CN111964758A - Constant flow control system and belt scale fault positioning method - Google Patents
Constant flow control system and belt scale fault positioning method Download PDFInfo
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- CN111964758A CN111964758A CN202010724921.8A CN202010724921A CN111964758A CN 111964758 A CN111964758 A CN 111964758A CN 202010724921 A CN202010724921 A CN 202010724921A CN 111964758 A CN111964758 A CN 111964758A
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- 238000000034 method Methods 0.000 title claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 117
- 238000005303 weighing Methods 0.000 claims abstract description 117
- 238000003860 storage Methods 0.000 claims abstract description 21
- 241000208125 Nicotiana Species 0.000 claims abstract description 20
- 235000002637 Nicotiana tabacum Nutrition 0.000 claims abstract description 20
- 238000009826 distribution Methods 0.000 claims abstract description 15
- 239000004744 fabric Substances 0.000 claims description 14
- 230000007704 transition Effects 0.000 claims description 14
- 229910052739 hydrogen Inorganic materials 0.000 claims description 6
- 230000008569 process Effects 0.000 abstract description 13
- 238000013024 troubleshooting Methods 0.000 abstract description 7
- 238000012545 processing Methods 0.000 abstract description 6
- 230000033228 biological regulation Effects 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000002159 abnormal effect Effects 0.000 description 3
- 230000001276 controlling effect Effects 0.000 description 3
- 238000007689 inspection Methods 0.000 description 3
- 238000012423 maintenance Methods 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000012544 monitoring process Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 238000012806 monitoring device Methods 0.000 description 2
- 206010024796 Logorrhoea Diseases 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
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- 238000001514 detection method Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G11/00—Apparatus for weighing a continuous stream of material during flow; Conveyor belt weighers
- G01G11/006—Special taring or checking devices therefor
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01F—MEASURING VOLUME, VOLUME FLOW, MASS FLOW OR LIQUID LEVEL; METERING BY VOLUME
- G01F23/00—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm
- G01F23/22—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water
- G01F23/28—Indicating or measuring liquid level or level of fluent solid material, e.g. indicating in terms of volume or indicating by means of an alarm by measuring physical variables, other than linear dimensions, pressure or weight, dependent on the level to be measured, e.g. by difference of heat transfer of steam or water by measuring the variations of parameters of electromagnetic or acoustic waves applied directly to the liquid or fluent solid material
- G01F23/284—Electromagnetic waves
- G01F23/292—Light, e.g. infrared or ultraviolet
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01G—WEIGHING
- G01G23/00—Auxiliary devices for weighing apparatus
- G01G23/01—Testing or calibrating of weighing apparatus
Abstract
The invention relates to the technical field of tobacco shred processing, in particular to a constant flow control system and a belt weigher fault positioning method, which comprise a material distribution device, a temporary storage cabinet and an electronic belt weigher system, wherein the temporary storage cabinet is arranged below the material distribution device, and the electronic belt weigher system is provided with a limiting pipe; electronic belt scale system includes controller, bearing roller, drive roll, driven voller, and the belt encircles in bearing roller, drive roll and driven voller, and the bearing roller is located between drive roll and the driven voller, and the limit buret is located belt tip top: a laser range finder is arranged above the belt; the driving roller is connected with a driving motor, and a rotating shaft of the driving motor is provided with a rotary encoder; a plurality of groups of weighing sensors are arranged below the carrier roller and are positioned at different positions of the carrier roller. The invention can not only monitor the metering accuracy of the belt scale in real time, but also accurately judge the fault position caused by the weighing sensor, reduce the fault troubleshooting time and reduce the process quality risk.
Description
Technical Field
The invention relates to the technical field of tobacco shred processing, in particular to a constant flow control system and a belt scale fault positioning method.
