CN102919995B - Method and system for quality control and diagnostic analysis in tobacco primary machining process - Google Patents
Method and system for quality control and diagnostic analysis in tobacco primary machining process Download PDFInfo
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Abstract
The invention provides a method and system for quality control and diagnostic analysis in a tobacco primary machining process. The system comprises a parameter acquiring module for acquiring processing parameters and device parameters of a main device, a device performance analysis module for analyzing processing performance of the main device, a closed-loop return circuit analysis module for analyzing a closed-loop return circuit of the main device, an external input analysis module for analyzing external input capable of influencing main device performance, a contrast analysis module for performing contrastive analysis on input or output of at least two identical main devices and a scoring module for scoring the main devices and tobacco primary machining batches in a workshop section. The method and system can rapidly position reasons of devices, processes and the like causing abnormal quality, enables device maintainers to know running states of the devices clearly, and can evaluate influencing factors of device capacity, process index completion, incoming materials, process matching and the like all-around.
Description
Technical field
The present invention relates to the control appliance technical field in tobacco production process, particularly relate to quality control and diagnostic analysis method and system in a kind of tobacco cutting process.
Background technology
Cigarette manufacturing process is mainly comprised of throwing and cigarette bag two parts, wherein technology for making tobacco threds process operation is maximum, technological process is the longest, and throwing processing is a complicated physical and chemical changes process, the variation of moisture content and temperature and reinforced (perfume (or spice)) ratio and all kinds ofly mix the variation of joining product ratio in its production process, all can affect its aesthetic quality.In quality management in the past, often adopt sampling inspection, weigh quality and the process crudy of entire block by the assay of procedure quality characteristic value, its limitation is apparent.And SPC(Statistical Process Control, statistical Process Control) technology is emphasized go out to send evaluation quality and deal with problems from whole process, system, this also controls parameter and changes, by output control, to process control, changed by controlling mark sense with new edition < < cigarette process standard > > emphasizes, to improve machining accuracy thought, is consistent.
Tobacco cutting belongs to process industry, from situation in external industry, can find out, industrial flow automation at present, from the control to single production equipment, single production procedure, develops into the advanced person of whole production line is controlled and optimal control.The multiple machinery of tobacco equipment is abnormal, and equipment used on tobacco cutting production line, can be divided into following a few class according to its design feature:
1, cylinder kind equipment: as drum-type damping machine, charger, Perfuming machine, Rotary drier etc., mainly formed by frame, cylinder, transmission system, pipe-line system, hot-air system, electrical system etc.
2, vibration cell body kind equipment: as jigging conveyer (having plate-spring type, rocker-type), tunnel reversion machine, channel type cut tobacco drying machine etc.The mass transport of this kind equipment is partly eccentric ratio balanced type jigging conveyer, frame, cell body, spring plank (or rocking bar), balanced body, eccentric rod gear and motor, consists of.
3, conveyer belt kind equipment: as ribbon conveyer, elevator, feeding machine, reciprocal belt type material distributing machine, storage cabinet etc.The mass transport part of this kind equipment consists of drive unit, tensioning apparatus, clearing apparatus, belt idler and frame.
5, material pneumatic conveying, dust catch system and equipment exhauster system: material pneumatic conveying dedusting, equipment exhauster system are the indispensable parts of the normal operation of primary processing line.
By above explanation, can be found out, tobacco cutting technical process processing apparatus is very many, and the SPC system that tobacco business is used at present is only controlled production process and result, cause plant maintenance personnel can not have a clear understanding of in time the operation conditions of each equipment, cannot coaching device attendant maintain and service equipment, the tobacco quality that also cannot cause a variety of causes fluctuation is carried out quick diagnosis to get rid of in time extremely.In addition, in existing SPC system, adopt the form of CPK to the judgement of processing quality index and examination, because CPK examination can only be accomplished the judgement of result, in the process of throwing, more play the effect of examination, for the judge of the quality of production and capacity of equipment, there is no the evaluation of overall process, for equipment, process matching etc., do not contain, so yet cannot all sidedly processing quality index be judged and be examined.
Summary of the invention
The shortcoming of prior art in view of the above, the object of the present invention is to provide quality control and diagnostic analysis method and system in a kind of tobacco cutting process, for solving tobacco quality fluctuation that prior art cannot cause a variety of causes, to carry out quick diagnosis abnormal to get rid of in time, the problem that also cannot all sidedly processing quality index be judged and be examined simultaneously.
For achieving the above object and other relevant objects, the invention provides quality control and diagnostic analysis method in a kind of tobacco cutting process, comprise the steps:
S1, identification main process equipment processing quality index aborning, and be main process equipment configuration device parameter and the technological parameter relevant to described processing quality index;
S2 gathers technological parameter and the device parameter of main process equipment in tobacco cutting process, the technological parameter of collection and device parameter is stored in historical data base, and realizes list by relational database;
S3, carries out equipment and process analysis according to technological parameter and the device parameter of the main process equipment gathering to main process equipment; Described equipment and process analysis comprises: S3-1, the apparatus and process performance evaluation that the processing performance of main process equipment is carried out; S3-2, the main process equipment closed loop analysis of carrying out according to the input value of main process equipment, actual value and output valve; S3-3, the outside input analysis of carrying out affecting the outside input of main process equipment performance; Described outside input comprises process matching and supplied materials; S3-4, the equipment comparative analysis of the same race that inputing or outputing of at least two identical main process equipments is analyzed, by the big or small performance that judges main process equipment of the difference inputing or outputing of main process equipment of the same race;
S4, analyzes and equipment comparative analysis of the same race batch is carried out equipment and process marking to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.
