CN109636152B - Homogenization processing regulation and control method and system for chemical components of product - Google Patents
Homogenization processing regulation and control method and system for chemical components of product Download PDFInfo
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Abstract
A method for regulating and controlling the homogenization of chemical components of product includes such steps as determining the links needed to regulate and control the material on product line, building regulation model for each regulation link, homogenizing, and controlling the uniformity of material. The regulation and control system at least comprises a chemical component acquisition and identification module, an equipment management module, an external system interface module, a model management module, an intelligent formula management module and a quality management module. The invention can carry out flexible configuration according to actual needs, carry out multi-ring regulation and control, and realize homogenization production processing regulation and control of collection, regulation and control and production.
Description
Technical Field
The invention relates to the technical field of methods and systems for homogenizing and regulating chemical components of products in the production processes of agricultural products, foods, medicines, chemical products and the like.
Background
With the continuous progress of science and technology, traditional raw material processing has changed from common physical index control to intrinsic chemical index control. For example, tobacco threshing and redrying processing is mainly examined before to obtain indexes such as stem content in leaves, large and medium piece rate, piece yield and the like, after years of development, examination standards and control measures corresponding to the physical indexes are mature, and the technical control indexes focused by people start to turn to chemical component related indexes such as nicotine, sugar-alkali ratio and the like which have a closer relationship with tobacco quality.
According to the current production raw material homogenization processing flow, after all raw materials arrive, sampling personnel adopts a diagonal sampling method or a nine-point sampling method to extract partial samples from a certain area to perform chemical component offline analysis, and after the analysis is finished, EXCEL is adopted to perform formula calculation. This method is time-consuming and labor-consuming, and if the amount of raw materials is large, it takes days or even weeks to sample, prepare samples and calculate the formulation, and the responsibility and professional quality requirements for the operators are extremely high. In addition, the method has more links with manual participation and no controllability, and the final processing result is influenced as long as any link is careless; because of sampling limitations (when the amount is large, all raw materials are difficult to perform offline analysis), sampling data per se has a certain contingency, and the deviation of processing results from expected results is large.
With the continuous development of acquisition technology and computer control system technology, many enterprises have begun to apply on-line chemical component acquisition equipment to production lines, and perform production finishing in combination with production line control and computer system control. A method for homogenizing tobacco leaves of flat warehouse by threshing and redrying, as disclosed in Chinese patent application with the application number of 201410114282.8, which points out a method for regulating and controlling homogenizing processing on the premise of not influencing warehouse management; a tobacco leaf processing technology capable of realizing homogenization control is disclosed in China patent application No. 201610664913.2, and the technology uses on-line near infrared equipment to collect chemical components of tobacco leaves, stores the chemical components in a classified manner according to the chemical components, and performs warehouse-out according to the matching of the chemical components.
When the method is used, the regulation and control system can be regulated and controlled only for a certain link (working procedure), and if more links need to be regulated and controlled, the regulation and control system is required to be readjusted; in addition, when the method is executed, the control can be started after the chemical component information of the raw materials is acquired, namely, the raw materials are all put in storage, the production efficiency is low, and the execution difficulty in actual production is high.
Disclosure of Invention
The invention aims to solve the defects of the prior art, and provides a homogenization processing regulation and control method and a system based on chemical components of a product, which can flexibly configure according to actual needs, perform multi-loop regulation and control, and realize homogenization production processing regulation and control of acquisition, regulation and control and production at the same time.