Background
In the pipe tobacco production and processing process, constant flow control system is indispensable, often includes distributing device, the cabinet of keeping in, and electronic belt conveyor scale, wherein: the temporary storage cabinet is used as a buffer device between an upper production process and a lower production process, is generally positioned at the upper position of the electronic belt scale and stably provides materials for the electronic belt scale; the electronic belt scale is used for controlling and monitoring the flow and weight of conveyed materials in real time. However, the electronic belt scale lacks scientific and effective supervision means in the production and operation process, the maintenance of the electronic belt scale is mainly focused on after-the-fact maintenance, and precautionary measures are only spot inspection before starting, or the belt scale runs for a certain time in a single machine state, the accumulated value of the belt scale is checked, if the accumulated value is found to be abnormal, the adjustment and the calibration are only limited to the experience of operators and maintainers, data in the idle running process cannot be traced, the state of the belt scale cannot be detected and targeted inspection and maintenance can not be carried out, and if the belt scale breaks down, the fault position cannot be quickly positioned, and the inspection process is long.
Chinese patent CN201410281120.3 discloses a state monitoring system of an electronic belt scale, which comprises an electronic belt scale, a monitoring device and a processing device: when the tobacco leaves pass through the electronic belt scale, the monitoring device monitors the instantaneous flow P of the tobacco leaves; if 2300kg/h is greater than P which is not less than 2000kg/h, the processing device sends out a fault signal; if P is larger than or equal to 2300kg/h, the processing device sends out a serious fault signal; although the scheme can effectively ensure the instantaneous flow of the materials passing through the electronic belt scale system and avoid the phenomenon that the materials are not completely processed due to excessive materials, the faults of the belt scale cannot be quickly positioned. Chinese patent CN201110253276.7 discloses an electronic belt scale and a measurement accuracy compensation method, which can calibrate the accuracy of the belt scale, but also cannot quickly locate a fault.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide a constant flow control system and a belt scale fault positioning method, which can monitor the metering accuracy of a belt scale in real time, judge the fault position, reduce the fault troubleshooting time and reduce the process quality risk.
In order to solve the technical problems, the invention adopts the technical scheme that:
the constant flow control system comprises a material distribution device, a temporary storage cabinet and an electronic belt scale system, wherein the temporary storage cabinet is arranged on a limiting tube, and the electronic belt scale system is provided with the limiting tube for receiving tobacco shreds from the temporary storage cabinet; the electronic belt scale system comprises a controller, a carrier roller, a driving roller and a driven roller, wherein the belt is surrounded on the carrier roller, the driving roller and the driven roller, the carrier roller is positioned between the driving roller and the driven roller, and the limiting pipe is positioned above the end part of the belt: a laser range finder for measuring the height of the material is arranged above the belt; the drive roll is connected with driving motor, be equipped with the rotary encoder who is used for measuring belt functioning speed in the driving motor pivot, the bearing roller has multiunit weighing sensor, and multiunit weighing sensor is located the different positions of bearing roller, laser range finder, weighing sensor, rotary encoder all connect in the controller.
According to the constant flow control system, the material distribution device controls the material distribution action to keep the material height in the temporary storage cabinet moderate and the material distribution is uniform; the temporary storage cabinet supplies materials to the limiting pipe and enables the materials in the limiting pipe to keep stable height, a weighing sensor on a weighing carrier roller of the belt weigher monitors the weight of the materials above in real time, and the running speed of the belt weigher is adjusted according to the set flow of the belt weigher to realize constant flow control. According to the invention, a laser range finder monitors the height of a material in real time, a rotary encoder monitors the running speed of a belt scale in real time, the flow Q of the belt scale is calculated according to monitored data and the attribute of the material, a weighing sensor monitors the weight of the material above in real time, the flow Q1 of the belt scale is calculated according to the monitored weight of the material, and the flow Q1 of the belt scale is compared with the flow Q of the belt scale so as to judge whether a fault occurs; when a fault occurs, the data monitored by the weighing sensors at different positions on the same weighing carrier roller are compared, and the data monitored by the weighing sensors at different weighing carrier rollers along the material conveying direction are compared, so that the fault occurring position can be judged. The invention can not only monitor the metering accuracy of the belt scale in real time, but also accurately judge the fault position caused by the weighing sensor, reduce the fault troubleshooting time and reduce the process quality risk.