Alternatively, in step S3-1, described apparatus and process performance evaluation comprises the steps:
A: to closed loop kind equipment
S3-1-a1, sets up a right angle two-dimensional coordinate system, and X-axis is defined as to input, Y-axis is defined as to output, is input as the device parameter of main process equipment, is output as the processing quality index of the outlet of main process equipment; In this right angle two-dimensional coordinate system, divide at least one abnormal area and at least one non-abnormal area, and corresponding each abnormal area is stored corresponding non-conformance description and abnormal solution;
S3-1-a2, obtains output input ratio according to the ratio of output valve and input value;
S3-1-a3, according to output input ratio falling into a little in right angle two-dimensional coordinate system, judge whether main process equipment completes corresponding processing quality index with normal state: if falling into o'clock at an abnormal area in batches, judgement main process equipment does not complete corresponding processing quality index with normal state, main process equipment exists abnormal, according to the abnormal cause and the analysis solution that are preset in internal system, and check relevant solution that should abnormal area; If fall into o'clock at a non-abnormal area, judgement main process equipment completes corresponding processing quality index with the state of presetting, and main process equipment does not exist extremely, with normal state, produces;
B: divided ring kind equipment
S3-1-b1, obtains the output valve of main process equipment and affects all enter factors of this output valve;
S3-1-b2, according to pipe tobacco batch total quantity and have the ratio of the pipe tobacco batch quantity of fluctuation synchronously to calculate the contributive rate of each enter factor to output valve, sorts to all enter factors by the size of each contributive rate;
S3-1-b3, occurs when abnormal at main process equipment, and the contributive rate sequence according to enter factor, judges abnormal reason, provides solution that should be abnormal simultaneously.
Alternatively, in step S3-2, the analysis of described main process equipment closed loop comprises the steps:
S3-2-1, obtains setting value curve, actual value curve and output valve curve according to the setting value of obtaining, actual value and output valve;
S3-2-2, obtain some decomposition variable and macros of the described setting value of impact, when setting value curve and actual value curve over default deviation range, according to some decomposition variable and macros of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value;
S3-2-3, according to the actual value of closed loop and output valve, sets up right angle two-dimensional coordinate system, divides an abnormal area and a non-abnormal area in this right angle two-dimensional coordinate system, and abnormal solution corresponding to corresponding abnormal area storage.
Alternatively, the analysis of described main process equipment closed loop also comprises according to the method for the sensor servicing manual of the xml form that can check online and checks abnormal solution.
Alternatively, in step S4, the marking of described equipment and process comprises: according to the result of apparatus and process performance evaluation to the main process equipment in workshop section and tobacco cutting, batch carry out first order marking; According to the result of main process equipment closed loop analysis to the main process equipment in workshop section and tobacco cutting, batch carry out second level marking; The result of analyzing according to outside input batch is carried out third level marking to the main process equipment in workshop section and tobacco cutting; According to the result of equipment comparative analysis of the same race to the main process equipment in workshop section and tobacco cutting, batch carry out fourth stage marking; After phase weighting that CPK and the first order are given a mark by adopting, give a mark in the second level, the third level is given a mark and the fourth stage is given a mark, calculating the mode of total points judges and examines the processing quality index in the quality and performance of main process equipment and tobacco cutting.
The present invention also provides quality control and the diagnostic analysis system in a kind of tobacco cutting process, comprising: parameter acquisition module gathers technological parameter and the device parameter of main process equipment in tobacco cutting process; Equipment performance analysis module, is connected with parameter acquisition module, according to technological parameter and the device parameter of the main process equipment gathering, the processing performance of main process equipment is analyzed; Closed loop analysis module, carries out the analysis of main process equipment closed loop according to the setting value of main process equipment, actual value and output valve; Outside input analysis module, analyzes affecting the outside input of main process equipment performance; Described outside input analysis module comprises the supplied materials analytic unit that outside supplied materials is analyzed and the process matching analytic unit that outside process matching is analyzed; Comparative analysis module, is analyzed inputing or outputing of at least two identical main process equipments, and by the difference the inputing or outputing size of equipment of the same race, judges the performance of main process equipment; Marking module, analyzes and equipment comparative analysis of the same race batch giving a mark to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.
Alternatively, described equipment performance analysis module comprises: contrast display unit, and contrast shows actual value curve and the setting value curve of main process equipment; Nine grids analytic unit, divides abnormal lattice region and non-abnormal lattice region, according to the ratio of output in main process equipment and input, the falling into a little of nine grids, judges whether main process equipment completes corresponding processing quality index with normal state; Fault analysis and diagnosis unit is non-conformance description corresponding to each abnormal lattice area stores and abnormal solution.
Alternatively, described closed loop analysis module comprises: closed loop curve display unit, for display setting value curve, actual value curve or and output valve curve; Specific targets resolving cell, for obtaining the decomposition variable and macro of the described setting value of impact, when setting value curve and actual value curve over default deviation range, if according to the variable and macro that decomposes of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value; Biosensor analysis unit, is provided with the sensor servicing manual of each sensor being connected with main process equipment of the xml form that can check online, obtains the solution of sensor abnormality by this sensor servicing manual.
Alternatively, described comparative analysis module comprises: equipment contrast of the same race unit, for inputing or outputing of at least two identical main process equipments on same production line is analyzed, and by the big or small performance that judges main process equipment of the difference inputing or outputing of equipment of the same race; Different line analysis contrast unit, for the inputing or outputing of at least two same host equipment of different production lines is analyzed, and the performance of the difference the inputing or outputing size judgement main process equipment of the main process equipment of the same race by different production lines.
