CN113341867A - Full-automatic green tea stir-frying distributed control system and method based on PLC - Google Patents
Full-automatic green tea stir-frying distributed control system and method based on PLC Download PDFInfo
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- CN113341867A CN113341867A CN202110664332.XA CN202110664332A CN113341867A CN 113341867 A CN113341867 A CN 113341867A CN 202110664332 A CN202110664332 A CN 202110664332A CN 113341867 A CN113341867 A CN 113341867A
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- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
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Abstract
The invention discloses a full-automatic green tea stir-frying distributed control system and a full-automatic green tea stir-frying distributed control method based on a Programmable Logic Controller (PLC), wherein the full-automatic green tea stir-frying distributed control system comprises an information management level, a user monitoring level, a system control level and a field device level; the information management stage comprises an industrial control computer and a printer; the user monitoring stage comprises a touch screen, a camera and a digital tube display screen; the system control level comprises a weighing system and a frying system; the field control stage comprises a feeding mechanism, a lifting mechanism, a material conveying mechanism, a weighing mechanism, a stir-drying mechanism, a polishing mechanism, an actuating mechanism, a power transmission mechanism, a PLC (programmable logic controller) and a data acquisition system; the system control level realizes automatic control through Ethernet communication of the master station PLC and the slave station PLC, the user monitoring level can effectively monitor the operation of the whole system, when a fault occurs, a monitoring picture can directly jump to a fault page, and an industrial personal computer monitors and feeds back in real time and timely checks and processes the fault. The distributed control system realizes accurate control on temperature, leaf throwing amount, running time and the like.
Description
Technical Field
The invention relates to the field of tea production line control, in particular to a full-automatic green tea stir-frying distributed control system and method based on a Programmable Logic Controller (PLC).
Background
The green tea is unfermented, has the highest Chinese yield, is the most widely drunk tea, contains tea polyphenol, has the antioxidation effect, and the caffeine in the green tea can promote the excitation of the central nerve of a human body, enhance the excitation process of cerebral cortex, and has the effects of refreshing, benefiting thinking and clearing heart. In the production process of green tea, the green tea needs to be subjected to enzyme deactivation, rolling, drying and stir-frying. The green tea is fried to dry mainly by removing water from the tea, the step is also a key step related to the color, aroma and taste of the finally formed tea, meanwhile, the temperature for frying is well controlled, and if the temperature is too high, the water loss of the tea is too much, so that the tea is dried; if the temperature is too low, the moisture content of the tea leaves is too high, which is not beneficial to subsequent storage and reduces the quality of the tea leaves. However, in China, the tea leaf stir-drying machine is still in a semi-mechanical and semi-manual level, intelligent full-automatic production is not formed, most of tea leaves are manually judged to be dry-dried time and temperature according to feeling and experience, and the quality of the tea leaves cannot be guaranteed. The existing tea roasting machine can not accurately set feeding amount, the distribution of the roasting time is unreasonable, and the temperature can not be accurately controlled. Tea manufacturing cost is big, and tea factory's benefit is low, based on this problem, provides a full-automatic green tea stir-fry futilely distributed control system based on PLC, can realize full-automatic intelligent control, has guaranteed the accurate cooperation of each link of the feeding volume and temperature and time that tealeaves was fried futilely, and distributed control system has reduced artificial intervention, has reduced manufacturing cost, and tealeaves quality has obtained the assurance.
Disclosure of Invention
The technical problem that this patent was solved adopts following technical scheme to realize: the utility model provides a full-automatic green tea stir-fry futilely distributed control system and method based on PLC, whole stir-fry futilely distributed control system full automatization operation, to wherein key link, the weight of weighing, stir-fry futilely the temperature, stir-fry machine operating time isoparametric carries out accurate the accuse, timely investigation and the trouble of solving to fry the dry in-process appearance, guaranteed that the moisture content after tealeaves is fried futilely is in certain extent, reduced artificial intervention, improved the quality of tealeaves.
