BR102018001611A2 - stem and leaf analysis system applied in the smoke production process - Google Patents

Abstract

The stalk and leaf analysis system applied to the smoke production process of the present invention comprises a stalk and leaf analysis system applied to the smoke production process comprising a system using image processing and learning algorithms. of a machine to continuously estimate the particle size and particle percentage of the particles separated in one stage, this system being coupled to the waterfall or in the wind tunnel itself. The vision system performs image analysis to ignore portions that correspond to the background of the scene and account for areas corresponding to blade and stem particles of different sizes. The ratio between areas is used as a reference for the estimation of grain size and percentage of stalk. Thus, the system developed and claimed in the present invention seeks to minimize the occurrence of separate stalk particles as if they were blade and to maximize the size of the blade particles automatically without the need for manual separation and control by the operator.

Description

SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS

FIELD OF THE INVENTION [01] The present invention describes a stalk and leaf analysis system applied in the smoke production process. More specifically, it comprises a system that uses image processing and machine learning algorithms to continuously estimate the particle size and percentage of particles separated in one stage, this system being coupled to the waterfall or in the wind tunnel itself. The vision system performs image analysis to ignore the plots that correspond to the background of the scene and to account for areas corresponding to blade and stem particles of different sizes. The proportion between the areas is used as a reference for the estimation of granulometry and percentage of stalk.

[02] In addition, the visual aspect patterns of the particles are used so that the system performs the classification of each portion of the image as a stalk or blade particle of a certain size, these standards being defined during the calibration step of the system.

[03] Thus, the system developed and claimed in the present invention, seeks to minimize the occurrence of separate stem particles as if they were a blade and to maximize the size of the blade particles, in an automated manner without the need to perform separation and manual control by operator.

BACKGROUND OF THE INVENTION [04] Part of the smoke production process consists of breaking up the tobacco leaves and segregating blade particles from the stem particles

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2/13 (Green Leaf Threshing), as they should receive different treatment. The blade / stem separation lines are formed by multiple waterfalls, where the segregated particles pass in each separation stage.

[05] Currently, the regulation of the separators depends on the operator's "feeling", which ends up generating inaccuracy in the separation, due to the flow of products being too high for the operator to be able to visually evaluate the characteristics of the separation in each waterfall.

[06] However, to minimize these flaws and increase the separation precision, the tobacco companies use the mechanical method to measure granulometry and stem percentage, where this method performs a measurement every 30 minutes at the general outlet of the machine (which accumulates output from more than more than 10 stages of the line). However, the method used presents several drawbacks to the production process due to the delay in the analysis (the samples need to be taken, taken to the laboratory, passed through the sieves, etc.), the samples collected are destroyed in the process, present difficulty in identifying which of the stages is with separation problem and the fact that it needs human intervention to perform this operation.

[07] Therefore, it is necessary to have a system that allows individual (per stage) and continuous (minute by minute) analysis, so that the corrective action of the separation regulation is faster and more effective, without the need for intervention operator.

[08] In research carried out in the state of the art, we identified several documents claiming conference systems and

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3/13 analysis of the stems and leaves in the smoke production process in an automated way, where we can quote the following documents:

[09] CN202525064 describes a tobacco leaf stem detection classification device comprising the perspective detection device which is disposed under a tobacco leaf outlet end of the tobacco leaf dilution device and the computer of industrial host control that is connected to the perspective detection device. The sampling device can take a threshing sample from the threshing and spin production line online. The perspective detection device can extract the characteristics of the tobacco leaf blade and the shape, as well as the size of the stem, and the host's industrial control computer can be used to calculate the leaf stem ratio according to characteristic acquired parameters.

[010] This document identified in the state of the art describes a tobacco leaf stem screening system that can be used to acquire the tobacco leaf stem image characteristics based on the combined light perspective. However, this system has several drawbacks due to the amount of components necessary to perform the reading, in order to make a complex system difficult to apply in the smoke production processes.

