include a top opening 196 for receiving the pre-roll cones 190 and a bottom opening 198. When pre-roll cones 20 are supported in the sloped cavity 194, top, open-end portions of the pre-roll cones 190 may protrude from the top opening 196 and at least bottom portions (e.g., a filter) of the pre-roll cones 190 may protrude from the bottom opening 198. The one or more supporting walls 192 of a holder 186 define a slope or taper that is configured for holding a pre-roll 190 in a stable fixed position for pre-folding and folding without allowing the pre-roll cone 190 to fall out through a bottom opening 198.

FIGS. 6E-6F show an exemplary material loader assembly 200 for use with the holder assembly 184. The material loading tray 200 can include a plurality of channels 202 that have a configuration complementary to the holders 186 of the holder assembly 184 such that each of the channels 202 can be aligned with one of the holders 186 (having a pre-roll cone 190 supported therein). The channels 202 can be filled with a filler material. After alignment of the filled material loader assembly 200 with the holder assembly 184 (having a plurality of pre-roll cones 190 supported in the holders 186), a removable plate 204 can be withdrawn from a lower surface of the material loader assembly 200 for releasing the filler material into the pre-roll cones 190. In some examples, the loader assembly 200 can be agitated and/or tapped to encourage release of the filler material from the loader assembly 200. For example, the material loader assembly 200 can be tapped with a side edge of the plate 204.

FIG. 6G shows the pre-roll cones 190 supported in the holder assembly 184 and filled with the filler material. As can be seen therein, at opposing sides thereof, the holder assembly 184 can include projections or stands 206 that extend downward from the lower surface of the holder assembly. FIG. 6H shows the projections or stands 206 inserted into the receptacles 170 of the couplers 168 for attachment of the holder assembly 184 to the platform 104. Also shown in FIG. 6H, the multi-axis positioning system 100 (including the carriage 102 having the packer plunger 144a coupled thereto) can be utilized for compressing the filler material within each of the pre-roll cones 190 within the holder assembly 184, which is discussed further below.

FIGS. 7A-7E show an exemplary pre-roll cone folder assembly 208 for use with the holder assembly 184. Referencing FIGS. 7A and 7B, in some examples, the folder assembly 208 can include a plurality of pre-roll cone folders 210. In some examples, each of the folders 210 can include recess 214 in an upper surface 212 of the pre-roll folder assembly 208 and slot or openings 216 at a center of the recess 214. In some examples, at least a portion of the slots 216 can have a six-point cross or star configuration complementary to the plunger 144b.

As shown in FIGS. 7C and 7D, in some examples, the pre-roll cone folder 210 can further include one or more walls 218 forming a receptacle that defines a receiving cavity 220 that is in communication with the slot 216 and the recess 214. The receptacle 220 can be configured to receive at least a top portion of a pre-roll cone 190 supported in the sloped cavity 194 of the pre-roll cone holder 186. In some examples, the receptacle 220 has a narrowed or tapered portion and/or a narrowed or tapered shape for compressing a top portion of a pre-roll cone 190 inserted into the receptacle 220 into a partially folded state and/or partially compressed state.

The folder assembly 208 can be configured to be coupled to the holder assembly 184. In some examples, guideposts 222 (e.g. dowels) can extend from a bottom surface of the pre-roll cone folder assembly 208 and can be configured to mate with (e.g., be inserted into) the corresponding holes 188 in the pre-roll cone holder assembly 184. In some examples, a bottom surface of the folder assembly 208 can engage a top surface of the holder assembly 184. In some examples, other or additional coupling mechanisms can be utilized to couple the folder assembly to the holder assembly. As shown in FIG. 7E, the multi-axis positioning system 100 (including the carriage 102 having the packer plunger 144b coupled thereto) can be utilized with the folder assembly 208 for folding each of the pre-roll cones 190 in the holder assembly 184, which is discussed further below.