Further, the carrier rollers comprise a first transition carrier roller, a second transition carrier roller, a first weighing carrier roller and a second weighing carrier roller which are arranged in parallel, the first weighing carrier roller and the second weighing carrier roller are located between the first transition carrier roller and the second transition carrier roller, and the weighing sensors are installed on the first weighing carrier roller and the second weighing carrier roller.
Further, the weighing sensors comprise a first weighing sensor, a second weighing sensor, a third weighing sensor and a fourth weighing sensor, the first weighing sensor and the second weighing sensor are respectively installed at two end portions of the first weighing carrier roller, and the third weighing sensor and the fourth weighing sensor are respectively installed at two end portions of the second weighing carrier roller.
Furthermore, the limiting pipe is of a square structure, and the material falling into the belt by the limiting pipe is a cuboid.
Further, the limit pipe includes the body and is used for measuring the measurement light curtain of the real-time height of pipe tobacco, the measurement light curtain is installed in the body lateral part and is measured the light curtain and be connected with the controller.
Furthermore, the limiting tube is at least provided with a transparent side wall, the measuring light curtain is arranged on the transparent side wall, and the measuring light curtain outputs a current signal of 4 mA-20 mA according to the height of the cut tobacco in the limiting tube.
Further, the distributing device includes the cloth area and locates the altitude sensor at cloth area both ends, altitude sensor connects in the input of controller, the output of controller is connected with and is used for showing the display module of keeping in the interior material height of cabinet.
Furthermore, the height sensor is an ultrasonic sensor, and each end of the cloth belt is at least provided with two groups of ultrasonic sensors.
Further, the two groups of ultrasonic sensors comprise a high material level ultrasonic sensor and a low material level ultrasonic sensor.
The invention also provides a belt scale fault positioning method, which comprises the following steps:
s10, establishing a material model conveyed to the belt weigher by a limiting pipe, and calculating the flow Q of the belt weigher according to the following formula:
in the formula, L, H, D respectively represents the length, height and width of the material above the belt scale, H is measured by a laser range finder, rho is the material density, and S represents the speed of the belt scale measured by a rotary encoder; in the formula, H and S are in inverse proportion;
s20, calculating the flow Q1 of the real-time belt scale according to the following formula by using the weight G of the material measured by the weighing sensor:
s30, calculating the deviation ratio P of Q and Q1 according to the following formula, wherein P is [ -0.5%, 0.5% ]:
P＝[(Q-Q1)/Q]*100％
s40, when P is larger than 0.5% or smaller than-0.5%, outputting early warning, and checking whether the material height is proper: if the height of the material is not appropriate, adjusting the height of the material; if the material height is proper, indicating that the weighing sensor is in fault, and turning to the step S50;
s50, calculating the deviation C1 of G1 and G4 by taking the weight signal of the material passing through the first weighing sensor as G1 and the weight signal of the material passing through the fourth weighing sensor as G4, wherein C1 is [ (G1-G4)/G1 ]. 100%, and C1 is [ -0.5% and 0.5% ]; the weight signal passing through the second load cell is G2, the weight signal passing through the third load cell is G3, and the deviation C2 between G2 and G3 is calculated, C2 ═ G2-G3/G2 ] × 100%, and C2 is [ -0.5%, 0.5% ];
s60, if the C1 exceeds the range of +/-0.5 percent and the C2 does not exceed the range, the first weighing sensor or the fourth weighing sensor is in fault; calculating the deviation C3 between G1 and G2, wherein C3 is [ (G1-G2)/G1] 100%, and C3 is [ -0.5% and 0.5% ]; the deviation C4 between G4 and G3, C4 ═ G4-G3/G4 ] 100%, C4 [ -0.5%, 0.5% ]; if C3 is out of range, the first load cell fails; if C4 is out of range, the fourth load cell fails.