The aim of the invention is realized by the following technical scheme:
a method for regulating and controlling the homogenization processing of chemical components of a product includes determining the links of the product production line that the homogenization of the chemical components of the product needs to be regulated and controlled, and then respectively establishing a regulating and controlling model for each regulating and controlling link to continuously carry out the homogenization processing of the material and control the uniformity of the processed material in and among batches; the material homogenization processing process of each regulation and control link is as follows:
(1) Sequentially boxing production raw materials with different sources or batches, warehousing and storing, and setting an acquisition device at a boxing point to acquire chemical component information of the raw materials in real time while boxing; the method comprises the steps that a boxing control system is connected with a regulation and control system through a network, when the boxing control system sends out an instruction to start boxing, the regulation and control system records the starting boxing time of each box, when the raw materials in the boxes reach a set weight, the boxing control system sends out an instruction to stop boxing, and a full box signal is transmitted to the regulation and control system; after the regulating and controlling system receives the full box signal, calculating chemical component information of each box raw material according to the starting box time and the ending box time, simultaneously acquiring an RFID electronic tag mounted on the box body, and writing the RFID tag number, the weight of each box and the chemical component information into the regulating and controlling system;
(2) Inputting at least one material formula information to be regulated and controlled into a regulating and controlling system, selecting a material formula to be regulated and controlled according to production requirements when the number of material boxes to be put in a warehouse reaches the required number, calculating material box batch information meeting material formula conditions by the regulating and controlling system according to the material box RFID tag number, the weight of each box and chemical component information stored by the regulating and controlling system, and transmitting the batch information to a warehouse-out executing mechanism;
(3) The warehouse-out execution mechanism is used for taking the corresponding raw material boxes according to the received batch information and the instruction of the regulation and control system, uniformly mixing the raw materials after the corresponding raw material boxes are warehouse-out, assembling to obtain a required material formula, namely a regulation and control product, boxing again, and then conveying to a subsequent production link for direct feeding or warehouse-in; the method comprises the steps that a real-time monitoring device is arranged at the output end of a regulating product, chemical component information of the regulating product is monitored on line, and when the fact that the chemical component information of the regulating product deviates from a set interval is monitored, a regulating system sends out an instruction to fault cabinet control equipment, and abnormal materials are led into a fault cabinet;
and warehousing the qualified regulated product obtained by the homogenization processing of the first regulation link, serving as a raw material of the second regulation link, warehousing the qualified regulated product obtained by the homogenization processing of the second regulation link, serving as a raw material of the third regulation link, and pushing the raw material until the last regulation link, so as to realize the homogenization processing of the chemical components of the product.
The acquisition device arranged at the boxing point and the real-time monitoring device arranged at the output end of the regulating product are near infrared acquisition equipment or a microwave moisture meter; the warehouse-out executing mechanism is one of a stacker, a forklift and a shuttle plate.
The product chemical component homogenizing processing regulation and control system for realizing the method at least comprises a chemical component acquisition and identification module, an equipment management module, an external system interface module, a model management module, an intelligent formula management module and a quality management module;
the chemical component collection and identification module: collecting chemical component information and boxing identification information of boxing production raw materials of an automatic boxing system in real time through a wireless connected collecting device; the module is a data supporting layer of a regulation and control system and is used for preparing data for later regulation and control;
and the equipment management module: all the accessed acquisition equipment and execution equipment are managed and controlled through wireless connection, and state information of the equipment is acquired in real time, so that preparation is made for later-stage dynamic regulation and control of the execution equipment;
an external system interface module: the external system connected with the external system interface module comprises an automatic boxing system, a warehouse management system and a production management system;
model management module: modeling a production unit, modeling a production mode, modeling an access library strategy and modeling a multi-objective optimizing intelligent formula;
the intelligent formula management module: according to the selected production model, setting corresponding parameters to automatically complete calculation of a feeding formula and a warehouse entry position;
and a quality management module: the chemical components of the raw materials of each box formed by the chemical component collection and the processing of the identification module are uniformly managed, and the statistical value, the quality characteristic, the change trend and the chemical component distribution condition of each chemical component of each batch of raw materials and the change and the difference of each chemical component value among each batch of raw materials are displayed;
the chemical component acquisition and identification module is respectively in information connection with the equipment management module, the external system interface module, the quality management module and the intelligent formula management module; the equipment management module is in information connection with the chemical component acquisition and identification module, the model management module and the intelligent formula management module respectively; the model management module is respectively in information connection with the equipment management module and the intelligent formula management module; the external system interface module is in information connection with the chemical component acquisition and identification module, the intelligent formula management module and the quality management module respectively; the quality management module is in information connection with the chemical component acquisition and identification module, the intelligent formula management module and the external system interface module respectively; the intelligent formula management module is a core of the regulation and control system and is respectively in information connection with the chemical component acquisition and identification module, the equipment management module, the external system interface module, the model management module and the quality management module;
the chemical component collection and identification module identifies the chemical component information of each raw material box collected by the collection equipment managed by the equipment management module and the box packing control logic information transmitted by the automatic box packing system connected with the external system interface module, and transmits the information to the intelligent formula management module, and the intelligent formula management module calculates the warehouse entry position of the raw material box according to the inventory information and the regulation model information in the warehouse; the external system interface module acquires production plan and raw material proportioning information from the production management system, and transmits the information to the intelligent formula management module for calculating a feeding formula; the external system interface module transmits warehouse inventory information of the raw materials and warehouse inventory information of the buffer library acquired by the warehouse management system to the intelligent formula management module at the same time; after the intelligent formula management module calculates the feeding formula, feeding task information is issued to the warehouse management system, the warehouse management system sends information to the equipment management module, and the execution equipment is informed to execute feeding action; the warehouse management system automatically feeds back a feeding execution result to the external system interface module and transmits the feeding execution result to the intelligent formula management module; the equipment management module transmits the equipment state information to the intelligent formula management module in real time, and transmits the equipment parameter information to the model management module; the model management module carries out production unit modeling, production mode modeling, access library strategy modeling and multi-objective optimizing intelligent formula modeling and then transmits the modeling to the intelligent formula management module, and the intelligent formula management module sends an instruction to the external system interface module according to the modeling, and controls the chemical component acquisition and identification module and the equipment management module to execute corresponding actions; the quality management module receives and stores the batch information of the materials sent by the intelligent formula management module, compares the batch information with the box material information which is sent by the chemical component acquisition and identification module and is subjected to homogenization treatment, sends the material box information with abnormal indexes to the external system interface module, and the external system interface module starts the warehouse management system to recycle the material box with abnormal information.