Alternatively, described marking module comprises workshop section marking unit and batch batch marking unit of giving a mark to tobacco cutting that the main process equipment in workshop section is given a mark.
As mentioned above, quality control and diagnostic analysis method and system in a kind of tobacco cutting process of the present invention, have following beneficial effect:
1, the present invention can locate the reason such as equipment, technique that causes abnormal quality fast, to solve in former statistical process control system, can only observe process and final mass, but the tobacco quality that cannot cause a variety of causes fluctuation is carried out quick diagnosis to get rid of in time abnormal problem.
2, the present invention can make plant maintenance personnel have a clear understanding of in time the operation conditions of equipment, with coaching device attendant, maintains and service equipment.
3, the present invention is by adopting CPK and apparatus and process performance evaluation, main process equipment closed loop is analyzed, workshop section in outside input analysis and equipment comparative analysis of the same race, batch the mode of the concrete score phase weighting form of calculating total points the processing quality index in the quality and performance of main process equipment and tobacco cutting is judged and is examined, only replaced in existing SPC system form by CPK to the judgement of processing quality index and examination, the present invention can be omnibearing to capacity of equipment, technic index performance, the influence factor such as supplied materials and process matching is evaluated.
3, the present invention is practical, and diagnosis is accurately directly perceived, can be widely used in the analyzing and diagnosing of the quality analysis of tobacco cutting production process and machine operation, for homogenizing of tobacco cutting art production process, produces and has stronger supporting role.
Accompanying drawing explanation
Fig. 1 is shown as quality control in tobacco cutting process of the present invention and the overall flow figure of diagnostic analysis method.
Fig. 2 is shown as the flow chart of the apparatus and process performance evaluation of quality control in tobacco cutting process of the present invention and diagnostic analysis method.
Fig. 3 is shown as the flow chart that the main process equipment closed loop of quality control in tobacco cutting process of the present invention and diagnostic analysis method is analyzed.
Fig. 4 is shown as quality control in tobacco cutting process of the present invention and the structural representation of diagnostic analysis system.
Fig. 5 is shown as the schematic diagram of the marking module of quality control in tobacco cutting process of the present invention and diagnostic analysis system.
The specific embodiment
Below, by specific instantiation explanation embodiments of the present invention, those skilled in the art can understand other advantages of the present invention and effect easily by the disclosed content of this description.The present invention can also be implemented or be applied by the other different specific embodiment, and the every details in this description also can be based on different viewpoints and application, carries out various modifications or change not deviating under spirit of the present invention.
It should be noted that, the diagram providing in the present embodiment only illustrates basic conception of the present invention in a schematic way, satisfy and only show with assembly relevant in the present invention in graphic but not component count, shape and size drafting while implementing according to reality, during its actual enforcement, kenel, quantity and the ratio of each assembly can be a kind of random change, and its assembly layout kenel also may be more complicated.
Tobacco cutting technical process processing apparatus is very many, and the SPC system that tobacco business is used at present is only controlled production process and result, cause plant maintenance personnel can not have a clear understanding of in time the operation conditions of each equipment, cannot coaching device attendant maintain and service equipment, the tobacco quality that also cannot cause a variety of causes fluctuation is carried out quick diagnosis to get rid of in time extremely.In addition, in existing SPC system, adopt the form of CPK to the judgement of processing quality index and examination, because CPK examination can only be accomplished the judgement of result, and coverage is very low, for equipment, process matching etc., do not contain, so yet cannot all sidedly processing quality index be judged and be examined.
In view of this, the invention provides quality control and diagnostic analysis method and system in a kind of tobacco cutting process, for solving tobacco quality fluctuation that prior art cannot cause a variety of causes, to carry out quick diagnosis abnormal to get rid of in time, the problem that also cannot all sidedly processing quality index be judged and be examined simultaneously.By elaborating quality control in a kind of tobacco cutting process of the present invention and principle and the embodiment of diagnostic analysis method and system, make those skilled in the art not need creative work can understand quality control and diagnostic analysis method and the system in a kind of tobacco cutting process of the present invention below.
First, the invention provides quality control and diagnostic analysis method in a kind of tobacco cutting process, diagnostic analysis method of the present invention is that to take the equipment of each operation of tobacco cutting be research object, mass property point and equipment operational factor around the equipment of each operation carry out model construction or the mass property point of critical process are combined with device performance parameters forming crucial transfer function, and the operation conditions of the main process equipment of each operation key of tobacco cutting is monitored and diagnosed.
It should be noted that, the invention of abnormity diagnosis in the present invention is to be based upon tobacco cutting to carry out carrying out on the basis of SPC system of process control simultaneously.So-called SPC(Statistical Process Control) be statistical Process Control, to utilize statistical method to control each stage in process, determine that production process is under the state of control, to reduce the variation of product quality, thereby reach, improve and the object of ensuring the quality of products.
Refer to Fig. 1, be shown as quality control in a kind of tobacco cutting process in the present embodiment and the flow chart of steps of diagnostic analysis method.As shown in Figure 1, said method comprising the steps of:
S1, identification main process equipment processing quality index aborning, and be main process equipment configuration device parameter and the technological parameter relevant to described processing quality index.Described device parameter comprises setting value, actual value, the output valve of the main closed loop of equipment, resolution parameter of equipment closed loop, sensor internal parameter etc., described technological parameter comprises: process data, and as temperature, moisture, flow, environment moisture content etc.