The belt scale fault positioning method compares the real-time belt scale flow with the belt scale flow to judge whether a fault occurs; when a fault occurs, the problem of the height of the material is firstly solved, then the data monitored by the weighing sensors at different positions on the same weighing carrier roller are compared, the data monitored by the weighing sensors at different weighing carrier rollers in the material conveying direction are compared, and then the fault occurring position can be judged. The invention can not only monitor the metering accuracy of the belt scale in real time, but also accurately judge the fault position caused by the weighing sensor, reduce the fault troubleshooting time and reduce the process quality risk.
Compared with the prior art, the invention has the beneficial effects that:
the constant flow control system and the belt scale fault positioning method not only can monitor the metering accuracy of the belt scale in real time, but also can accurately judge the fault position caused by the weighing sensor, thereby reducing the fault troubleshooting time and reducing the process quality risk.
Drawings
FIG. 1 is a schematic structural diagram I of an electronic belt scale system;
FIG. 2 is a schematic structural diagram II of an electronic belt scale system;
FIG. 3 is a schematic view of the construction of the limiting tube;
FIG. 4 is a schematic structural view of a material distribution device;
in the drawings: 1-a material distribution device; 11-a cloth belt; 12-a height sensor; 2-temporary storage cabinet; 3-electronic belt scale system; 31-a limiting tube; 32-a drive roll; 33-a driven roller; 34-a belt; 35-laser rangefinder; 36-a drive motor; 37-a first transition idler; 38-a second transition idler; 39-a first weighing idler; 310-a second weighing idler; 311-a first load cell; 312-a second load cell; 313-a third load cell; 314-a fourth load cell; 315-a tubular body; 316-measuring the light curtain.
Detailed Description
The present invention will be further described with reference to the following embodiments. Wherein the showings are for the purpose of illustration only and are shown by way of illustration only and not in actual form, and are not to be construed as limiting the present patent; to better illustrate the embodiments of the present invention, some parts of the drawings may be omitted, enlarged or reduced, and do not represent the size of an actual product; it will be understood by those skilled in the art that certain well-known structures in the drawings and descriptions thereof may be omitted.
The same or similar reference numerals in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there is an orientation or positional relationship indicated by the terms "upper", "lower", "left", "right", etc. based on the orientation or positional relationship shown in the drawings, it is only for convenience of describing the present invention and simplifying the description, but it is not intended to indicate or imply that the referred device or element must have a specific orientation, be constructed in a specific orientation, and be operated, and therefore, the terms describing the positional relationship in the drawings are only used for illustrative purposes and are not to be construed as limiting the present patent, and the specific meaning of the terms may be understood by those skilled in the art according to specific circumstances.
Example one
The embodiment of the constant flow control system includes a feeder including a material distribution device 1, a temporary storage cabinet 2 and an electronic belt scale system 3, wherein the temporary storage cabinet 2 is disposed below the material distribution device 1, and the electronic belt 34 scale system is provided with a limiting pipe 31 for receiving cut tobacco from the temporary storage cabinet 2. As shown in fig. 1, the electronic belt scale system 3 includes a controller, a carrier roller, a driving roller 32, a driven roller 33, a belt 34 surrounding the carrier roller, the driving roller 32 and the driven roller 33, the carrier roller being located between the driving roller 32 and the driven roller 33, and a limiting tube 31 being located above an end of the belt 34: a laser range finder 35 for measuring the height of the material is arranged above the belt 34; the driving roller 32 is connected with a driving motor 36, and a rotating shaft of the driving motor 36 is provided with a rotary encoder for measuring the running speed of the belt 34; the bearing roller has multiunit weighing sensor, and multiunit weighing sensor is located the different positions of bearing roller, and laser range finder 35, weighing sensor, rotary encoder all connect in the controller.
In the implementation of the embodiment, the laser range finder 35 monitors the height of a material in real time, the rotary encoder monitors the running speed of the belt scale in real time, the flow Q of the belt scale is calculated according to monitored data and the attribute of the material, the weighing sensor monitors the weight of the material above in real time, the flow Q1 of the belt scale is calculated according to the monitored weight of the material, and the flow Q1 of the belt scale is compared with the flow Q of the belt scale to judge whether a fault occurs; when a fault occurs, the data monitored by the weighing sensors at different positions on the same weighing carrier roller are compared, and the data monitored by the weighing sensors at different weighing carrier rollers along the material conveying direction are compared, so that the fault occurring position can be judged. Therefore, the belt scale can monitor the metering accuracy of the belt scale in real time, can accurately judge the fault position caused by the weighing sensor, reduces the fault troubleshooting time and reduces the process quality risk.