The invention solves the technical problems by the following scheme:
a full-automatic green tea stir-frying distributed control system based on a PLC comprises an information management level, a user monitoring level, a system control level and a field device level, wherein the information management level is connected with the user monitoring level, the system control level and the field device level in a management mode, the user monitoring level is connected with the system control level and the field device level in a monitoring mode, and the system control level is connected with the field device level in a control mode; the information management stage comprises an industrial personal computer and a printer; the user monitoring stage comprises a touch screen, a camera and a digital tube display screen; the system control level comprises a stir-drying system and a weighing system; the field device level comprises a drying mechanism, a feeding mechanism, a stir-frying unit, a lifting mechanism, a weighing unit, a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an executing mechanism, a PLC (programmable logic controller), a PLC-controlled electrical cabinet and a data acquisition system; the feeding mechanism is connected with the drying mechanism and the weighing unit, the lifting mechanism is connected with the frying unit and the weighing unit, and the conveying mechanism is integrally arranged on the rear side of the frying unit; the polishing mechanism is arranged at the front lower part of the frying unit; the power transmission mechanism is respectively arranged at the bottoms of the feeding mechanism, the material conveying mechanism, the frying unit, the lifting mechanism and the polishing mechanism, and the rotating speed is adjusted through a frequency converter; the PLC is divided into a master station PLC and a slave station PLC, the master station PLC is installed in a PLC control electric cabinet of the master station, the slave station PLC is installed in a PLC control electric cabinet of the slave station, communication is achieved through Ethernet connection, and an execution mechanism is connected with a drying mechanism, a feeding mechanism, a stir-frying unit, a lifting mechanism, a weighing unit, a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an execution mechanism, the PLC and a data acquisition system; the data acquisition system comprises a temperature detection module, an analog input module and an analog output module.
Preferably, two industrial control computers are arranged, one industrial control computer is used for automatically operating monitoring and control of a field device level, checking historical operation data in real time, troubleshooting and alarming; and the other industrial control computer is connected with the camera through Bluetooth and is used for monitoring pictures of field device level operation, and if the field device level fails, the other industrial control computer jumps to the failure pictures in real time to remove the failures in time.
Preferably, the touch screen and the nixie tube display screen are respectively and independently installed on a panel of the PLC controlled electrical cabinet, and the nixie tube display screen is used for displaying the weighing weight data, the serial number of the roasting mechanism, the working time of the roasting mechanism and the working time of the polishing mechanism; the touch screen is connected with the master station PLC through the Ethernet, and programs on the touch screen comprise a user login interface, parameter setting, stir-drying process monitoring and the change trend of analog input data.
Preferably, the weighing sensor transmits the collected weight signal to be converted into a voltage signal, and the voltage signal is input into the analog quantity input module and output through the analog quantity input module; the temperature detection module adopts a PT100 resistance-type temperature sensor, is uniformly arranged on the outer wall of the roasting mechanism, and outputs a resistance signal which is transmitted and converted into a voltage signal, and the voltage signal is input into the analog input module and output through the analog input module; the nixie tube display screen is communicated with the master station PLC and the slave station PLC through an MODBUS protocol to display data output by the analog input module in real time.
Preferably, every two frying mechanisms are controlled by one slave station PLC, and all the slave station PLCs realize automatic operation through communication with the master station PLC.
The data acquisition system sends data to the slave station PLC, the slave station PLC program sends commands to control all the devices, all the devices automatically run through the slave station PLC program, an engineer can monitor the running state and change of the program in real time, and when one device breaks down, troubleshooting and fault handling can be carried out in real time.
Preferably, the frying unit comprises a frying machine, a smoke outlet, a feeding auger, a biomass fuel feeding port, a frying machine engine and a fried dry tea residue port; the smoke outlet is arranged at the upper part of the roasting machine, the biomass fuel feeding port is arranged at the middle part of the roasting machine and is connected with the roasting machine through the feeding auger, the engine of the roasting machine is arranged at the lower part of the rear part of the roasting machine, and the tea leaf residue frying port is arranged at the front part of the roasting machine.
Preferably, the material conveying mechanism comprises a material conveying conveyor belt No. 4, a material conveying conveyor belt No. 3, a material conveying conveyor belt No. 2, a material conveying conveyor belt No. 1 and a material conveying conveyor belt main bracket; the rear upper portion of the frying unit is provided with a material conveying conveyor belt main support, and a material conveying conveyor belt 4, a material conveying conveyor belt 3, a material conveying conveyor belt 2 and a material conveying conveyor belt 1 are sequentially arranged on the material conveying conveyor belt main support from left to right.
Preferably, the polishing mechanism comprises a polishing machine, a polishing machine engine, a polishing machine feeding port and a step; the polishing mechanism is arranged at the lower part of the frying unit, a polishing machine engine is arranged at the rear part of the polishing machine, the polishing machine engine is in power connection with the polishing machine, a polishing machine feeding port is arranged at the joint of the frying unit and the polishing mechanism, and a step is arranged at the front part of the polishing machine feeding port.