S2 gathers technological parameter and the device parameter of main process equipment in tobacco cutting process, the technological parameter of collection and device parameter is stored in historical data base, and realizes list by relational database.
S3, carries out equipment and process analysis according to technological parameter and the device parameter of the main process equipment gathering to main process equipment, and described equipment and process analysis comprises four parts:
S3-1, apparatus and process performance evaluation.
S3-2, main process equipment closed loop is analyzed.
S3-3, outside input is analyzed.
S3-4, equipment comparative analysis of the same race.
Below describe above-mentioned four kinds of analyses in detail.
[one] described apparatus and process performance evaluation is the analysis that the processing performance of main process equipment is carried out, refer to Fig. 2, be shown as the flow chart of the apparatus and process performance evaluation of quality control in tobacco cutting process of the present invention and diagnostic analysis method, as shown in Figure 2, described apparatus and process performance evaluation comprises the steps:
A: to closed loop kind equipment.
S3-1-a1, sets up a right angle two-dimensional coordinate system, and X-axis is defined as to input, Y-axis is defined as to output, is input as the device parameter of main process equipment, is output as the processing quality index of the outlet of main process equipment; In this right angle two-dimensional coordinate system, divide at least one abnormal area and at least one non-abnormal area, and corresponding each abnormal area is stored corresponding non-conformance description and abnormal solution.
S3-1-a2, obtains output input ratio according to the ratio of output valve and input value.
S3-1-a3, according to output input ratio falling into a little in right angle two-dimensional coordinate system, judge whether main process equipment completes corresponding processing quality index with normal state: if falling into o'clock at an abnormal area in batches, judgement main process equipment does not complete corresponding processing quality index with normal state, main process equipment exists abnormal, according to the abnormal cause and the analysis solution that are preset in internal system, and check relevant solution that should this abnormal area; If fall into o'clock at a non-abnormal area, judgement main process equipment completes corresponding processing quality index with the state of presetting, and main process equipment does not exist extremely, with normal state, produces.
B: divided ring kind equipment: particularly, in the present embodiment, described open loop kind equipment comprises loosening and gaining moisture cylinder.
S3-1-b1, obtains the output valve of main process equipment and affects all enter factors of this output valve.
S3-1-b2, according to pipe tobacco batch total quantity and have the ratio of the pipe tobacco batch quantity of fluctuation synchronously to calculate the contributive rate of each enter factor to output valve, sorts to all enter factors by the size of each contributive rate.
S3-1-b3, occurs when abnormal at main process equipment, and the contributive rate sequence according to enter factor, judges abnormal reason, provides solution that should be abnormal simultaneously.
[two] analysis of described main process equipment closed loop is the analysis that input value, actual value and output valve according to main process equipment are carried out, refer to Fig. 3, be shown as the flow chart that the main process equipment closed loop of quality control in tobacco cutting process of the present invention and diagnostic analysis method is analyzed.As shown in Figure 3, the analysis of described main process equipment closed loop comprises the steps:
S3-2-1, obtains setting value curve, actual value curve and output valve curve according to the setting value of obtaining, actual value and output valve.
S3-2-2, obtain some decomposition variable and macros of the described setting value of impact, when setting value curve and actual value curve over default deviation range, according to some decomposition variable and macros of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value.
S3-2-3, according to the actual value of closed loop and output valve, sets up right angle two-dimensional coordinate system, divides an abnormal area and a non-abnormal area in this right angle two-dimensional coordinate system, and abnormal solution corresponding to corresponding abnormal area storage.
In addition, the analysis of described main process equipment closed loop also comprises according to the method for the sensor servicing manual of the xml form that can check online and checks abnormal solution.
[three] outside input analysis is the analysis of carrying out affecting the outside input of main process equipment performance, and described outside input comprises process matching and supplied materials.
[four] in equipment comparative analysis of the same race, inputing or outputing of at least two identical main process equipments is analyzed, by the difference the inputing or outputing size of main process equipment of the same race, judges the performance of main process equipment.
S4, analyzes and equipment comparative analysis of the same race batch is carried out equipment and process marking to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.
In S4, the marking of described equipment and process specifically comprises: according to the result of apparatus and process performance evaluation to the main process equipment in workshop section and tobacco cutting, batch carry out first order marking; According to the result of main process equipment closed loop analysis to the main process equipment in workshop section and tobacco cutting, batch carry out second level marking; The result of analyzing according to outside input batch is carried out third level marking to the main process equipment in workshop section and tobacco cutting; According to the result of equipment comparative analysis of the same race to the main process equipment in workshop section and tobacco cutting, batch carry out fourth stage marking; After phase weighting that CPK and the first order are given a mark by adopting, give a mark in the second level, the third level is given a mark and the fourth stage is given a mark, calculating the mode of total points judges and examines the processing quality index in the quality and performance of main process equipment and tobacco cutting.
For realizing said method, the invention provides quality control and diagnostic analysis system in a kind of tobacco cutting process.Refer to Fig. 4, be shown as quality control in tobacco cutting process of the present invention and the structural representation of diagnostic analysis system.As shown in Figure 4, described system comprises: parameter acquisition module 1, equipment performance analysis module 2, closed loop analysis module 3, outside input analysis module 4, comparative analysis module 5 and marking module 6.The composition of each functional module and the function of specific implementation will be described in detail below.
Parameter acquisition module 1 gathers technological parameter and the device parameter of main process equipment in tobacco cutting process.Described device parameter comprises setting value, actual value, the output valve of the main closed loop of equipment, resolution parameter of equipment closed loop, sensor internal parameter etc., described technological parameter comprises: process data, and as temperature, moisture, flow, environment moisture content etc.