The idler comprises a first transition idler 37, a second transition idler 38, a first weighing idler 39 and a second weighing idler 310 which are arranged in parallel, the first weighing idler 39 and the second weighing idler 310 are located between the first transition idler 37 and the second transition idler 38, and the weighing sensors are mounted on the first weighing idler 39 and the second weighing idler 310. The belt weigher of the present embodiment adopts a double-idler belt weigher, but the idler of the present invention is not limited to two sets of weighing idlers, namely the first weighing idler 39 and the second weighing idler 310, and the number of the weighing idlers can be correspondingly increased or the positions of the weighing idlers can be adjusted according to application requirements. In the normal production process, the material uniformly and continuously passes through the first weighing carrier roller 39 and the second weighing carrier roller 310, theoretically, the weight signals of the same material passing through the first weighing carrier roller 39 and the second weighing carrier roller 310 are consistent, and the condition that the weight signals are inconsistent can be generated only when a weighing sensor fails.
The weighing sensors comprise a first weighing sensor 311, a second weighing sensor 312, a third weighing sensor 313 and a fourth weighing sensor 314, the first weighing sensor 311 and the second weighing sensor 312 are respectively installed at two end parts of the first weighing carrier roller 39, and the third weighing sensor 313 and the fourth weighing sensor 314 are respectively installed at two end parts of the second weighing carrier roller 310. The positions of the first weighing sensor 311, the second weighing sensor 312, the third weighing sensor 313 and the fourth weighing sensor 314 are arranged in such a way that on one hand, the weight difference of different positions on the same weighing idler can be compared, on the other hand, the weight difference of different weighing idlers monitored along the material direction can be compared, and on the other hand, the fault occurrence positions can be accurately and quickly determined through transverse comparison and longitudinal comparison.
The limiting tube 31 is of a square structure, and the material falling into the belt 34 from the limiting tube 31 is approximately cuboid. The shape of the material falling from the limiting tube 31 is similar to that of the limiting tube 31, and the volume, weight and belt scale flow of the material can be calculated simply and quickly by setting the limiting tube 31 to be a square body in the embodiment. When the material is a cube, the correlation between the flow of the belt scale and the weight of the material and the running speed of the belt scale can be deduced from a calculation formula of the flow of the belt scale, and the running speed of the belt 34 is inversely proportional to the height of the material. It can be presumed that: when the monitored belt scale flow is abnormal, the height of the material is possibly abnormal, the weighing sensor is possibly failed, and if the height of the material is eliminated, the failure position can be determined according to the monitoring data of the weighing sensors at different positions.
The distributing device 1 comprises a cloth belt 11 and height sensors 12 arranged at two ends of the cloth belt 11, the height sensors 12 are connected to the input end of the controller, and the output end of the controller is connected with a display module used for displaying the height of materials in the temporary storage cabinet 2. In prior art, the diffuse reflection photoelectric tube is adopted at cloth motor both ends to detect the material height, and the photoelectric tube is used for surveying the material height, and when two photoelectric tubes all detected the material, it had piled up required height to explain the material, and the cloth car was moved to the direction of keeping away from the stockpile this moment, stopped immediately when high material level detection photoelectric switch can not visit the material, continues the feeding at this new position, so relapse. The mode of adopting photoelectric tube to survey, if the material does not have at suitable high cloth in the cabinet, the material height of unable timely regulation photoelectric tube under the condition of having the material in the cabinet, and adjust again and have the difference with actual material under the material condition, need adjust many times sometimes and just can reach suitable height, on the other hand, when adjusting, maintainer need get into the internal regulation of cabinet, though there is the safeguard measure, but can not avoid the possibility of maloperation completely and lead to the emergence of incident.
