CN101488024A - On-line quality evaluation and real-time intelligent control method for tobacco process parameter - Google Patents
On-line quality evaluation and real-time intelligent control method for tobacco process parameter Download PDFInfo
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- CN101488024A CN101488024A CNA2009100737394A CN200910073739A CN101488024A CN 101488024 A CN101488024 A CN 101488024A CN A2009100737394 A CNA2009100737394 A CN A2009100737394A CN 200910073739 A CN200910073739 A CN 200910073739A CN 101488024 A CN101488024 A CN 101488024A
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses a method for online quality evaluation and real-time intelligent control of a parameter during a process for processing tobacco. The method comprises the following steps: a parameter value between an operating parameter of raw material processing equipment and inner quality of a processed product is preset through a data management system; online acquisition is carried out in real time through a data management acquisition system; a parameter acquired by real-time online acquisition is compared with the preset parameter value through an intelligent control system of a data management layer; a valve, a draught fan and an air door power element on the equipment and parameter regulation of tobacco strip remoistening and rotating speed of a conditioning cylinder can be controlled through regulating the operating parameter of the PLC control system and a setting value of a PID open-close loop automation control parameter, thereby realizing accurate and dynamic control of raw material quality variation tendency during a tobacco online processing process and ensuring that the inner quality of the product can be controlled in an excellent and stable range in real time. The method is applicable to control of inner index in a tobacco primary processing line, a tobacco beating and redrying line, a CO2 swelling tobacco line and a rolling, connecting and packaging processing process.
Description
Technical field
The present invention relates in the tobacco processing course multiple arrangement integrated system of real assessment and decision-making PLC control system running status during central data management system.Being particularly related to can be according to process parameter real-time estimate finished product result, and can real-time intelligent adjusts the novel tobacco Working control device of control system.
Background technology
Existing traditional cigarette product processing control, tobacco moisture content, temperature after to be the device control layer with this manufacturing procedure finish are controlled target, by moisture content, the temperature parameter feedback PLC control system input signal of the result who processes the back detection being processed the back discharging, utilize the PID closed-loop control unit in the PLC programmable controller, performer such as the humidity discharging of adjusting the process equipment configuration sealed up a door, steam valve, realizes tobacco moisture content, temperature dynamic stability in control target bound scope after worker's operation finishes.Whole automatic control process is to realize by the indirect detection result's of discharging dynamic stability after the processed finished products processing is controlled; Whether the interior quality key element to the discharging of processed finished products processing back qualified, both can't detect in real time more do not implement dynamically control.Therefore, cause in the cigarette product process, the stable control of inherent quality is existed the drawback that can't overcome always, specific as follows:
1, be that the result controls owing to what implement, promptly by per pass operation process being finished the indirect detection result of back product, feed back to control system, control system is adjusted controlled variable according to the result error degree, because of equipment running status will be through one section time lag transient process, so the product that following process is come out index as a result progressively reaches stable controlled target through the time-delay of one section fluctuation oscillation damping.To make that the interior quality fluctuation of product is big through one section time-delay process of adjusting hysteresis and process is stable.
2, traditional controlled target of product processing is moisture content, temperature etc., but this is for the requirement of product inherent quality stability index, is far from being enough.These examinations " standard " parameter only is the middle monitored variable of Equipment Inspection product quality, is not the real quality index of product, more can not guarantee the stable of product inherent quality.Because: the one, the equipment operation that satisfies this controlled target is formed by various control parametric synthesis effect; The 2nd, although it is not necessarily just qualified, more stable to reach the inherent aesthetic quality of the product of this controlled target, even if the intermediate controlled parameter is improper, what may process is waste product and the testing result of classic method still can satisfy these indexs.
3, because the limitation of detection means, make product interior quality parameter such as color and luster, inhale flavor, pleasant impression, assorted gas, harmony, perfume quantity, fragrance matter, richness) can't real-time online sample detecting and control.And these inherent indexs have determined peculiar fragrance wind such as the lattice and the taste feature of cigarette product just.These indexs can not be strict, accurate in process, stably implements control, is difficult to realize the target of Chinese style cigarette.