Additional examples and details of holder assemblies and folder assemblies that can be utilized with the with the systems and methods described herein are disclosed in U.S. Pat. No. 11,766,069, previously incorporated by reference herein. In some examples, other types of holder assemblies and/or folder assemblies can be utilized with the systems disclosed herein. For example, a holder assembly can include cavities that have parallel side walls (non-tapered cavities). In some examples, a holder assembly can include a single row of cavities. In some examples, a holder assembly can include a continuous row of cavities that are coupled to a conveyor belt. In some examples, a folder assembly can be a single folder coupled to a carriage of the multi-axis positioning system. For example, a folder assembly can include a folder mounted to the carriage via one or more compressible members (e.g., one or more telescoping member including a spring or other resilient member), and, via positioning of the carriage, the folder can be aligned over each of the pre-roll cones in the holder assembly along with the folder plunger. As the carriage is translated downward along the Y-axis, the compressible members can be compressed and a bottom surface of the folder can contact the top surface of the holder assembly over the pre-roll cone. The folder plunger can then be inserted through the folder to cause folding of the open-end portion of the pre-roll conc.

Turning to FIG. 8, communication of exemplary components of the packing and/or folding multi-axis positioning system 100 with a computerized controller 300 is schematically illustrated. In some examples, the computerized controller 300 can include one or more processors 316, a data communication interface 318, and memory 320 (e.g., non-transitory computer-readable storage media) having one or more programs (each comprising e.g., a plurality of computer-executable instructions) stored thereon that are configured to be executed by the one or more processors. For example, the memory 320 can store application specific programming for packing, folding, and/or packing and folding (such as for the applications/methods illustrated in FIGS. 9-11 or other applications). In some examples, the processors can be a general-purpose central processing unit (CPU), processor in an application-specific integrated circuit (ASIC), or another type of processor. In some examples, the memory 320 may be volatile memory (e.g., registers, cache, RAM), non-volatile memory (e.g., ROM, EEPROM, flash memory, etc.), or some combination of the two, accessible by the processor(s).

In some examples, the computerized controller 300 can be in data communication with or can be a component of the on-board display and/or user input device 124. In some examples, the computerized controller 300 can be in data communication with or can be a component of an off-system display device and/or user input device 324 (e.g., a computer or a mobile device). In some examples, the computerized controller 300 can be in data communication with a network platform and/or network data storage location 322. In some examples, the computerized controller can receive user selections and/or input via one or more of the on-board display and/or user input device 124 or the off-system display device and/or user input device 324. In some examples, the computerized controller 300 can transmit and/or receive data from the network platform and/or data storage location 322.

As discussed above, in some examples, the computerized controller 300 can be configured for communication with the X-axis actuator 114, the Y-axis actuator 116, and/or the Z-axis actuator 118. Thus, in some examples, the computerized controller 300 can control the X-axis actuator 114 for driving movement (e.g., leftward and rightward translation) of the carriage 102 along the X-axis stage 110. In some examples, the computerized controller 300 can control the Y-axis actuator 116 for driving movement (e.g., upward and downward translation) of the X-axis stage 110 along the Y-axis stages 108a, 108b, thereby driving movement (e.g., upward and downward translation) of the carriage 102. In some examples, the computerized controller 300 can control the Z-axis actuator 118 for driving movement (e.g., forward and rearward translation) of the platform 104 along the Z-axis stages 112a, 112b. In some examples, the system 100 can additionally include an auxiliary positioning system 230 (e.g., a robotic arm, a rotatable arm, an arm moveable along the Y-axis or other positioning system including an actuator and one or more position sensors) in communication with the computerized controller 300 for positioning the folder assembly 208 onto the holder assembly 184. For example, in folding and packing applications, after completion of a packing application, the auxiliary positioning system 230 can couple the folder assembly to the holder assembly 184 prior to initiating a folding application. As noted above, in some examples where the system 100 is configured for packing and folding applications, the carriage 102 can include a rotation mechanism than can be controlled via an actuator 232 in communication with the computerized controller 300.