The height sensor 12 is an ultrasonic sensor, and at least two groups of ultrasonic sensors are arranged at each end of the cloth belt 11. Wherein, two sets of ultrasonic sensor include a high material level ultrasonic sensor and a low material level ultrasonic sensor. The ultrasonic sensor is adopted to replace a photoelectric tube in the prior art to detect the height of the material, the analog quantity is used for outputting, and the real-time height H of the material can be displayed in real time to achieve the visualization of the height; in the feed process, height value H is set for in the input, when H is greater than or equal to H, the control cloth vehicle keeps away from the operation of stockpile direction, novel distributing device 1 is the material height when more being convenient for adjust the cloth, the regulatory function when being convenient for there is the material in the cabinet, reliability when having improved the cloth, the operating personnel's of being more convenient for regulation, high efficiency when having improved the regulation material, accuracy, operating personnel's when having improved the regulation security, the material stability for follow-up belt weigher provides reliable assurance.
The limiting tube 31 comprises a tube body and a measuring light curtain 316 used for measuring the real-time height of tobacco shreds, the measuring light curtain 316 is installed on the side portion of the tube body, the measuring light curtain 316 is connected with a controller, and materials in the temporary storage cabinet 2 are conveyed into the limiting tube 31 through a lifting assembly consisting of a lifting belt and a lifting belt motor. In the prior art, the height of tobacco shreds is monitored by adopting an upper photoelectric sensor, a middle photoelectric sensor and a lower photoelectric sensor: when the lower sensor is empty, the limiting tube 31 feeds materials at a high speed; when the lower sensor is shielded, feeding at a medium speed; when the middle sensor shelters from, then low-speed feeding, stop the feeding when the high-order shelters from, this kind of controlling means and method can lead to the lifting belt to open frequently because how much of tobacco shred volume opens and stops, leads to equipment mechanical loss great. In this embodiment, the measuring light curtain 316 is used to replace the original sensor, and the original digital output signal is changed into the analog output signal. Specifically, the limiting tube 31 is at least provided with a transparent side wall, the measuring light curtain 316 is installed on the transparent side wall, and the measuring light curtain 316 outputs a current signal of 4 mA-20 mA according to the height of the tobacco shred in the limiting tube 31. During implementation, the tobacco shred height H in the limiting tube 31 is set, a set output analog signal A corresponding to the measuring light curtain 316 is calculated, the real-time tobacco shred height is measured, an analog signal A1 is output, A1 and A are compared, and when A1 is smaller than A, the lifting belt motor is controlled to operate at an accelerated speed by a coefficient X, and material supply is accelerated; when A1 is larger than A, controlling the lifting belt motor to run at a speed reduction coefficient X to slow down material supply; through this kind of control mode, guarantee that the pipe tobacco in the limit pipe 31 maintains at setting for height H, when guaranteeing steadily to give the downstream equipment feed, reduced the steady operation of upper reaches hoisting belt, reduce the number of times that frequently opens and stops, can reduce the loss of equipment machinery, reduce the garrulous of making of pipe tobacco. In summary, in the constant flow control system of the present invention, the material distributing device controls the material distributing action through the height sensor 12, so that the material in the temporary storage cabinet 2 is moderate in height and is evenly distributed, the material feeding process of the temporary storage cabinet 2 changes the bottom belt running speed of the upper temporary storage cabinet 2 through the signal feedback of the measuring light curtain 316 on the limiting pipe 31, so that the material in the limiting pipe 31 keeps stable height, and provides stable material support for the belt scale, the weighing sensor on the weighing carrier roller of the belt scale monitors the weight G of the material above in real time, and calculates the real-time belt scale running speed V according to the set flow rate, the belt scale runs stably at the running speed V, when the weighing sensor detects that the weight G1 of the material above is less than G, the belt scale increases the running speed, and when G1 is greater than G, the belt scale decreases the running speed, so as to achieve the effect of.