Compared with the prior art, the invention has the following advantages:
(1) Flexibility is optimized and expansion is facilitated. The invention determines the links of the product production line, which need to regulate and control the materials, and establishes a regulation and control model for each regulation and control link respectively, so as to continuously carry out homogenization processing on the materials, and facilitate the production enterprises to determine the homogenization regulation and control of different links, different modes and different methods according to respective production conditions.
(2) The homogenization effect is good by adopting multi-stage regulation and control. The homogenization processing regulation and control is a continuous average process, and the invention connects the whole production line in series, and continuously carries out homogenization processing in different production links, thereby effectively controlling the uniformity of the processing raw materials in and among batches.
(3) The degree of automation is high. And all links, peripheral devices and systems are comprehensively integrated, a data link is opened, and data interaction is automatically carried out. The regulation and control system automatically monitors key equipment and data information, automatically delivers batch data of feeding, has good production continuity and more accurate regulation and control results.
Drawings
FIG. 1 is a flow chart of a method for controlling a homogenization process according to an embodiment of the invention;
FIG. 2 is a diagram of a homogenization processing conditioning system in accordance with the present invention.
Detailed Description
The invention is further elucidated below in connection with the drawings and the embodiments.
Example 1
The invention relates to a method for regulating and controlling the homogenization processing of chemical components of a product, which comprises the steps of collecting chemical component information of raw materials by using on-line or off-line equipment, abstracting each regulating and controlling link into a regulating and controlling model, wherein each regulating and controlling model is provided with a preamble unit, a follow-up unit, constraint conditions, an algorithm model and an objective function. The preamble unit determines the source of the regulated raw material, the follow-up unit determines the equipment or system to be sent with the regulated result, the constraint condition determines what raw material is needed and when the regulation is performed, the algorithm model calculates the feeding formula by what calculation method is used by the computer system, and the objective function determines what purpose the regulation needs to achieve.
As shown in fig. 1, the method of the present invention comprises the following steps:
s1: firstly determining links on a product production line, which need to regulate and control materials, respectively establishing a regulation and control model for each regulation and control link, determining a preamble unit and a follow-up unit of each regulation and control link, realizing modeling of the whole production and processing flow, continuously carrying out homogenization processing on the materials, and controlling the uniformity in and among batches of the processed materials. The uniformity of chemical components of materials in the regulating batches is controlled by a material mixing device of each batch, and the uniformity of chemical components of materials among the regulating batches is controlled by a regulating system.
Four regulation links are set in the embodiment: the raw material delivery and storage link (raw material delivery and unpacking, raw material storage), the raw material delivery and storage link (raw material storage, semi-finished product processing), the semi-finished product production off-line and storage returning link (semi-finished product processing, storage), and the semi-finished product feeding production link (storage, production and processing). The front unit of the raw material arrival and warehousing link is set as raw tobacco arrival and warehousing, and the subsequent unit is a raw material bin; the front unit of the link from raw material delivery to semi-finished product processing is a raw material warehouse, and the subsequent unit is a semi-finished product processing feed inlet; the front unit of the off-line warehouse returning link of the semi-finished product production is a semi-finished product production line, and the subsequent unit is a semi-finished product warehouse; the front unit of the semi-finished product feeding production link is a semi-finished product warehouse, and the subsequent unit is a semi-finished product feeding port.