Also discussed above, the on-carriage sensors 150 and/or the off-carriage sensors 150′ can be in communication with the computerized controller 300. In some examples, the on-carriage sensors 150 (e.g., one or more pressure sensors and/or one or more position sensors) can be coupled to the plunger 144 and can transmit signals to the computerized controller 300. In some examples, the one or more off-carriage sensors 150′ (e.g., one or more position sensors such as a rotary encoder, an optical encoder, or others type of position sensor) can be coupled to one or more of the actuators 114, 116, 118 and/or other location of the system and can transmit signals to the computerized controller 300. In some examples, the computerized controller can process signals received from the pressure sensor(s) to generate data related to a degree of compression of filler material within a pre-roll cone. In some examples, the computerized controller can process signals received from the position sensor(s) to generate data related to a position of the carriage 102/plunger 144 and/or data related to a position the platform 104. In some examples, the pressure data and/or the position data can be utilized by the computerized controller for controlling operation of the system 100.

FIGS. 9-12 illustrate exemplary computerized methods that can be executed by the computerized controller 300 for operating the packing and/or folding multi-axis positioning system 100 and/or the other exemplary packing and/or folding multi-axis positioning systems described herein. FIG. 9 shows an exemplary high-level method 400 that can be executed by the computerized controller 300 for packing and/or folding of pre-roll cones in a holder assembly via the system 100. In some examples, a high-level method of operating the system 100 includes receiving or determining a selected packing and/or folding operation (step 402), receiving or accessing compression criteria for performing the selected application (step 404), performing the packing and/or folding operation (step 406), determining that the operation is complete (step 408), and stopping the operation (step 410). FIGS. 10-12 illustrate exemplary detailed methods that can be executed by the computerized controller 300 for packing and/or folding of pre-roll cones in a holder assembly via the system 100. In some examples, the method 400 can include one or more of the steps described below with reference to FIGS. 10-12.

For example, FIG. 10 shows an exemplary method 500 that can be executed by the computerized controller 300 for packing and/or folding of pre-roll cones in a holder assembly via the system 100. At step 502, the computerized controller can receive or determine a selected application (which can also be referred to as a “selected operation”). In some examples, a user can select one of a packing application or a folding application or a packing and folding application via a user input device (e.g., a touch screen of the display device 124 or via an external user device 324) and the computerized controller can operate the system based on the user input. In some examples, the computerized controller can determine whether to perform a packing application or a folding application via e.g., determining that a packing application is complete and performing a subsequent folding application, or detecting that a holder assembly is coupled to the platform without a folder assembly and determining a packing application should be performed, or detecting that a holder assembly is coupled to the platform with a folder assembly coupled thereto and determining that a folding application should be performed. For example, the folder assembly can include an optical tag that can be identified by the sensors of the system 100 to determine whether or not the folder assembly is present. In another example, the method can include making a first downward pass of the carriage and plunger along the Y-axis at a location that is offset from the openings of the holders so that the plunger makes contact with a top surface of the assembly for determining a height of the holder assembly. The method can further include selecting a packing or a folding application based on the determined height corresponding to the holder assembly alone or the holder assembly having the folder assembly coupled thereto. In some examples, the system can be a dedicated packing system or a dedicated folding system and step 502 can include receiving a user selection to start the operation. FIGS. 13A and 13B show exemplary graphical user interfaces (GUIs) that can be utilized to receive user input/commands to start, pause, and stop the system 100 (GUI 1300), and to select a packing and/or folding application (GUI 1302).

At step 504, the computerized controller can determine or detect a height of the folder assembly coupled to the platform. As noted above, in some examples, a first folder assembly can have a larger size for receiving larger pre-roll cones and a second folder assembly can have a smaller size for receiving smaller pre-roll cones. Compression criteria may differ for the first and second folder assemblies. In some examples, the first and second holder assemblies can each include an optical marker, for example a marker on a top surface of the assembly, that can be detected by an optical sensor of the system 100 for determining whether the smaller holder assembly or the larger holder assembly is coupled to the platform. In some examples, the method can include making a first downward pass of the carriage and plunger along the Y-axis at a location that is offset from the openings of the holders so that the plunger makes contact with a top surface of the assembly for determining a height of the holder assembly. In some examples, where only a single sized holder assembly is utilized with the system 100, step 504 can be excluded.