Described main process equipment comprises loosening and gaining moisture cylinder, charger, tunnel reversion machine, Rotary drier, air current type tobacco shred drying machine and mixes and join flavoring system.
Particularly, the input value of described loosening steam conditioner is that the sub-closed-loop data output valve of each equipment is smoked sheet silk outlet temperature; The input value of described charger is electronic scale flow before reinforced, and output valve is reinforced instantaneous delivery; The input value of described tunnel reversion machine is for applying steam pressure, and output valve is pipe tobacco/smoked sheet outlet temperature; The input value of described Rotary drier is barrel temperature, and output valve is pipe tobacco moisture content of outlet; The input value of described air current type tobacco shred drying machine is process gas temperature, and output valve is pipe tobacco moisture content of outlet; Described to mix the input value of joining Perfuming machine be electronic scale flow, and output valve is for mixing flow amount and perfuming flow.
By gathering the parameter in the controller being connected with main process equipment and this parameter being introduced in throwing central control system and being completed as main process equipment configuration device parameter and technological parameter.
In the present embodiment, also comprise a relational database and a historical data base, for the technological parameter of collection and device parameter are stored in to historical data base, and realize list by relational database.
Meanwhile, in the present embodiment, described industry control environment is PLC, for example Siemens PLC C; Described translation and compiling environment is the operating environment of VISUIOSTUDIO 2008 compilings.
Equipment performance analysis module 2, is connected with parameter acquisition module 1, according to technological parameter and the device parameter of the main process equipment gathering, the processing performance of main process equipment is analyzed.
Described equipment performance analysis module 2 comprises: contrast display unit, and contrast shows actual value curve and the setting value curve of main process equipment; Nine grids analytic unit, divides abnormal lattice region and non-abnormal lattice region, according to the ratio of output in main process equipment and input, the falling into a little of nine grids, judges whether main process equipment completes corresponding processing quality index with normal state; Fault analysis and diagnosis unit is non-conformance description corresponding to each abnormal lattice area stores and abnormal solution.
Particularly, described equipment performance analysis module 2 can be realized the performance evaluation to closed loop kind equipment and open loop kind equipment.
To closed loop kind equipment: in the present embodiment, described closed loop kind equipment comprises HT tunnel reversion machine, Rotary drier, air current type tobacco shred drying machine, charger, Perfuming machine.
Set up a right angle two-dimensional coordinate system, X-axis is defined as to input, Y-axis is defined as to output, be input as the device parameter of main process equipment, be output as the processing quality index of the outlet of main process equipment; In this right angle two-dimensional coordinate system, divide nine lattice regions, form nine grids analytic unit, described nine grids analytic unit comprises at least one abnormal lattice region and at least one non-abnormal lattice region, in the present embodiment, the lattice region that setting falls into nine grids center is non-abnormal area, all the other 8 is abnormal lattice regions, and corresponding each abnormal area is stored corresponding non-conformance description and abnormal solution (part for fault analysis and diagnosis unit).
Divided ring kind equipment, particularly, in the present embodiment, described open loop kind equipment comprises loosening and gaining moisture cylinder.
Obtain the output valve and all enter factors that affect this output valve of loosening and gaining moisture cylinder; According to qualified pipe tobacco batch quantity and have the ratio of the pipe tobacco batch quantity of fluctuation synchronously to calculate the contributive rate of each enter factor to output valve, by the size of each contributive rate, all enter factors are sorted.
For example, smoked sheet temperature for its output valve of loosening and gaining moisture cylinder for outlet, input value is process cycles air temperature, newly air temperature, process cycles apply steam flow, negative pressure, four enter factors all have impact to outlet smoked sheet temperature, by setting up the correlation analysis of mass data index, with thickness silk lot data, support the contributive rate of enter factor to outlet.
Particularly, such as always having 2000 batches of pipe tobaccos batch, be kept in database, wherein to the fluctuation of outlet smoked sheet temperature, there are 1900 batches to be that process cycles air temperature causes, 1400 batches because new air temperature causes, 500 batches cause because process cycles applies steam flow, have 0 batch because negative pressure causes.Process cycles air temperature, new air temperature, process cycles apply steam flow and negative pressure is respectively 1900/2000,1400/2000,500/2000,0/2000 to the contributive rate of outlet smoked sheet temperature so.And 1900 batches because process cycles air temperature causes, specifically decompose all kinds of termination factors, for example in 1900 batches 1700 batches due to process cycles air temperature, to control diaphragm valve EP controller out of control, 100 batches is because process cycles wind internal pipeline has dirt blocking pipe, 100 batches is because steam supplied materials technique is undesired, and operating personnel see that the termination factor of corresponding decomposition can carry out simple fault eliminating.
At loosening and gaining moisture cylinder, occur when abnormal, the contributive rate sequence according to enter factor, judges abnormal reason.For example, according to above-mentioned, process cycles air temperature, new air temperature, process cycles are applied to steam flow and calculating and the rank of negative pressure to the contributive rate of outlet smoked sheet temperature, in the outlet smoked sheet temperature of loosening and gaining moisture cylinder, occur when abnormal, first check whether be the impact being brought by process cycles air temperature, if not, check successively in order other enter factor.