S2: unpacking production raw materials of different sources or batches in sequence, then, loading the unpacked raw materials into a raw material warehouse for storage, and simultaneously, setting an acquisition device at the unpacking and packing point to acquire chemical component information of the raw materials in real time; the method comprises the steps that a boxing control system is connected with a regulation and control system through a network, when the boxing control system sends out an instruction to start boxing, the regulation and control system records the starting boxing time of each box, when the raw materials in the boxes reach a set weight, the boxing control system sends out an instruction to stop boxing, and a full box signal is transmitted to the regulation and control system; after the regulating and controlling system receives the full box signal, calculating chemical component information of each box raw material according to the starting box time and the ending box time, simultaneously acquiring an RFID electronic tag mounted on the box body, and writing the RFID tag number, the weight of each box and the chemical component information into the regulating and controlling system; the detected raw materials enter a raw material warehouse;
s3: and inputting at least one material formula information required to be regulated and controlled into a regulating and controlling system, selecting a material formula required to be regulated and controlled according to production requirements when the warehouse-in material boxes reach the required number, calculating material box batch information meeting material formula conditions by the regulating and controlling system according to the material box RFID tag numbers, the weight of each box and the chemical component information stored by the regulating and controlling system, and transmitting the batch information to a warehouse-out executing mechanism.
S4: and the warehouse-out execution mechanism is used for taking the corresponding raw material boxes in the raw material warehouse according to the received batch information and the instruction of the regulation and control system, uniformly mixing the raw materials after the raw material boxes are discharged from the warehouse, processing the raw materials to obtain a required material formula, namely a semi-finished product, boxing the raw materials again and conveying the raw materials to a slow warehouse. When the raw materials arrive at the stock, the average value of the chemical components of the raw materials in the whole processing batch is not clear by the control system, so that the semi-finished product processing can be started after all the raw materials are detected completely. When the semi-finished product processing is needed, the raw material output to semi-finished product processing regulation and control link automatically calculates batch data needing to be fed according to the set conditions and informs corresponding execution mechanisms to perform feeding actions. When the semi-finished product is processed, the semi-finished product is placed in a box, and the semi-finished product is subjected to online chemical component collection by a collection device. When the semi-finished products need to be returned to the warehouse, the system dynamically determines the warehouse entry position of each semi-finished product box according to preset warehouse entry conditions, and informs an executing mechanism to carry out warehouse entry actions. And a real-time monitoring device is arranged at the processing tail end of the semi-finished product, the chemical component information of the semi-finished product is monitored on line, and when the deviation of the chemical component information of the semi-finished product from a set interval is monitored, a regulating and controlling system sends a command to a fault cabinet control device to guide abnormal materials into a fault cabinet.
S5: when production and processing are needed, the regulation and control system automatically calculates batch data of the materials according to a semi-finished product material feeding production regulation and control model, informs an executing mechanism to carry out warehouse discharging of the semi-finished products in a slow warehouse, and feeds the materials after uniform mixing for production and processing. And a real-time monitoring device and on-line monitoring of chemical component information of the finished product are arranged at the tail end of production and processing, and when the deviation of the chemical component information of the finished product from a set interval is monitored, the regulation and control system sends a command to the control equipment of the fault cabinet to guide abnormal materials into the fault cabinet. The fault cabinet may be located in a cache. The abnormal material can be used for the raw material regulated in the next batch.
The materials entering the raw material bin through the raw material arrival and storage link are taken as raw materials from the raw material delivery and storage link to the semi-finished product processing link, and the qualified semi-finished products obtained through the raw material delivery and storage link to the semi-finished product processing link are taken as raw materials from the semi-finished product feeding production link after being returned to the storage. The regulating and controlling system unpacks the raw materials to the raw material warehouse, the boxing materials in the raw material warehouse are regulated and discharged from the warehouse to process semi-finished products, the processed semi-finished products are taken as new raw materials to enter the slow warehouse, the semi-finished products in the slow warehouse are regulated and discharged from the warehouse to feed materials to produce and process, and the whole production process is subjected to homogenization processing twice.
The collection device arranged at the boxing point and the real-time monitoring device arranged at the output end of the regulating product can be near infrared collection equipment or other on-line chemical component monitoring instruments, and the embodiment adopts the near infrared collection equipment, so that the device can be purchased in the market, such as Petern7440. The warehouse-out executing mechanism is one of a stacker, a forklift and a shuttle plate, and the stacker is adopted in the embodiment.
By adopting the method, the regulation and control system can automatically monitor the batch information of the feeding materials. After the current batch is finished, the system automatically issues the next batch data. If the raw material warehouse and the buffer warehouse adopt a mode of entering and exiting at the same time, when the number of newly-entered boxes reaches the proportion set by the regulation and control system, the regulation and control system controls the automatic recovery of the undelivered batch data boxes, and automatically recalculates batch data information according to the executed batch data; the intervention control time of the regulation and control system can be after all the materials are put in storage, or when the quantity of the materials put in storage reaches a certain proportion.
The chemical component homogenizing control system of the invention is shown in figure 2, and at least comprises a chemical component acquisition and identification module, an equipment management module, an external system interface module, a model management module, an intelligent formula management module and a quality management module.