At step 506, the computerized controller can receive or access compression criteria to be utilized in the folding and/or packing application. In some examples, compression criteria can be selected by a user via a user input device (e.g., a touch screen of the display device 124 or via an external user device 324) and the computerized controller can operate the system based on the user input. For example, compression criteria (e.g., a selected depth or a selected pressure) can be selected by a user based on one or more characteristics of the filler material (e.g., size of the particles forming the filler material, dryness of the filler material, a type of filler material, etc.), one or more characteristics of the pre-roll cone (e.g., a type of material of the pre-roll cone and/or a length of the open-end portion of the pre-roll cone), and/or user preference for a degree of compression. For example, FIG. 13C shows an exemplary GUI 1304 that can be utilized to receive user input/commands to select a first pressure, a second pressure, or a third pressure to result in a soft compression, a medium compression, or a hard compression (respectively). FIG. 13D shows an exemplary GUI 1306 that can be utilized to calibrate pressure sensor(s) and/or the system 100.

In some examples, the computerized controller can access stored compression criteria (e.g., data stored in the memory 320, an external computing device 324, and/or at the network storage location 322) and can operate the system based on the stored compression criteria. In some examples, stored compression criteria can be selected based on the determination of whether a packing application or a folding application is being performed. In some examples, stored compression criteria can be selected based on the determined height of the holder assembly.

In some examples, the compression criteria is data related to a threshold compression depth, such as, for example, data related to a specified depth of insertion of a plunger relative to a portion of the holder or folder assembly, data related to a specified depth of insertion of a plunger relative to a pre-roll cone supported in a cavity (that is, a holder) of the holder assembly, and/or data related to a specified depth of insertion of a plunger relative to filler material within a pre-roll cone supported in a cavity (that is, a holder) of the holder assembly. For example, a compression criteria related to a specified depth can be a depth of insertion of a distal tip (or another reference location) of the plunger into the holder and/or folder assemblies relative to a top surface of the assembly. In some examples, the depth of insertion relative to the top surface of the assembly can be in a range of 10 mm to 40 mm. In some examples, the depth of insertion relative to the top surface of the assembly can be 30 mm.

In some examples, the compression criteria can be data related to a threshold compression pressure. For example, a threshold pressure can be a pressure or resistance exerted on the plunger by the filler material within a pre-roll cone supported in a cavity of a holder assembly. In another example, a threshold pressure can be a pressure or resistance exerted on the plunger by folded paper at the folded-end portion of a pre-roll cone. In some examples, pressure is detected by a pressure sensor coupled to the plunger. In some examples, the threshold pressure can be in a range of 0.1 to 10 psi. In some examples, the threshold pressure can be 4 psi.

In some examples, a first compression criteria can be utilized in a first phase of a packing and/or folding operation and a second compression criteria can be utilized in a second phase of a packing and/or folding operation. For example, in a packing and folding operation (discussed further with reference to FIG. 12), a first compression criteria can be utilized during the packing phase of the operation, and a second compression criteria can be utilized during the folding phase of the operation. In another example, where the larger holder assembly is determined to be coupled to the platform, the computerized controller can implement to two-phase packing operation wherein a first portion of filler material is loaded into the cones and packed in a first phase and a second portion of filler material is loaded into the cones and packed in a second phase. A first compression criteria can be utilized in the first phase (e.g., a greater depth or pressure) and a second compression criteria can be utilized in the second phase (e.g., a lesser depth or pressure).

Per step 508, the computerized controller can control the actuators to position the carriage 102 and the platform 104 relative to one another along the X and Z-axes. For example, the computerized controller can position the carriage and/or the platform such that the plunger is positioned over a first one of the cavities in the holder assembly. In some examples, the computerized controller can determine whether the platform is in a designated initial position, and, if not, can actuate the Z-axis actuator 118 to move the platform 104 to the initial position. In some examples, the computerized controller can determine whether the carriage is in a designated initial position, and, if not, can actuate the X-axis actuator 114 to move the platform 104 to the initial position.