Closed loop analysis module 3, carries out the analysis of main process equipment closed loop according to the setting value of main process equipment, actual value and output valve.Particularly, described closed loop analysis module 3 comprises:
Closed loop curve display unit, for display setting value curve, actual value curve or and output valve curve.According to the relevant actual value of closed loop and the output valve of PID, set up right angle two-dimensional coordinate system, in this right angle two-dimensional coordinate system, divide an abnormal area and a non-abnormal area, and abnormal solution corresponding to corresponding abnormal area storage, a closed loop scatter diagram formed.
Specific targets resolving cell, for obtaining the decomposition variable and macro of the described setting value of impact, when setting value curve and actual value curve over default deviation range, if according to the variable and macro that decomposes of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value.
For example in Rotary drier, there are 4 closed loops, in the closed loop for Rotary drier is analyzed, we can put into setting value, actual value, the output valve of 4 closed loops, then in 4 closed loop scatter diagrams, actual value and output valve are done to ratio, within whether the closed loop of finding out Rotary drier is operated in a normal range (NR).
Biosensor analysis unit, is provided with the sensor servicing manual of each sensor being connected with main process equipment of the xml form that can check online, obtains the solution of sensor abnormality by this sensor servicing manual.The solution of the method that for example, thermometer, steam pressure instrument, steam-flow meter, anemobiagraph, differential pressure pickup etc. keep in repair or the reason of failure exception.
Outside input analysis module 4, analyzes affecting the outside input of main process equipment performance; Described outside input analysis module 4 comprises the supplied materials analytic unit that outside supplied materials is analyzed and the process matching analytic unit that outside process matching is analyzed.The analysis that supplied materials analytic unit carries out comprises flow, the moisture of prime equipment, the analysis of temperature, concrete analysis history curve, mean value and standard deviation, the analysis that process matching analytic unit carries out comprises flow and the temperature of process steam, is also analysis of history curve, mean value and standard deviation.
Comparative analysis module 5, is analyzed inputing or outputing of at least two identical main process equipments, and by the difference the inputing or outputing size of equipment of the same race, judges the performance of main process equipment.
Particularly, described comparative analysis module 5 comprises: equipment of the same race contrast unit and different line analysis contrast unit.
Equipment contrast of the same race unit, for inputing or outputing of at least two identical main process equipments on same production line is analyzed, and by the big or small performance that judges main process equipment of the difference inputing or outputing of equipment of the same race.
Different line analysis contrast unit, for the inputing or outputing of at least two same host equipment of different production lines is analyzed, and the performance of the difference the inputing or outputing size judgement main process equipment of the main process equipment of the same race by different production lines.
By the difference between the inputing or outputing of equipment of the same race, plant maintenance personnel can intuitively understand poor-performing or in-problem main process equipment, have a clear understanding of the operation conditions of main process equipment, make technical staff to poor-performing or in-problem main process equipment, be further analyzed inspection in time.So the present embodiment is coaching device attendant maintenance and maintenance host equipment well.
Therefore, by diagnostic analysis system of the present invention, plant maintenance personnel can also have a clear understanding of the operation conditions of each equipment, diagnostic analysis system of the present invention can coaching device attendant be maintained and service equipment, and the tobacco quality fluctuation that coaching device attendant causes a variety of causes is carried out quick diagnosis to get rid of in time extremely.
Marking module 6, analyzes and equipment comparative analysis of the same race batch giving a mark to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.As shown in Figure 5, described marking module 6 comprises workshop section marking unit and batch batch marking unit of giving a mark to tobacco cutting that the main process equipment in workshop section is given a mark.At the present embodiment, workshop section's marking unit comprises gives a mark to a plurality of main process equipments in workshop section, and a batch marking unit comprises the marking of section section, feeding section marking, the marking of chopping section and dries the marking of silk section.
Particularly, workshop section marking unit and batch marking unit according to the result of apparatus and process performance evaluation to the main process equipment in workshop section and tobacco cutting batch carry out first order marking, according to the result of main process equipment closed loop analysis to the main process equipment in workshop section and tobacco cutting batch carry out second level marking, batch the carrying out third level marking, batch carry out fourth stage marking according to the result of equipment comparative analysis of the same race to the main process equipment in workshop section and tobacco cutting the main process equipment in workshop section and tobacco cutting according to the result of outside input analysis.
By the first order, give a mark, in apparatus and process performance evaluation process, for the workshop section of main process equipment, tobacco cutting with batch carry out an evaluation; By the second level, give a mark, in main process equipment closed loop analytic process, for the workshop section of main process equipment, tobacco cutting with batch carry out an evaluation, second level marking at least comprises, the main process equipment in close loop control circuit exist when abnormal the workshop section of main process equipment, tobacco cutting and batch scoring in can remove corresponding score value by button.By the third level, give a mark, in outside input analytic process, for the workshop section of main process equipment, tobacco cutting with batch carry out an evaluation; By the fourth stage, give a mark, in equipment comparative analysis process of the same race, for the workshop section of main process equipment, tobacco cutting with batch carry out an evaluation.
The mode that the module of finally giving a mark 6 is calculated total points afterwards by employing CPK and first order marking, second level marking, third level marking and the weighting of fourth stage marking phase is judged and examines the processing quality index in the quality and performance of main process equipment and tobacco cutting.
The present invention is by adopting CPK and apparatus and process performance evaluation, main process equipment closed loop is analyzed, equipment in outside input analysis and equipment comparative analysis of the same race, workshop section, batch the mode of the concrete score phase weighting form of calculating total points the processing quality index in the quality and performance of main process equipment and tobacco cutting is judged and is examined, only replaced in existing SPC system form by CPK to the judgement of processing quality index and examination, the present invention can be omnibearing to capacity of equipment, technic index performance, the influence factor such as supplied materials and process matching is evaluated.