[011] CN102339385 describes a method of detecting visual recognition based on combined light from the stem of the tobacco leaves. The method comprises the following steps: diluting and spreading tobacco leaves by vibrating plates, star-shaped rollers and a high-speed belt conveyor; forming

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4/13 perspective images of tobacco leaves and stems based on the perspective of parallel combined light; extracting image characteristics to recognize tobacco stems and leaves; and calculating the proportions of the stem in the leaves, namely, the calculation of the volumes of the tobacco stems and the leaves according to the shape and size characteristics obtained from the tobacco stems and the leaves, and combining the measured density of the tobacco stems and the leaves to calculate the masses of the tobacco stems and the leaves, thus obtaining the stem indexes on the leaves.

[012] This document identified in the prior art describes a visual recognition detection system based on combined light from the stem of the tobacco leaves. However, this system has several drawbacks due to the amount of components necessary to perform the reading, in order to make a complex system difficult to apply in the smoke production processes.

[013] CN106343607 describes a method and device for consistency discrimination for tobacco leaves. A camera acquires tobacco leaf images, an image processing system performs characteristic cluster analysis in various color spaces of the images according to the classification characteristics of the tobacco leaves. A certain proportion of tobacco leaves with the same characteristics are discriminated against as current grade tobacco leaves, tobacco leaves with different characteristics from current grade tobacco leaves are discriminated against.

[014] This document identified in the state of the art describes a method and device of consistency discrimination for tobacco leaves. However, this system has several drawbacks

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5/13 due to the amount of components necessary to perform the reading, in order to make a complex system difficult to apply in the smoke production processes.

[015] Therefore, the present holder has developed a system for analyzing the estimate of granulometry and stem percentage that allows individual (per stage) and continuous (minute by minute) analysis, so that the corrective action of the separation regulation is faster and more effective when compared to state of the art documents. [016] Thus, it is the object of the present invention, a stalk and leaf analysis system applied in the smoke production process that comprises a system that uses image processing and machine learning algorithms to continuously estimate the particle size and the percentage of stalk of particles separated in one stage, this system being coupled to the waterfall or in the wind tunnel itself. The vision system performs image analysis to ignore the plots that correspond to the background of the scene and to account for areas corresponding to blade and stem particles of different sizes. The proportion between the areas is used as a reference for the estimation of granulometry and percentage of stalk.

SUMMARY OF THE INVENTION [017] It is characteristic of the privilege of invention that a stalk and leaf analysis system applied in the smoke production process provides a system that continuously estimates the particle size and the stalk percentage of the particles separated in one stage.

[018] It is characteristic of the privilege of invention to have a stalk and leaf analysis system applied in the smoke production process

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6/13 that provides a system that performs the analysis of particles that pass through the wind tunnel and the waterfall.

[019] It is characteristic of the privilege of invention to have a stalk and leaf analysis system applied in the smoke production process that provides the use of a goalkeeper to fix the camera and illuminators, which will be installed in front of the waterfall.

[020] It is characteristic of the privilege of invention that a stalk and leaf analysis system applied in the smoke production process provides the fixation of the electrical panel near the waterfall, serving as a point of interconnection between the devices.

[021] The characteristic of the privilege of invention is a stalk and leaf analysis system applied in the smoke production process that provides a place to accommodate computers and accessories with protection against dirt.

[022] The characteristic of the privilege of invention is a system of analysis of stems and leaves applied in the smoke production process that provides a way of fixing the camera next to the goaltower that prevents vibrations.

[023] It is characteristic of the privilege of invention that a stalk and leaf analysis system applied in the smoke production process provides the ramp with an opaque and dark color (without marks) and restrictions.

[024] The characteristic of the privilege of invention is a system of analysis of stems and leaves applied in the smoke production process that provides that the camera must be at a distance of 450mm from the ramp and forming a right angle in relation to the surface of the ramp.

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7/13 [025] It is characteristic of the privilege of invention that a stalk and leaf analysis system applied in the smoke production process provides a system that uses image processing and machine learning algorithms to continuously estimate the particle size and the stalk percentage of the particles separated in one stage.

[026] The characteristic of the privilege of invention is a system of analysis of stems and leaves applied in the smoke production process that provides patterns of visual aspect of the particles that are used so that the system performs the classification of each portion of the image as a stalk or blade particle of a certain size.

BRIEF DESCRIPTION OF THE FIGURES [027] Figure 1 shows the diagram of the electrical and logical connections for the devices involved in the vision system.

[028] Figure 2 shows the general representation of the structure and arrangement of equipment at the waterfall of the production process.