After relative positioning of the carriage and platform, the computerized controller 300 can cause movement of the plunger relative to the platform along the Y-axis (step 510). For example, the computerized controller can actuate the Y-axis actuator 116 to cause downward movement of the carriage 102 and the plunger 144 coupled thereto. At step 512, the computerized controller 300 can determine whether the selected compression criteria is met. In other words, the computerized controller 300 can cause movement of the plunger until the compression criteria is met (e.g., until a specified pressure is detected, or until a specified depth of the plunger is met). When it is determined that the compression criteria is met, the computerized controller can cause retraction of the carriage 102 and the plunger 144 along the Y-axis in an opposing (upward) direction (step 514). In some examples, upon retraction (e.g., completion of a compression cycle), the computerized controller 300 can add one to one or more counters (e.g., a counter for a single packing or folding application, a total daily counter, a total monthly, etc.) (step 516). For example, FIG. 13E shows a GUI 1308 displaying exemplary counters for the system 100.

As shown in the method 500, the computerized controller 300 can then determine whether a threshold count has been met (for example, a threshold number equal to the total number of holders within the holder assembly) (step 518). If the threshold count has not been met, the computerized controller 300 can return to step 508 and cause repositioning the carriage 102 and the platform 104 relative to one another. For example, the computerized controller 300 can actuate the X-axis actuator 114 to cause the carriage 102 to move along the X-axis such that the plunger 144 is positioned over an adjacent holder (cavity) of the holder assembly. In another example, the computerized controller can actuate the Z-axis actuator 118 to cause the carriage 102 to move along the Z-axis such that the plunger 144 is positioned over a cavity in an adjacent row of holders of the holder assembly. In some examples, the positioning can be based on stored mapping data or dimension data of the holder assembly (e.g., data stored in the memory 320, an external computing device 324, and/or at the network storage location 322). In some examples, the repositioning can be based on feedback information from or more of the sensors 150, 150′. Alternatively, if the threshold count is met, the computerized controller 300 can stop the packing and/or folding operation (step 520).

FIG. 11 shows another exemplary method 600 that can be executed by the computerized controller 300 for packing and/or folding of pre-roll cones in a holder assembly via the system 100. In some examples, the method 600 can include one or more of the steps of method 500, such as receiving or determining a selected application (similar to the step 502) and/or determining a height of the holder assembly (similar to the step 504). As shown as step 602, the method 600 can include receiving or accessing first compression criteria and second compression criteria. The first compression criteria can be a primary compression criteria, which can be selected by a user or the computerized controller can access stored primary compression criteria selected based on, for example, whether a packing application or a folding application is being performed and/or the determined height of the holder assembly (similar to step 506). In some examples, the primary compression criteria can be a user-selected compression criteria. The second compression criteria can be a secondary compression criteria (which can also be referred to as a “back-up compression criteria” or a “safety compression criteria”), which can be selected by a user or the computerized controller can access stored secondary compression criteria selected based on, for example, whether a packing application or a folding application is being performed and/or the determined height of the holder assembly. In some examples, the primary compression criteria can be a non-user-selected compression criteria. In some examples, based on a threshold pressure being selected as the primary compression criteria, a threshold depth can be selected as the secondary compression criteria. In some examples, based on a threshold depth being selected as the primary compression criteria, a threshold pressure can be selected as the secondary compression criteria.

At step 604, the computerized controller can control the actuators to position the carriage 102 and the platform 104 relative to one another along the X and Z-axes (similar to step 508). At step 606, the computerized controller 300 can cause movement of the plunger relative to the platform along the Y-axis (similar to step 510). At step 608, the computerized controller 300 can determine whether the selected first compression criteria is met. In other words, the computerized controller 300 can cause movement of the plunger until the primary compression criteria is met (e.g., until one of a threshold pressure or a threshold depth that has be selected as the primary compression criteria is met). When it is determined that the primary compression criteria is met, the computerized controller can cause retraction of the carriage 102 and the plunger 144 along the Y-axis in an opposing (upward) direction (step 614). In some examples, upon retraction (e.g., completion of a compression cycle), the computerized controller 300 can add one to one or more counters (e.g., a counter for a single packing or folding application, a total daily counter, a total monthly, etc.) (step 616).