From description above, can know, quality control of the present invention and diagnostic analysis method are based among device analysis, the main process equipment of each generation processing quality index is designed to the analyzing subsystem of a set of personalization, the analyzing subsystem of each main process equipment is by above-mentioned four independent analysis module (equipment performance analysis modules 2, closed loop analysis module 3, outside input analysis module 4, comparative analysis module 5) form, by the series connection of four analysis modules having been formed to equipment scoring (marking module 6), equipment scoring has comprised workshop section's score and batch score.
In sum, quality control and diagnostic analysis method and system in a kind of tobacco cutting process of the present invention, have following beneficial effect:
1, the present invention can locate the reason such as equipment, technique that causes abnormal quality fast, to solve in former statistical process control system, can only observe process and final mass, but the tobacco quality that cannot cause a variety of causes fluctuation is carried out quick diagnosis to get rid of in time abnormal problem.
2, the present invention can make plant maintenance personnel have a clear understanding of in time the operation conditions of equipment, with coaching device attendant, maintains and service equipment.
3, the present invention is by adopting CPK and apparatus and process performance evaluation, main process equipment closed loop is analyzed, workshop section in outside input analysis and equipment comparative analysis of the same race, batch the mode of the concrete score phase weighting form of calculating total points the processing quality index in the quality and performance of main process equipment and tobacco cutting is judged and is examined, only replaced in existing SPC system form by CPK to the judgement of processing quality index and examination, the present invention can be omnibearing to capacity of equipment, technic index performance, the influence factor such as supplied materials and process matching is evaluated.
3, the present invention is practical, and diagnosis is accurately directly perceived, can be widely used in the analyzing and diagnosing of the quality analysis of tobacco cutting production process and machine operation, for homogenizing of tobacco cutting art production process, produces and has stronger supporting role.
So the present invention has effectively overcome various shortcoming of the prior art and tool high industrial utilization.
Above-described embodiment is illustrative principle of the present invention and effect thereof only, but not for limiting the present invention.Any person skilled in the art scholar all can, under spirit of the present invention and category, modify or change above-described embodiment.Therefore, such as in affiliated technical field, have and conventionally know that the knowledgeable, not departing from all equivalence modifications that complete under disclosed spirit and technological thought or changing, must be contained by claim of the present invention.
Claims (10)
1. quality control and the diagnostic analysis method in tobacco cutting process, is characterized in that, comprises the steps:
S1, identification main process equipment processing quality index aborning, and be main process equipment configuration device parameter and the technological parameter relevant to described processing quality index;
S2 gathers technological parameter and the device parameter of main process equipment in tobacco cutting process, the technological parameter of collection and device parameter is stored in historical data base, and realizes list by relational database;
S3, carries out equipment and process analysis according to technological parameter and the device parameter of the main process equipment gathering to main process equipment; Described equipment and process analysis comprises:
S3-1, the apparatus and process performance evaluation that the processing performance of main process equipment is carried out;
S3-2, the main process equipment closed loop analysis of carrying out according to the setting value of main process equipment, actual value and output valve;
S3-3, the outside input analysis of carrying out affecting the outside input of main process equipment performance; Described outside input comprises process matching and supplied materials;
S3-4, the equipment comparative analysis of the same race that inputing or outputing of at least two identical main process equipments is analyzed, by the big or small performance that judges main process equipment of the difference inputing or outputing of main process equipment of the same race;
S4, analyzes and equipment comparative analysis of the same race batch is carried out equipment and process marking to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.
2. quality control and the diagnostic analysis method in tobacco cutting process according to claim 1, is characterized in that, in step S3-1, described apparatus and process performance evaluation comprises the steps:
A: to closed loop kind equipment
S3-1-a1, sets up a right angle two-dimensional coordinate system, and X-axis is defined as to input, Y-axis is defined as to output, is input as the device parameter of main process equipment, is output as the processing quality index of the outlet of main process equipment; In this right angle two-dimensional coordinate system, divide at least one abnormal area and at least one non-abnormal area, and corresponding each abnormal area is stored corresponding non-conformance description and abnormal solution;
S3-1-a2, obtains output input ratio according to the ratio of output valve and input value;
S3-1-a3, according to output input ratio falling into a little in right angle two-dimensional coordinate system, judge whether main process equipment completes corresponding processing quality index with normal state: if falling into o'clock at an abnormal area in batches, judgement main process equipment does not complete corresponding processing quality index with normal state, main process equipment exists abnormal, according to the abnormal cause and the analysis solution that are preset in internal system, and check relevant solution that should abnormal area; If fall into o'clock at a non-abnormal area, judgement main process equipment completes corresponding processing quality index with the state of presetting, and main process equipment performance does not exist extremely, with normal state, produces;
B: divided ring kind equipment
S3-1-b1, obtains the output valve of main process equipment and affects all enter factors of this output valve;
S3-1-b2, according to pipe tobacco batch total quantity and have the ratio of the pipe tobacco batch quantity of fluctuation synchronously to calculate the contributive rate of each enter factor to output valve, sorts to all enter factors by the size of each contributive rate;
S3-1-b3, occurs when abnormal at main process equipment, and the contributive rate sequence according to enter factor, judges abnormal reason, provides solution that should be abnormal simultaneously.