4, it utilizes means, is most operating parameter setting of process constant on the one hand or is controlled at certain limit by adjusting performer; Be desired value to process back product (moisture content or temperature) qualified (according to the product technological standards) on the other hand, processing back product discharging detected value moisture content or the detected deviation of temperature monitor feed back to the PLC controller and carry out PID and calculate, adjust output signal, adapt specific performer (as humidity discharging air door or hot blast air door), finally make processing back product moisture content temperature dynamic be tending towards desired value.
Thereby in actual process, the process conditions that the external world provides, the temperature of environment, ambient humidity, preceding working procedure machined parameters all are variablees, by also real-time the changing of the dynamic parameter of setting constant control.These are used as the variable that " constant " simplifies control, and are very big to the variable effect of raw material inherent quality in process.
Summary of the invention
Situation in view of above-mentioned technology, the invention provides a kind of on-line quality evaluation and real-time intelligent control system of tobacco process parameter, it has in tobacco processing course can realize " on-line quality evaluation; real-time analysis and intelligent dynamically control; its raw material each procedure parameter in the processing overall process can both be controlled in the optimum parameters scope, be adjusted in the optimal parameter assembled state.
For achieving the above object, the on-line quality evaluation of tobacco process parameter provided by the invention and real-time intelligent control method comprise:
1, in data management layer intelligent evaluation control system, sets in advance the equipment operation parameter in the raw material process and process the parameter value between the product inherent quality afterwards;
2,, equipment operation parameter and processing back product inherent quality parameter are carried out online acquisition in real time by data management layer data acquisition system;
3, by data management layer intelligence control system, the equipment operation parameter of real-time online collection and the inherent quality parameter in the process are compared with the parameter value that sets in advance, judge whether to reach processing back product result's inherent quality;
4, open and close ring robotization controlled variable setting value by setting value and the PID that adjusts PLC control system operational factor, online intervention PLC control system is assigned adjustment, setting command, valve on the opertaing device, blower fan, air door executive component, and the baking silk gets damp again, parameter regulation, parameter correction and the parameter limit value of tobacco leaf moisting machine drum speed.
Therefore, in tobacco processing course, can realize " on-line quality evaluation; by gathering parameters optimization database in process parameter and the data monitoring management system; utilize and adjust the integrated control system of multiple arrangement of steering order software at many assessment result editors' intelligence in the data monitoring management system; make in its raw material each procedure parameter in the processing overall process can both be controlled at through the optimum parameters scope; according to procedure parameter actual value prediction finished product result with reference to carrying out real-time analysis and intelligent dynamically control; and adjust control system in real time, assurance is the high-quality of inherent quality as a result, stable.
In the present invention, central data management layer intelligent evaluation control system comprises: data management server is installed in intelligent process assessment Control Software, on-line quality evaluation software in the server, and is installed in parameters optimization database in the server.
In the present invention, described central data management layer data acquisition system, its acquisition controlling status signal comprises: leading portion machined parameters, environment temperature, humidity information, the key-course that equipment PLC control system is uploaded is all imported, the output state parameter, and relevant controlled variable.
In the present invention, described central data management layer data management intelligence control system comprises soft, the hardware of cover, preferentially is issued to adjustment, the execution of mechanical floor PLC control system, preferential modification, setting controlled variable, assessment result forces to revise the controlled variable of relevant device in real time.
In the present invention, described device control layer PLC programmable controller is the bottom actuating equipment of intelligence control system.
In above-mentioned, central data management layer data acquisition system is by LAN (Local Area Network) and data acquisition server networking and acquisition controlling status signal; Data acquisition server by Industrial Ethernet and last process section, environment temperature, moisture control system and the networking of equipment PLC control system, is realized uploading of tobacco processing equipment data message and assigning of central data management layer intelligent evaluation control system steering order again.
In above-mentioned, device control layer PLC programmable controller is used for the bottom of control system and carries out opertaing device.The device control layer input signal that it monitors by data and analog quantity input end receiving sensor (as temperature, flow, pressure transducer) on the one hand comprises: the status signal of supplied materials detection signal, each sensor of process equipment, processing back finished product detection signal before the processing.To carry out PID on the other hand and calculate adjustment control system output valve, change output signal and then adjust executive component such as valve opening degree by the PLC output terminal again, baking silk, moisture regain, tobacco leaf moisting machine drum speed, wind speed, air door etc.
In above-mentioned, indication assessment Control Software, on-line quality evaluation software are meant the equipment operation parameter that sets in advance in the raw material process and process the parameter value between the product inherent quality afterwards.