If the first compression criteria is not met, the method 600 can include determining whether the selected second compression criteria is met (step 610). In other words, the computerized controller 300 can cause movement of the plunger until the secondary compression criteria is met (e.g., until one of a threshold pressure or a threshold depth that has be selected as the secondary compression criteria is met). In some examples, if the second compression criteria is met, it may be indicative of an error or failure in the system 100, such as, for example, failure of one or more sensors (e.g., failure of a pressure sensor and/or failure of a position sensor) or misalignment of the one or more components of the system 100 and/or the holder and/or folder assemblies. Accordingly, in some examples, if the second compression criteria is met a user notification (e.g., a warning) can be generated (step 612).

In some examples, the computerized controller 300 can stop operation of the system 100 based on the determination that the secondary compression criteria is met. In other examples (as shown in FIG. 11), the computerized controller 300 can continue operation of the system 100 to complete the selected application by causing retraction of the carriage 102 and the plunger 144 along the Y-axis in an opposing (upward) direction (step 614) based on meeting the second compression criteria. In some examples, upon retraction (e.g., completion of a compression cycle), the computerized controller 300 can add one to one or more counters (e.g., a counter for a single packing or folding application, a total daily counter, a total monthly, etc.) (step 616) and can reposition the carriage and/or platform (step 604). In some examples, the method 600 can include determining whether a threshold count has been met (similar to step 518), and if the threshold count is met, the computerized controller 300 can stop the packing and/or folding operation (similar to step 520). In some examples, other “stop” criteria can be utilized. For example, the computerized controller 300 can determine that packing is completed based on feedback or signals from one or more position sensors (e.g., position signals indicating that one or more of the carriage 102 or the platform 104 are in an end position).

Turning to FIG. 12, another exemplary method 700 that can be executed by the computerized controller 300 for packing and folding of pre-roll cones in a holder assembly via the system 100 is shown and described. At step 702, the computerized controller 300 can initiate a packing and folding application. Per step 704, the computerized controller 300 can then cause the system 100 to iteratively perform packing for each of the holders in a holder assembly via a packing operation. In some examples, the packing operation can be carried out via the methods 400, 500, 600 described above. At step 706, the computerized controller 300 can determine whether one or more criteria for completion of the packing operation are met. For example, the computerized controller 300 can determine that the current count is equal to a threshold count, which can, for example correspond to a number of cavities in a holder. In another example, the computerized controller 300 can determine that packing is completed based on feedback or signals from one or more position sensors (e.g., position signals indicating that one or more of the carriage 102 or the platform 104 are in an end position).

Based on the determination that the completion of packing criteria is met, the computerized controller can reposition the carriage 102 and/or the platform 104 for a folding application (step 708). In some examples, the method 700 can include additional repositioning steps. For example, an additional repositioning step can include causing, via the actuator 232, rotation of a carriage 102 including both a packer plunger 144a and a folder plunger 144b such that the folder plunger 144b is in a downward orientation (i.e., oriented toward the platform 104). In another example, an additional repositioning step can include actuating a robotic arm or other auxiliary position subsystem 230 to couple a folder assembly to the holder assembly seated on the platform.

Per step 710, the computerized controller 300 can then iteratively perform folding for each folder in a folding assembly coupled to the holder assembly via a folding operation. In some examples, the folding operation can be carried out via the methods 400, 500, 600 described above. At step 712, the computerized controller 300 can determine whether one or more criteria for completion of folding are met. For example, the computerized controller 300 can determine that the current count is equal to a threshold count, which can, for example correspond to a number of cavities in a holder. In another example, the computerized controller 300 can determine that folding is completed based on feedback or signals from one or more position sensors (e.g., position signals indicating that one or more of the carriage 102 or the platform 104 are in an end position). Based on the determination that the completion of folding criteria is met, the computerized controller can end the packing and folding operation (step 714) or can move to a new (subsequent) packing and folding operation.

It will be appreciated the methods disclosed herein are exemplary and, in other examples, can include additional or fewer steps and/or other combinations of steps.

In view of the many possible embodiments to which the principles of the disclosed invention may be applied, it should be recognized that the illustrated embodiments are only preferred examples of the invention and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.