The product chemical component homogenizing processing regulation and control system for realizing the method at least comprises a chemical component acquisition and identification module, an equipment management module, an external system interface module, a model management module, an intelligent formula management module and a quality management module;
the chemical component collection and identification module: collecting chemical component information and boxing identification information of boxing production raw materials of an automatic boxing system in real time through a wireless connected collecting device; the module is a data supporting layer of a regulation and control system and is used for preparing data for later regulation and control;
and the equipment management module: all the accessed acquisition equipment and execution equipment are managed and controlled through wireless connection, and state information of the equipment is acquired in real time, so that preparation is made for later-stage dynamic regulation and control of the execution equipment;
an external system interface module: the regulation and control system of the invention is used as a decision system for production regulation and control, and needs to acquire data from an external system and send regulation and control results to a peripheral system. The external system connected with the external system interface module comprises an automatic boxing system, a warehouse management system and a production management system, wherein the module acquires basic data information such as the grade, the production place, the year and the like of raw materials, production plan, material formula information and other parameter information from the external system, and sends a regulation and control result to the warehouse management system and the production management system;
model management module: and carrying out production unit modeling, production mode modeling, access library strategy modeling and multi-objective optimizing intelligent formula modeling. The method comprises the following steps:
modeling a production unit: the production unit is the minimum unit of production modeling and is the logic definition of all relevant processing units in the chemical component homogenizing control process. Each production unit can customize properties, and the production unit is invoked by the production model.
Modeling a production mode: establishing a sectional production process regulation and control process model, regulating and control connection and flow direction relation of related units, and configuring a formula calculation model, an algorithm and intelligent calculation triggering conditions (calculation triggering setting: manual triggering, key equipment state change, stock quantity change reaching proportion and the like) related to each regulation and control link according to production practice;
modeling an input-output strategy: setting minimum access classification units for warehouse entry storage of different types of warehouses, and defining or automatically calculating the warehouse entry clustering difference degree, the classification number and the like according to the size, the total unit number and the like of the classification units. And (3) managing the warehouse-out strategies of different types of warehouses to ensure the feasibility and efficiency of feeding selection.
Multi-target optimizing intelligent formula modeling: the algorithm model used for managing intelligent formula calculation comprises the following steps:
a. objective function: the chemical component variation coefficient of the large batch is the smallest, the chemical component items contained in the objective function can be single or multiple, and the importance can be added and given by a user.
b. Constraint conditions: the constraint conditions to be met by the calculation of the feeding formula are maintained, for example, in the process of homogenizing tobacco raw materials, a feeding tobacco storage library, a threshing formula, the upper limit of variation coefficients of chemical component values of batches, the minimum mixing unit amount, mixing conditions and the like can be selected to consider the equipment conditions and the like of the links as the constraint conditions.
The intelligent formula management module: according to the selected production model, setting corresponding parameters to automatically complete calculation of a feeding formula and a warehouse entry position;
the model management module dynamically monitors the warehouse-in and production data, and when a certain triggering condition (such as that a key device fails and the new warehouse-in quantity reaches a certain ratio) is reached, the unremoved batch data of the materials are automatically recovered, recalculation is carried out according to the new data, the production continuity is ensured, and the accuracy of a regulation result is ensured. The model management module also automatically monitors the task execution condition, and automatically issues new task information when the task execution of the previous batch is completed.
And a quality management module: the chemical components of the materials in each box, which are processed by the chemical component collection and identification module, are uniformly managed, so that statistics of detection values of the chemical components of raw materials, semi-finished products and finished products can be reflected, and detailed detection of the statistics can be reflected. Simultaneously providing a plurality of patterns, showing the overall statistical values (mean value, variance and CV value) and distribution patterns of all chemical components of each batch of cigarettes, and reflecting the quality characteristics, variation trend and chemical component distribution condition of the whole batch; reflecting the variation and difference of chemical composition values among batches.