3. quality control and the diagnostic analysis method in tobacco cutting process according to claim 1, is characterized in that, in step S3-2, the analysis of described main process equipment closed loop comprises the steps:
S3-2-1, obtains setting value curve, actual value curve and output valve curve according to the setting value of obtaining, actual value and output valve;
S3-2-2, obtain some decomposition variable and macros of the described setting value of impact, when setting value curve and actual value curve over default deviation range, according to some decomposition variable and macros of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value;
S3-2-3, according to the actual value of closed loop and output valve, sets up right angle two-dimensional coordinate system, divides an abnormal area and a non-abnormal area in this right angle two-dimensional coordinate system, and abnormal solution corresponding to corresponding abnormal area storage.
4. quality control and the diagnostic analysis method in tobacco cutting process according to claim 3, it is characterized in that, the analysis of described main process equipment closed loop also comprises according to the method for the sensor servicing manual of the xml form that can check online checks abnormal solution.
5. quality control and the diagnostic analysis method in tobacco cutting process according to claim 1, is characterized in that, in step S4, described equipment and process marking comprises:
According to the result of apparatus and process performance evaluation to the main process equipment in workshop section and tobacco cutting, batch carry out first order marking;
According to the result of main process equipment closed loop analysis to the main process equipment in workshop section and tobacco cutting, batch carry out second level marking;
The result of analyzing according to outside input batch is carried out third level marking to the main process equipment in workshop section and tobacco cutting;
According to the result of equipment comparative analysis of the same race to the main process equipment in workshop section and tobacco cutting, batch carry out fourth stage marking;
After phase weighting that CPK and the first order are given a mark by adopting, give a mark in the second level, the third level is given a mark and the fourth stage is given a mark, calculating the mode of total points judges and examines the processing quality index in the quality and performance of main process equipment and tobacco cutting.
6. the quality control in tobacco cutting process and a diagnostic analysis system, is characterized in that, comprising:
Parameter acquisition module gathers technological parameter and the device parameter of main process equipment in tobacco cutting process;
Equipment performance analysis module, is connected with parameter acquisition module, according to technological parameter and the device parameter of the main process equipment gathering, the processing performance of main process equipment is analyzed;
Closed loop analysis module, carries out the analysis of main process equipment closed loop according to the setting value of main process equipment, actual value and output valve;
Outside input analysis module, analyzes affecting the outside input of main process equipment performance; Described outside input analysis module comprises the supplied materials analytic unit that outside supplied materials is analyzed and the process matching analytic unit that outside process matching is analyzed;
Comparative analysis module, is analyzed inputing or outputing of at least two identical main process equipments, and by the difference the inputing or outputing size of equipment of the same race, judges the performance of main process equipment;
Marking module, analyzes and equipment comparative analysis of the same race batch giving a mark to the main process equipment in workshop section and tobacco cutting according to apparatus and process performance evaluation, the analysis of main process equipment closed loop, outside input.
7. quality control and the diagnostic analysis system in tobacco cutting process according to claim 6, is characterized in that, described equipment performance analysis module comprises:
Contrast display unit, contrast shows actual value curve and the setting value curve of main process equipment;
Nine grids analytic unit, divides abnormal lattice region and non-abnormal lattice region, according to the ratio of output in main process equipment and input, the falling into a little of nine grids, judges whether main process equipment completes corresponding processing quality index with normal state;
Fault analysis and diagnosis unit is non-conformance description corresponding to each abnormal lattice area stores and abnormal solution.
8. quality control and the diagnostic analysis system in tobacco cutting process according to claim 6, is characterized in that, described closed loop analysis module comprises:
Closed loop curve display unit, for display setting value curve, actual value curve or and output valve curve;
Specific targets resolving cell, for obtaining the decomposition variable and macro of the described setting value of impact, when setting value curve and actual value curve over default deviation range, according to the decomposition variable and macro of described setting value, in judgement main process equipment closed loop there is the reason of deviation in setting value and actual value;
Biosensor analysis unit, is provided with the sensor servicing manual of each sensor being connected with main process equipment of the xml form that can check online, obtains the solution of sensor abnormality by this sensor servicing manual.
9. quality control and the diagnostic analysis system in tobacco cutting process according to claim 6, is characterized in that, described comparative analysis module comprises:
Equipment contrast of the same race unit, for inputing or outputing of at least two identical main process equipments on same production line is analyzed, and by the big or small performance that judges main process equipment of the difference inputing or outputing of equipment of the same race;
Different line analysis contrast unit, for the inputing or outputing of at least two same host equipment of different production lines is analyzed, and the performance of the difference the inputing or outputing size judgement main process equipment of the main process equipment of the same race by different production lines.
10. quality control and the diagnostic analysis system in tobacco cutting process according to claim 6, it is characterized in that, described marking module comprises workshop section marking unit and batch batch marking unit of giving a mark to tobacco cutting that the main process equipment in workshop section is given a mark.
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| CN108932571B (en) * | 2017-05-24 | 2022-01-07 | 龙岩烟草工业有限责任公司 | Method and device for setting initial technological parameters for cigarette shred making |
| CN109711648A (en) * | 2017-10-25 | 2019-05-03 | 秦皇岛烟草机械有限责任公司 | A kind of automatic generation method and system of tobacco production line work order formulation parameter |
| CN112036701B (en) * | 2020-07-30 | 2022-04-22 | 杭州安脉盛智能技术有限公司 | Technological parameter optimization method for multi-process industrial production process |
| CN112099393A (en) * | 2020-08-19 | 2020-12-18 | 张家口卷烟厂有限责任公司 | System and method for monitoring operation and judging abnormality of cigarette machine equipment |
| CN112674380A (en) * | 2020-12-29 | 2021-04-20 | 广西中烟工业有限责任公司 | Method for judging and evaluating overall comprehensive quality of cigarette cut tobacco |
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