Example two
The embodiment is an embodiment of a belt scale fault positioning method, and comprises the following steps:
s10, establishing a material model conveyed to the belt weigher by the limiting pipe 31, and calculating the flow Q of the belt weigher according to the following formula:
in the formula, L, H, D respectively represents the length, height and width of the material above the belt scale, H is measured by the laser range finder 35, rho is the material density, and S represents the speed of the belt scale measured by the rotary encoder; in the formula, H and S are in inverse proportion;
s20, calculating the flow Q1 of the real-time belt scale according to the following formula by using the weight G of the material measured by the weighing sensor:
s30, calculating the deviation ratio P of Q and Q1 according to the following formula, wherein P is [ -0.5%, 0.5% ]:
P＝[(Q-Q1)/Q]*100％
s40, when P is larger than 0.5% or smaller than-0.5%, outputting early warning, and checking whether the material height is proper: if the height of the material is not appropriate, adjusting the height of the material; if the material height is proper, indicating that the weighing sensor is in fault, and turning to the step S50;
s50, calculating the deviation C1 of G1 and G4 by using a weight signal G1 when the material passes through the first weighing sensor 311 and a weight signal G4 when the material passes through the fourth weighing sensor 314, wherein C1 is [ (G1-G4)/G1 ]. 100%, and C1 is [ -0.5% and 0.5% ]; the weight signal passing through the second load cell 312 is G2, the weight signal passing through the third load cell 313 is G3, and the deviation C2 between G2 and G3 is calculated, C2 ═ [ (G2-G3)/G2] × 100%, and C2 is [ -0.5%, 0.5% ];
s60, if the C1 exceeds the range of +/-0.5 percent and the C2 does not exceed the range, the first weighing sensor 311 or the fourth weighing sensor 314 is in fault; calculating the deviation C3 between G1 and G2, wherein C3 is [ (G1-G2)/G1] 100%, and C3 is [ -0.5% and 0.5% ]; the deviation C4 between G4 and G3, C4 ═ G4-G3/G4 ] 100%, C4 [ -0.5%, 0.5% ]; if C3 is out of range, first load cell 311 fails; if C4 is out of range, fourth load cell 314 fails.
Through the steps, the metering accuracy of the belt scale can be monitored in real time, meanwhile, the fault position caused by the weighing sensor can be accurately judged, the troubleshooting time is shortened, and the process quality risk is reduced.
It should be understood that the above-described embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. Other variations and modifications will be apparent to persons skilled in the art in light of the above description. And are neither required nor exhaustive of all embodiments. Any modification, equivalent replacement, and improvement made within the spirit and principle of the present invention should be included in the protection scope of the claims of the present invention.
Claims (10)
1. A constant flow control system comprises a material distribution device (1), a temporary storage cabinet (2) and an electronic belt scale system (3), wherein the temporary storage cabinet (2) is arranged below the material distribution device (1), and the electronic belt scale system (34) is provided with a limiting pipe (31) for receiving cut tobaccos from the temporary storage cabinet (2); the electronic belt scale system (3) is characterized by comprising a controller, a carrier roller, a driving roller (32) and a driven roller (33), wherein a belt (34) surrounds the carrier roller, the driving roller (32) and the driven roller (33), the carrier roller is positioned between the driving roller (32) and the driven roller (33), and a limiting pipe (31) is positioned above the end part of the belt (34): a laser range finder (35) for measuring the height of the material is arranged above the belt (34); the driving roller (32) is connected with a driving motor (36), and a rotating shaft of the driving motor (36) is provided with a rotary encoder for measuring the running speed of the belt (34); a plurality of groups of weighing sensors are arranged below the carrier roller and are positioned at different positions of the carrier roller; the laser range finder (35), the weighing sensor and the rotary encoder are all connected to the controller.
2. The constant flow control system according to claim 1, wherein the idlers include a first transition idler (37), a second transition idler (38), a first weighing idler (39) and a second weighing idler (310) which are arranged in parallel, the first weighing idler (39) and the second weighing idler (310) are positioned between the first transition idler (37) and the second transition idler (38), and the weighing sensors are mounted on the first weighing idler (39) and the second weighing idler (310).