The chemical component acquisition and identification module is respectively in information connection with the equipment management module, the external system interface module, the quality management module and the intelligent formula management module;
the equipment management module is in information connection with the chemical component acquisition and identification module, the model management module and the intelligent formula management module respectively;
the model management module is respectively in information connection with the equipment management module and the intelligent formula management module;
the external system interface module is respectively in information connection with the chemical component acquisition and identification module, the intelligent formula management module, the quality management module;
the quality management module is in information connection with the chemical component acquisition and identification module, the intelligent formula management module and the external system interface module respectively;
the intelligent formula management module is a core of the regulation and control system and is respectively in information connection with the chemical component acquisition and identification module, the equipment management module, the external system interface module, the model management module and the quality management module;
the chemical component collection and identification module identifies the chemical component information of each box raw material collected by the collection equipment managed by the equipment management module and the box packing control logic information (such as RFID tag number on the box body, weight of each box and the like) transmitted by the automatic box packing system connected with the external system interface module, and transmits the box packing control logic information to the intelligent formula management module, and the intelligent formula management module calculates the warehouse entry cargo space of the raw material box according to the inventory information and the regulation and control model information in the warehouse; the external system interface module acquires production plan and raw material proportioning information from the production management system, and transmits the information to the intelligent formula management module for calculating a feeding formula; the external system interface module transmits the warehouse stock information of the raw material warehouse and the warehouse stock buffer, and the basic data information of the raw materials (such as the grade, the production place and the year of the raw materials) acquired by the warehouse management system to the intelligent formula management module; after the intelligent formula management module calculates the feeding formula, feeding task information is issued to the warehouse management system, the warehouse management system sends information to the equipment management module, and the execution equipment is informed to execute feeding action; the warehouse management system automatically feeds back a feeding execution result to the external system interface module and transmits the feeding execution result to the intelligent formula management module; the equipment management module transmits the equipment state information to the intelligent formula management module in real time, and transmits the equipment parameter information to the model management module; the model management module carries out production unit modeling, production mode modeling, access library strategy modeling and multi-objective optimizing intelligent formula modeling and then transmits the modeling to the intelligent formula management module, and the intelligent formula management module sends an instruction to the external system interface module according to the modeling, and controls the chemical component acquisition and identification module and the equipment management module to execute corresponding actions; the quality management module receives and stores the batch information of the materials sent by the intelligent formula management module, compares the batch information with the box material information which is sent by the chemical component acquisition and identification module and is subjected to homogenization treatment, sends the material box information with abnormal indexes to the external system interface module, and the external system interface module starts the warehouse management system to recycle the material box with abnormal information.
Example 2
Taking tobacco nicotine uniformity regulation and control as an example, a regulation and control link is a formula warehouse-out to threshing and redrying feeding link, the formula warehouse is a three-dimensional warehouse, a formula warehouse is an preface unit, a follow-up unit is a threshing and redrying box-turning feeder, and the processing steps are as follows:
1. after receiving the production notice, the production part arranges a spreading and arranging staff to arrange the arranging staff, and the batch information is not required to be concerned in the arranging process, so that the spreading and arranging staff can be placed on an arranging line as long as materials exist.
2. An automatic boxing port is arranged at the tail end of each handle placing table, an online near infrared acquisition device is arranged at the top end of the automatic boxing port, and the automatic boxing system is controlled by a PLC (programmable logic controller), so that the tobacco leaves are selected tobacco leaves, the tobacco leaves are high in loose degree and low in moisture, and the boxing weight is preset to be 320kg. In the boxing process, the regulation and control system collects boxing starting and ending signals of each smoke box, and simultaneously collects chemical component information (such as nicotine, total sugar, reducing sugar, nitrogen, potassium, chlorine, temperature and moisture) of tobacco leaves collected by the online near infrared collection device. When receiving the signal of ending the boxing, the regulating and controlling system automatically calculates the comprehensive chemical component information of the tobacco box according to the starting and stopping time of boxing, writes the chemical component information into the PLC, and the automatic boxing system applies for warehousing, and when applying for warehousing, the automatic boxing system can report the information of tobacco grades, producing places, varieties and the like, weight information, RFID tag numbers of the boxes and chemical component classification information simultaneously. And after the automatic stereoscopic warehouse upper system responds, the corresponding goods taking mechanism such as a stacker is informed to carry out warehouse-in operation.
3. When the single-level regulation and control system calculates, every 24 cigarette frames are in one batch, and when the number of the cigarette boxes in stock reaches 5 batches, the regulation and control system starts to calculate the feeding formula. When the regulation and control system calculates the feeding formula, a proper smoke frame is selected to form a batch according to a preset expected target (such as nicotine CV value, namely variation coefficient is smaller than 2.8%), and when the feeding formula is calculated, the warehouse-out efficiency of the stacker is required to be comprehensively considered. After the calculation is completed, the operator manually issues the feeding formula for the first time, and when the regulating system issues batch information, the information is issued to the box-turning feeding machine at the same time.
4. And after receiving the feeding formula which is regulated and controlled and delivered simultaneously, the upper system of the automatic stereoscopic warehouse informs the stacker to carry out warehouse-out. When the stacker delivers the smoke box to the outlet of the three-dimensional warehouse, batch information of the smoke box is written into the PLC of the logistics electric control system, and the smoke box always carries the batch number in the moving process of the logistics circuit. When the smoke box reaches the box turning feeder, the box turning feeder control automatically compares the batch information of the smoke box, and if the batch number is found to be wrong, an alarm prompt is given, and the smoke box is manually processed by an operator.