[029] Figure 3 shows the side view of the adjustment and distance from the camera next to the waterfall ramp.

[030] Figure 4 shows the top view detailing the illuminators arranged next to the camera.

[031] Figure 5 shows the diagram of the information flow between the components of the solution.

[032] Figure 6 shows the diagram of the sequence of actions and agents involved when the system starts the inspection.

[033] Figure 7 shows the diagram of the sequence of actions and agents involved when the system stops the inspection.

[034] Figure 8 presents the interface of the inspection screen analyzed by the operator next to the monitor.

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8/13 [035] Figure 9 shows the interface of the historical query screen analyzed by the operator next to the monitor.

DESCRIPTION OF THE INVENTION [036] The stalk and leaf analysis system applied in the smoke production process, object of the present invention, comprises a system provided with a fixation structure (goal) (10) that receives a camera (11) and illuminators (12) installed in one or more waterfalls of the particle separator, these components being interconnected to an electrical panel (20) provided with a PLC (21), switch (22) and power supplies (23).

[037] The information obtained is managed through a computer (30) provided with a monitor (31) and accessories (keyboard and mouse), arranged in a specific location with protection against dirt, this location being close to the electrical panel (20) and easy access to the operator.

[038] The waterfall in the separation process is equipped with a mat (40) that directs the product to a chimney (41) equipped with a ramp (42), directing the product to a second mat (43) that gives continuity to the production process .

[039] Thus, for the system to read and analyze the stems and leaves, the fixation structure (10) is arranged so that the camera (11) and the illuminators (12) are positioned towards the ramp (42) , allowing the system to read the particles passing through the waterfall.

[040] For the system to perform the perfect reading and analysis of the products, the components must meet some requirements, which are: [041] The fixing structure (goal) (10) of the camera (11) and illuminators (12) must be vibration-free for operation

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9/13 of the vision system, as very intense vibrations can cause the cameras to sway (11), generating incorrect results;

[042] The arrangement between the ramp (42) and the chimney (41) must be aligned so that the leaves are all sliding down the ramp (42) when they pass through the camera's view point (11), ensuring that all the leaves are with the open face and the same distance from the camera (11);

[043] There is no explicit restriction on the angle of the ramp (42) of fall, being desirable the highest possible speed to minimize overlap of particles;

[044] For the sake of coloring the background of the image to be captured by the camera (11), the ramp (42) must be opaque, dark and constant (without marks);

[045] The waterfall system is equipped with adjustments that make it possible to distribute the fall of particles evenly across the width of the ramp (42) to minimize the overlap of particles and guarantee the sample representativeness of the system's viewing area;

[046] The system equipment must operate at temperatures below 45 ° C;

[047] The camera (11) is equipped with a protection box (111) equipped with a compressed air system (low pressure) that generates a positive pressure and prevents the entry of dirt and dust;

[048] The camera (11) must be at a distance of 450mm from the ramp (42) (from the tip of the lens), forming a right angle in relation to the surface of the ramp (42). The support structure (10) of the camera (11) must allow this configuration (angle and height). However, variations in the angle can affect the result of image processing, as described in figure 3;

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10/13 [049] The illuminators (12) must be attached to the fixing structure (10), one on each side of the camera housing (11), as described in figure 4.

[050] The system is made up of high performance microprocessed equipment and may suffer interference from power equipment, such as engines. In order for the devices to behave as expected, some requirements must be met: [051] The electrical network will need to be dedicated (isolated from the motors) and stabilized for the electrical panel (20). If it is not possible to obtain a stabilized network independent of motors and other electrical disturbance generators, it is recommended to use an online UPS before the electrical panel (20) to ensure electrical stability in place;

[052] All devices that have a grounding point (either in the housing or by their own wiring) must be connected to an equalized ground point;

[053] Electrical cabling must be installed for all equipment.

[054] The network structure designed for the system is shown in the connection diagram.

[055] In the vision system, the PLC (21) determines the sampling rate through the generation of digital pulses. Each pulse triggers image acquisition from the camera (11) synchronously with flashes from the illuminators (12), so each acquired image is sent to the vision system, which processes and calculates the information for measurement.