In a word, on-line intelligence control method of the present invention, realized that the equipment running process parameter is by the result of data management system On-line Control and the control program of PLC control system, optimizing integration of controlled variable, realize the best collocation of process equipment to the span and the parameter thereof of each controlled variable, constitute many group optimal control parameter group, real-time analysis to tobacco leaf (silk) process parameter, in time intervene in advance, revise the intelligent dynamically control of PLC control system, guarantee that stablizing of final products inherent quality is good, for each brand cigarette of producing all keeps having the peculiar fragrance style and the taste feature provides safeguard, simultaneously, make the database resource of tobacco processing industry obtain deep level development and high-level efficiency utilization.
Embodiment
The present invention is described in further detail below in conjunction with embodiment.
The real-time analysis of tobacco process parameter of the present invention and intelligent kinetic controlling equation method, its central principle are that the product inherent quality that processes of same raw material, auxiliary material, equipment is identical.The parameter of accurately controlling in real time of promptly participating in the raw material process is identical.
Its step comprises:
1, sets up the preset parameter value.In data management layer intelligent evaluation control system, set up the equipment operation parameter in the raw material process and process the parameter value between the product inherent quality afterwards, each equipment operation Parameter Optimization zone.
At primary processing line, successively drop into many batches of raw material trial productions, under the prerequisite that satisfies tobacco processing technology standard, various procedure parameters (as the detected value at the actual value of controlled variable, each reference mark and process conditions etc.) are carried out debugging in may span.Each batch is again respectively in planned working procedure parameter and the process conditions adjusted several times of different time sections, the quality change procedure of test objective material between each procedure technology point followed comprehensive record, sampling, test, until absorbing the relevant data (as aesthetic quality's assessment of data such as industrial analysis achievement data, physical and chemical index data, the indexs of smokeing panel test) of final products inherent quality, by coded combination, fill in a form, and its all data are classified, statistical analysis table edits out the intelligent quality assessment software.
Set up operational factor and product inherent quality numerical relationship model.By brand, control section, operation, batch, element such as time, carry out corresponding one by one classification, editor analyzes.Analyze and research funtcional relationship between each controlling element, process conditions and aesthetic quality (smokeing panel test), the test findings data such as (as physical and chemical indexs) is drawn online evaluation control module parameters relationship curve map, trend map, and finding out it influences trend.Online evaluation controlling element and concern as a result on the basis of experimental study that the equipment operation parameter of each road manufacturing procedure is to each brand, each craft quality standard index.Particularly find out the mathematics trend of the variation relation of relevant information, realize the quantification of related data.
Finish parameter optimization, on the basis of online evaluation controlling element and product inherent quality result relation, the equipment operation parameter of each road manufacturing procedure, according to each brand, each craft quality standard index, by debugging and industrial analysis, controlled parameters optimal value range, acceptability limit value, overproof ultimate value.
Relevant with the product inherent quality the most at last parameter, mathematical relation typing parameters optimization database.
2, operational parameter data collection.
Central data management system by data acquisition system (DAS) to executive component, sensing detection element state parameter, to the leading portion machined parameters information that influences the product internal soundness, to environment temperature in the process and humidity information, and to the key-course that this machine equipment PLC control system is uploaded is all imported, output status signal etc. influences quality armamentarium operational factor, whole process point detected parameters, information are carried out on-line sampling in real time, and be uploaded to the information management layer database.
Particularly-the integrated result of all information of above-mentioned acquisition system collection just determined the inherent quality parameter of processed finished products.
3, real-time online quality evaluation.
Data management system is passed through real-time one-parameter online evaluation, the comprehensive online evaluation of single operation operational factor, the comprehensive online evaluation of whole process section operational factor in the tobacco processing course.By various device, technological parameter to monitoring, relatively after the parameters optimization, dope processing back product as a result inherent quality promptly comprise the aesthetic quality, the index of smokeing panel test, physical and chemical index, the real-time online quality evaluation.This step comprises following content:
(1) in data management system, uses online evaluation special software bag;
(2) with " assessment with control criterion data " of presetting in the database and online real time collecting to data such as equipment fortune parameter, water percentage, temperature carry out real-time analysis;
(3) data of gathering are carried out intelligently filters, reject the disturbance variable effect;
(4) active data is analyzed, judged each (group) operational factor and relation best, qualified parameter region, calculate the deviation degree of depth of each on-line operation parameter;
(5) generating the real-time assessment result automatically---the procedure parameter that dopes current operation may cause the variation of the inherent quality that product occurs;
(6) will intervene object information is the product inherent quality deviation factor content and the deviation degree of depth, and prompting operation person notes.Be issued to supervisory layers, and on the CSRC picture, show, remind the monitoring operator on duty.