In the process of executing the warehouse-out of the automatic stereo warehouse, the regulation and control system can monitor the execution condition of each batch of materials in real time, and when the warehouse-out of the last smoke frame of the execution batch is completed, the regulation and control system can automatically issue the material-feeding data of the next batch.
When the new warehouse quantity reaches the set proportion, the regulation system automatically recovers the calculated but undelivered batch data, and simultaneously, the batch which is executed is considered to be finished, and the batch formula is recalculated.
When a certain stacker of the automatic three-dimensional warehouse fails, the regulation and control system automatically shields the inventory information of the channel where the failed stacker is located, and automatically recalculates the feeding formula.
When the last raw tobacco enters the three-dimensional warehouse, an operator manually sets materials on the regulation and control system to finish all warehouse entry, and the regulation and control system performs the last calculation. When all the calculated formulas are completely executed, the regulation and control of the batch of tobacco leaves are finished.
And (3) installing an on-line near infrared monitoring device at the tail of the redrying machine to detect the chemical composition information of the finished product in real time, and informing a fault cabinet control system when the nicotine of the finished product is found to exceed the set range, wherein the fault cabinet control system guides abnormal tobacco leaves into the fault cabinet.
5. And taking one sample every 50 cases by a sampling person at the off-line opening of the finished tobacco sheet box, and carrying out off-line chemical component analysis. Through detection, the batch of tobacco boxes are taken off a line to form a 1492 box, and the nicotine CV value of the tobacco is 2.71%.
Through testing, 10000 raw cigarettes are combined with 1214 frames of tobacco leaves, a regulating and controlling system calculates and generates 51 batches, the last batch is 14 frames, the other batches are 24 frames, the estimated nicotine CV value of the regulating and controlling system is 2.38%, the sampling CV is 2.71%, the originally set nicotine CV is less than 2.8% (in the actual production process, the execution degree of production equipment does not necessarily actually reach the expected production requirement, for example, a storage cabinet for mixing inside the batches does not necessarily fully mix materials, the index of the production result is generally higher than the index estimated by the system, and the tolerance is allowable in the tobacco industry).
Through the test, a conclusion can be drawn: the homogenization processing regulation and control method greatly reduces sampling and sample preparation work of a redrying plant, the system automatically calculates a feeding formula, and meanwhile, each link strictly clamps and controls batch information, the batch information is accurate, and the homogenization processing regulation and control based on nicotine is efficiently and accurately realized.
Claims (2)
1. A method for regulating and controlling the homogenization processing of chemical components of a product is characterized in that a product chemical component homogenization processing regulating and controlling system is firstly arranged, and the regulating and controlling system at least comprises a chemical component acquisition and identification module, an equipment management module, an external system interface module, a model management module, an intelligent formula management module and a quality management module;
the chemical component collection and identification module: collecting chemical component information and boxing identification information of boxing production raw materials of an automatic boxing system in real time through a wireless connected collecting device; the module is a data supporting layer of a regulation and control system and is used for preparing data for later regulation and control;
and the equipment management module: all the accessed acquisition equipment and execution equipment are managed and controlled through wireless connection, and state information of the equipment is acquired in real time, so that preparation is made for later-stage dynamic regulation and control of the execution equipment;
an external system interface module: the external system connected with the external system interface module comprises an automatic boxing system, a warehouse management system and a production management system;
model management module: modeling a production unit, modeling a production mode, modeling an access library strategy and modeling a multi-objective optimizing intelligent formula;
the intelligent formula management module: according to the selected production model, setting corresponding parameters to automatically complete calculation of a feeding formula and a warehouse entry position;
and a quality management module: the chemical components of the raw materials of each box formed by the chemical component collection and the processing of the identification module are uniformly managed, and the statistical value, the quality characteristic, the change trend and the chemical component distribution condition of each chemical component of each batch of raw materials and the change and the difference of each chemical component value among each batch of raw materials are displayed;
the chemical component acquisition and identification module is respectively in information connection with the equipment management module, the external system interface module, the quality management module and the intelligent formula management module; the equipment management module is in information connection with the chemical component acquisition and identification module, the model management module and the intelligent formula management module respectively; the model management module is respectively in information connection with the equipment management module and the intelligent formula management module; the external system interface module is in information connection with the chemical component acquisition and identification module, the intelligent formula management module and the quality management module respectively; the quality management module is in information connection with the chemical component acquisition and identification module, the intelligent formula management module and the external system interface module respectively; the intelligent formula management module is a core of the regulation and control system and is respectively in information connection with the chemical component acquisition and identification module, the equipment management module, the external system interface module, the model management module and the quality management module;