[056] The measurements are periodically displayed on the monitor (31) and recorded in the database for later consultation. Photos are also displayed on the monitor (31) and, if enabled, recorded for

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11/13 later use. The vision system is still responsible for configuring / activating the PLC (21) and camera (11), which occurs when the capture cycle is started or ended. Figure 5 presents in detail the diagram of the information flow between the components. [057] The vision system will operate independently from the automation of the separation line. In other words, no entry or exit is foreseen between the PLC of the vision system and the PLC of the line. The frequency of image acquisition is configurable and will be defined during the implementation of the system according to the processing time of each image.

[058] The range of calculation of estimates (granulometry and stem percentage) is configurable and will be defined during the implementation of the system according to the sampling necessary to have robust statistical measurements. When enabled, the system will allow you to record acquired images. These can be used for system calibration.

[059] The system will notify you when there is little free disk space, but it will be the responsibility of maintenance to control the free disk space (remove or transfer images for backup).

[060] When the analysis system is started for inspection, the camera (11) is configured and activated together with the PLC (21) in order to start the image capture cycles. The capture cycle (with x interval) is performed through the PLC (21) that activates the camera (11) and illuminators (12) directing and processing the information in order to constantly update the statistics generated on the monitor (31) and on the database. system data, as shown in figure 6.

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12/13 [061] When the analysis system is turned off, the camera (11) and illuminators (12) will be deactivated, by sending the command to interrupt the cycles to the PLC (21), which performs the stop of the inspection, as shown in figure 7.

[062] The objective of the system interface is to offer an easy-to-interpret control, both for monitoring measurements and for consulting previous statistics. Thus, figure 8 represents the view of the system inspection screen and figure 9 represents the view of the historical consultation screen.

[063] Optionally, the vision system equipped with a fixation structure (goaltender) (10) that receives a camera (11) and illuminators (12) can be installed in one or more waterfalls of the particle separator, so that the CLP ( 21) will manage all the information generated.

[064] Optionally, the vision system equipped with a fixation structure (goal keeper) (10) that receives a camera (11) and illuminators (12) can be installed next to the wind tunnel to perform the measurements.

[065] Optionally, the vision system equipped with a fixation structure (goalkeeper) (10) that receives a camera (11) and illuminators (12) can be attached to the waterfall (when the particles have already left the separator's wind tunnel and they are dumped in the secondary line destined for blade particles already segregated) and / or in the wind tunnel itself (when particles pass with greater speed, more widely spaced).

[066] Thus, it is the object of the present invention, a stalk and leaf analysis system applied in the smoke production process that comprises a system that uses processing algorithms

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13/13 of images and machine learning to continuously estimate the particle size and percentage of the particles separated in one stage, this system being coupled to the waterfall or in the wind tunnel itself. The vision system performs image analysis to ignore the plots that correspond to the background of the scene and to account for areas corresponding to blade and stem particles of different sizes. The proportion between the areas is used as a reference for the estimation of granulometry and percentage of stalk.

Claims (15)