3. The constant flow control system according to claim 2, wherein the load cells comprise a first load cell (311), a second load cell (312), a third load cell (313) and a fourth load cell (314), the first load cell (311) and the second load cell (312) are respectively mounted at two ends of the first weighing idler (39), and the third load cell (313) and the fourth load cell (314) are respectively mounted at two ends of the second weighing idler (310).
4. A constant flow control system according to any of claims 1 to 3, wherein the restriction (31) is of a cuboid configuration and the material falling from the restriction (31) onto the belt (34) is of a nearly cuboid configuration.
5. The constant flow control system according to claim 4, wherein the limiting tube (31) comprises a tube body (315) and a measuring light curtain (316) for measuring the real-time height of the cut tobacco, the measuring light curtain (316) is mounted at the side of the tube body (315) and the measuring light curtain (316) is connected with the controller.
6. The constant flow control system according to claim 5, wherein the limiting tube (31) is provided with at least one transparent side wall, the measuring light curtain (316) is installed on the transparent side wall, and the measuring light curtain (316) outputs a current signal of 4 mA-20 mA according to the height of tobacco shreds in the limiting tube (31).
7. The constant flow control system according to claim 1, wherein the material distribution device (1) comprises a material distribution belt (11) and height sensors (12) arranged at two ends of the material distribution belt (11), the height sensors (12) are connected to an input end of the controller, and an output end of the controller is connected with a display module for displaying the height of the material in the temporary storage cabinet (2).
8. The constant flow control system according to claim 7, wherein the height sensors (12) are ultrasonic sensors, and at least two sets of ultrasonic sensors are provided at each end of the cloth tape (11).
9. The constant flow control system of claim 8, wherein the two sets of ultrasonic sensors comprise a high level ultrasonic sensor and a low level ultrasonic sensor.
10. A belt scale fault positioning method is characterized by comprising the following steps:
s10, establishing a material model conveyed to the belt weigher by a limiting pipe (31), and calculating the flow Q of the belt weigher according to the following formula:
in the formula, L, H, D respectively represents the length, height and width of the material above the belt scale, H is measured by a laser range finder (35), rho is the material density, and S represents the running speed of the belt scale measured by a rotary encoder; in the formula, H and S are in inverse proportion;
s20, calculating the flow Q1 of the real-time belt scale according to the following formula by using the weight G of the material measured by the weighing sensor:
s30, calculating the deviation ratio P of Q and Q1 according to the following formula, wherein P is [ -0.5%, 0.5% ]:
P＝[(Q-Q1)/Q]*100％
s40, outputting early warning when P is larger than 0.5% or smaller than-0.5%; checking whether the material height is proper: if the height of the material is not appropriate, adjusting the height of the material; if the material height is proper, indicating that the weighing sensor is in fault, and turning to the step S50;
s50, calculating the deviation C1 of G1 and G4 by taking the weight signal of the material passing through the first weighing sensor (311) as G1 and the weight signal passing through the fourth weighing sensor (314) as G4, wherein C1 is [ (G1-G4)/G1] 100%, and C1 is [ -0.5% and 0.5% ]; the weight signal passing through the second load cell (312) is G2, the weight signal passing through the third load cell (313) is G3, and the deviation C2 of G2 and G3 is calculated, wherein C2 is [ (G2-G3)/G2 ]. 100%, and C2 is [ -0.5%, 0.5% ];
s60, if the C1 exceeds the range of +/-0.5% and the C2 does not exceed the range, the first weighing sensor (311) or the fourth weighing sensor (314) is in fault; calculating the deviation C3 between G1 and G2, wherein C3 is [ (G1-G2)/G1] 100%, and C3 is [ -0.5% and 0.5% ]; the deviation C4 between G4 and G3, C4 ═ G4-G3/G4 ] 100%, C4 [ -0.5%, 0.5% ]; if C3 is out of range, the first load cell (311) is malfunctioning; if C4 is out of range, the fourth load cell (314) fails.
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