the chemical component collection and identification module identifies the chemical component information of each raw material box collected by the collection equipment managed by the equipment management module and the box packing control logic information transmitted by the automatic box packing system connected with the external system interface module, and transmits the information to the intelligent formula management module, and the intelligent formula management module calculates the warehouse entry position of the raw material box according to the inventory information and the regulation model information in the warehouse; the external system interface module acquires production plan and raw material proportioning information from the production management system, and transmits the information to the intelligent formula management module for calculating a feeding formula; the external system interface module transmits warehouse inventory information of the raw materials and warehouse inventory information of the buffer library acquired by the warehouse management system to the intelligent formula management module at the same time; after the intelligent formula management module calculates the feeding formula, feeding task information is issued to the warehouse management system, the warehouse management system sends information to the equipment management module, and the execution equipment is informed to execute feeding action; the warehouse management system automatically feeds back a feeding execution result to the external system interface module and transmits the feeding execution result to the intelligent formula management module; the equipment management module transmits the equipment state information to the intelligent formula management module in real time, and transmits the equipment parameter information to the model management module; the model management module carries out production unit modeling, production mode modeling, access library strategy modeling and multi-objective optimizing intelligent formula modeling and then transmits the modeling to the intelligent formula management module, and the intelligent formula management module sends an instruction to the external system interface module according to the modeling, and controls the chemical component acquisition and identification module and the equipment management module to execute corresponding actions; the quality management module receives and stores the batch information of the materials fed from the intelligent formula management module, compares the batch information with the information of the packaged materials which are subjected to homogenization treatment and sent from the chemical component acquisition and identification module, sends the information of the material boxes with abnormal indexes to the external system interface module, and the external system interface module starts the warehouse management system to recycle the material boxes with abnormal information;
the homogenizing processing regulation method of the chemical components of the product comprises the steps of determining links on a product production line, which need to regulate and control materials, respectively establishing a regulation and control model for each regulation and control link, continuously homogenizing the materials, and controlling the uniformity in and among batches of the processed materials; the material homogenization processing process of each regulation and control link is as follows:
(1) Sequentially boxing production raw materials with different sources or batches, warehousing and storing, and setting an acquisition device at a boxing point to acquire chemical component information of the raw materials in real time while boxing; the method comprises the steps that a boxing control system is connected with a regulation and control system through a network, when the boxing control system sends out an instruction to start boxing, the regulation and control system records the starting boxing time of each box, when the raw materials in the boxes reach a set weight, the boxing control system sends out an instruction to stop boxing, and a full box signal is transmitted to the regulation and control system; after the regulating and controlling system receives the full box signal, calculating chemical component information of each box raw material according to the starting box time and the ending box time, simultaneously acquiring an RFID electronic tag mounted on the box body, and writing the RFID tag number, the weight of each box and the chemical component information into the regulating and controlling system;
(2) Inputting at least one material formula information to be regulated and controlled into a regulating and controlling system, selecting a material formula to be regulated and controlled according to production requirements when the number of material boxes to be put in a warehouse reaches the required number, calculating material box batch information meeting material formula conditions by the regulating and controlling system according to the material box RFID tag number, the weight of each box and chemical component information stored by the regulating and controlling system, and transmitting the batch information to a warehouse-out executing mechanism;
(3) The warehouse-out execution mechanism is used for taking the corresponding raw material boxes according to the received batch information and the instruction of the regulation and control system, uniformly mixing the raw materials after the corresponding raw material boxes are warehouse-out, assembling to obtain a required material formula, namely a regulation and control product, boxing again, and then conveying to a subsequent production link for direct feeding or warehouse-in; the method comprises the steps that a real-time monitoring device is arranged at the output end of a regulating product, chemical component information of the regulating product is monitored on line, and when the fact that the chemical component information of the regulating product deviates from a set interval is monitored, a regulating system sends out an instruction to fault cabinet control equipment, and abnormal materials are led into a fault cabinet;
and warehousing the qualified regulated product obtained by the homogenization processing of the first regulation link, serving as a raw material of the second regulation link, warehousing the qualified regulated product obtained by the homogenization processing of the second regulation link, serving as a raw material of the third regulation link, and pushing the raw material until the last regulation link, so as to realize the homogenization processing of the chemical components of the product.
2. The method for regulating and controlling the homogenization processing of chemical components of a product according to claim 1, wherein the acquisition device arranged at the boxing point and the real-time monitoring device arranged at the output end of the regulating and controlling product are both near infrared acquisition equipment or a microwave moisture meter; the warehouse-out executing mechanism is one of a stacker, a forklift and a shuttle plate.
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