1. SACK AND SHEET ANALYSIS SYSTEM APPLIED TO THE SMOKE PRODUCTION PROCESS that describes a waterfall arranged in the separation process that is provided with a mat (40) that directs the product to a chimney (41) provided with a ramp (42) which directs the product to a second belt (43), characterized by comprising a system equipped with a fixation structure (goal) (10) that receives a camera (11) and illuminators (12) installed in one or more waterfalls of the water separator. particles, these components being connected to an electrical panel (20) equipped with a PLC (21), switch (22) and power supplies (23), and the information obtained is managed through a computer (30) provided with a monitor (31) and accessories (keyboard and mouse), arranged in a specific place with protection against dirt; the fixing structure (10) is arranged so that the camera (11) and the illuminators (12) are positioned towards the ramp (42) so that these components have the following requirements: a) the fixing structure (goal) (10) of the camera (11) and illuminators (12) must be free of vibration for the vision system to function; b) the arrangement between the ramp (42) and the chimney (41) must be aligned so that the leaves are all sliding down the ramp (42) when they pass through the camera's view point (11), ensuring that all the leaves have the face open and with the same distance from the camera (11); Petition 870180006641, of 25/01/2018, p. 17/33 2/6 c) there is no explicit restriction on the angle of the fall ramp (42), with the highest possible speed being desirable to minimize particle overlap; d) for the sake of coloring the background of the image to be captured by the camera (11), the ramp (42) must be opaque, dark and constant (without marks); e) the waterfall system is equipped with adjustments that make it possible to distribute the fall of particles evenly across the width of the ramp (42) to minimize the overlap of particles and guarantee the sample representativeness of the system's viewing area; f) the system's equipment must operate at temperatures below 45 ° C; g) the camera (11) is equipped with a protection box (111) equipped with a compressed air system (low pressure) that generates a positive pressure and prevents the entry of dirt and dust; h) the camera (11) must be at a distance between 350 to 450mm from the ramp (42) (from the lens tip), forming a right angle in relation to the ramp surface (42) so that the support structure (10) the camera (11) must allow this configuration (angle and height); i) the illuminators (12) must be attached to the fixing structure (10), one on each side of the camera housing (11). 2. SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the electrical network is dedicated (isolated from the motors) and stabilized for the electrical panel (20); if it is not possible to obtain a stabilized network independent of engines Petition 870180006641, of 25/01/2018, p. 18/33 3/6 and other electrical disturbance generators, online UPS is used before the electrical panel (20) to ensure electrical stability in place; 3. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized by all devices that have a grounding point (either in the housing or by their own wiring) must be connected to a equalized earth; 4. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the CLP (21) vision system determines the sampling rate through the generation of digital pulses, where each pulse triggers image acquisition from the camera (11) synchronously with flashes from the illuminators (12), so each acquired image is sent to the vision system, which processes and calculates the information for measurement. 5. SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the measurements are periodically presented on the monitor (31) and recorded in the database for later consultation; photos are also displayed on the monitor (31) and, if enabled, recorded for later use. 6. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the vision system is responsible for configuring / activating the PLC (21) and camera (11), which occurs when the capture cycle is started or ended. Petition 870180006641, of 25/01/2018, p. 19/33 4/6 7. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the vision system will operate independently of the automation of the separation line, with no entrances or exits between CLP of the vision system and PLC of the line, where the frequency of image acquisition is configurable and will be defined during the implementation of the system according to the processing time of each image. 8. SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the range of calculation of estimates (grain size and stem percentage) is configurable and will be defined during the implementation of the According to the sampling necessary to have robust statistical measurements, when enabled, the system will allow recording acquired images so that they will be used for system calibration. 9. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized by the system notifying when there is little free disk space, but it will be the responsibility of maintenance to control the free disk space ( remove or transfer images for backup). 10. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized by the fact that when the analysis system is started for inspection, the camera (11) is configured and activated together with the PLC (21 ) in order to start the capture cycles Petition 870180006641, of 25/01/2018, p. 20/33 5/6 of the images, the capture cycle (with x interval) is performed through the PLC (21) that activates the camera (11) and illuminators (12) directing and processing the information in order to constantly update the statistics generated on the monitor ( 31) and in the system database. 11. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that when the analysis system is turned off, the camera (11) and illuminators (12) will be deactivated, by sending the command to interrupt the cycles for the PLC (21), which stops the inspection system. 12. SACK AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized by the objective of the system interface to offer an easy-to-interpret control, both for monitoring the measurements and for consulting the measurements. previous statistics. 13. SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the vision system is optionally provided with a fixation structure (goal) (10) that receives a camera (11 ) and illuminators (12) that can be installed in one or more waterfalls of the particle separator, so that PLC (21) will manage all the information generated. 14. TALOS AND SHEETS ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized by optionally, the Petition 870180006641, of 01/25/2018, p. 21/33 6/6 vision be equipped with a fixation structure (goalkeeper) (10) that receives a camera (11) and illuminators (12) that can be installed next to the wind tunnel to carry out the measurements. 15. SHAFT AND SHEET ANALYSIS SYSTEM APPLIED IN THE SMOKE PRODUCTION PROCESS, according to claim 1, characterized in that the vision system is optionally provided with a fixation structure (goal) (10) that receives a camera (11 ) and illuminators (12) that can be attached to the waterfall (when the particles have already left the separator's wind tunnel and are dumped in the secondary line destined for already segregated blade particles) and / or in the wind tunnel itself (when particles pass faster, more widely spaced).