4, on-line intelligenceization is dynamically controlled.
The conclusion that data management system draws according to online evaluation, analysis in conjunction with process equipment operating condition (the parameter error degree of depth), Intelligence Selection is called PLC control system parameters optimization, the setting value and the PID that adjust PLC control system operational factor open and close ring robotization controlled variable setting value, the parameter regulation of intervening the PLC control system, data management system force to assign the correction and the parameter limit value of controlled variable to the PLC control system.
Particularly the software of PLC control system, hardware capability all will with the central data management system seamless link, when carrying out the mechanical floor programmed control, the preferential execution assessed adjustment, the setting command that Control Software is assigned, valve on the opertaing device, blower fan, air door executive component, and dry by the fire silk, moisture regain, tobacco leaf moisting machine drum speed, realize dynamically principal and subordinate's cooperation of control of online intellectuality.
During normal the operation, the operation Parameter On-line control result of equipment is the optimal zone thresholding.The canonical reference value that the PLC control system is set according to operating personnel and professional technician's associated rights is carried out PID and is opened and closed ring control automatically.
When on-line control system predicts some equipment operation parameter variation tendency will cause the product inherent quality overproof the time, the preferential automatically acceptance of PLC control system is also carried out the control system parameter modification adjustment instruction that data management system is assigned in real time, at this moment adjustment parameter is through determining of optimizing, selecting parameter and method is the unique of intelligence, and the final finished quality results is to realize that online intellectuality dynamically controls.
Claims (5)
1, a kind of on-line quality evaluation of tobacco process parameter and real-time intelligent control method is characterized in that may further comprise the steps:
(1), sets in advance the equipment operation parameter in the raw material process and process the parameter value between the product inherent quality afterwards by data management layer intelligent evaluation control system;
(2), equipment operation parameter and processing back product inherent quality parameter are carried out online acquisition in real time by data management layer data acquisition system;
(3) by data management layer intelligence control system, the equipment operation parameter and the inherent quality parameter in the process of real-time online collection are compared with the parameter value that sets in advance, and forecast assessment processing back product is aesthetic quality, the index of smokeing panel test, the physical and chemical index of inherence as a result;
(4) open and close ring robotization controlled variable setting value by setting value and the PID that adjusts PLC control system operational factor, online intervention PLC control system is assigned adjustment, setting command, valve on the opertaing device, blower fan, air door executive component, and the baking silk gets damp again, parameter regulation, parameter correction and the parameter limit value of tobacco leaf moisting machine drum speed.
2, press the on-line quality evaluation and the real-time intelligent control method of the described a kind of tobacco process parameter of claim 1, it is characterized in that, described central data management layer intelligent evaluation control system comprises: data management server, with the intelligent process assessment Control Software, the on-line quality evaluation software that are installed in the server, and be installed in parameters optimization database in the server.
3, press the on-line quality evaluation and the real-time intelligent control method of the described a kind of tobacco process parameter of claim 1, it is characterized in that, described central data management layer data acquisition system, its acquisition controlling status signal comprises: the leading portion machined parameters, environment temperature, humidity information, the key-course that equipment PLC control system is uploaded is all imported, the output state parameter, and relevant controlled variable.
4, the on-line quality evaluation of the described a kind of tobacco process parameter of claim 1 and real-time intelligent control method, it is characterized in that, described central data management layer data management intelligence control system, comprise soft, the hardware of cover, preferentially be issued to adjustment, the execution of mechanical floor PLC control system, preferential modification, setting controlled variable, assessment result forces to revise the controlled variable of relevant device in real time.
5, the on-line quality evaluation of the described a kind of tobacco process parameter of claim 1 and real-time intelligent control method is characterized in that, described device control layer PLC programmable controller is the bottom actuating equipment of intelligence control system.
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| CN101763109A (en) * | 2010-03-05 | 2010-06-30 | 湖南中烟工业有限责任公司 | Integrated system for controlling production processes of coiling, connecting and wrapping cigarettes |
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