Preferably, the weighing unit comprises an upper weighing conveyor belt, a lower weighing conveyor belt and a weight sensor; the weight sensors are fixed at the lower parts of the upper weighing conveyer belt and the lower weighing conveyer belt; install the blanking funnel directly over one side between upper weighing conveyer belt and the lower floor weighing conveyer belt, the inboard fender that installs of blanking funnel turns over the board, keeps off and turns over board electric connection photoelectric sensor, and photoelectric sensor electric control keeps off the material and turns over the board.
Further, weight data among the weighing sensor can set for certain weight through the display screen, and weighing sensor and changer are connected with slave station PLC through MODBUS communication protocol, can show the weight data on the conveyer belt on the charactron display screen in real time, conveniently observe.
Further, the frequency converter is connected with an analog output module EMAQ04 through a slave station PLC and outputs voltage signals to control the rotating speed of each engine.
Furthermore, the temperature sensor of the temperature detection module adopts PT100 as a temperature measuring element, the temperature sensor is uniformly arranged on the wall and the bottom of the roasting machine barrel, the output resistance value is converted into a voltage value through a temperature transmitter, then the output resistance value is connected with an analog quantity input module EMAE04 through a station PLC, and the temperature is regulated and controlled by fuzzy PID, so that the temperature is kept constant.
Furthermore, the touch screen is a Willon touch screen, an upper computer program is compiled to set relevant parameters, the variation trend of temperature and weight data is monitored, and the operation of the distributed control system of the roasting machine is realized in real time.
Further, the master station PLC model is Siemens PLC S7-200 smart CPU ST 60.
Further, the slave station PLC model is Siemens PLC S7-200 smart CPU ST 30.
Furthermore, the type of the weighing sensor is JLBU-1, and the weight is 200kg at most.
Furthermore, the rated power of the engine is 0.55KW, and the frequency is 50 Hz.
Further, the frequency converter is a Siemens frequency converter, and the model of the Siemens frequency converter is MM 440.
A full-automatic green tea stir-frying distributed control method based on a PLC comprises the following steps:
1) weighing: tea leaves are dried by the drying mechanism and then conveyed to the weighing unit by the feeding mechanism for weighing, the tea leaves firstly enter the blanking hopper, the photoelectric sensor receives signals to control the material blocking turning plate to face upwards and blank the tea leaves to the upper layer weighing conveyor belt, at the moment, the frequency converter controls the upper layer weighing conveyor belt to firstly realize slow operation, and the operation is stopped for 2s every 8 s;
the weighing sensor reads weight data of the upper weighing conveyor belt, the weight data are converted into voltage signals through transmission, the voltage signals enter the slave station PLC, the voltage signals are displayed on the nixie tube display screen through an MODBUS protocol, the weight data can be read in real time, when the weight of tea leaves on the upper weighing conveyor belt reaches a preset value, the frequency converter controls the upper weighing conveyor belt to rapidly operate, and quantitative tea leaves are conveyed to the No. N roasting machine through the lifting mechanism and the material conveying mechanism to be roasted and polished;
meanwhile, once the weight of the upper weighing conveyor belt reaches a set value, the photoelectric sensor controls the turning plate to move downwards, tea leaves are discharged to the lower weighing conveyor belt, the frequency converter is provided with two sections of low speed and high speed respectively, the low speed is 8s when the lower weighing conveyor belt runs and is stopped for 2s, after a certain time, the lower weighing conveyor belt conveys the tea leaves to a No. N +1 roasting machine through the lifting mechanism after the tea leaves reach the set weight, and the process is repeated;
2) parching: firstly, starting a roasting machine engine behind a roasting machine, starting a polishing machine engine at the same time, enabling the roasting machine to rotate forwards to preheat the roasting machine, controlling a No. 1 material conveying conveyor belt, a No. 2 material conveying conveyor belt, a No. 3 material conveying conveyor belt and a No. 4 material conveying conveyor belt to rotate forwards from a slave station PLC (programmable logic controller), and enabling tea leaves to enter the No. 1, the No. 2, the No. 3 and the No. 4 roasting machines respectively;
when the number 1 roasting machine is ready for feeding, a signal can be fed back to the master station PLC by the slave station PLC, the master station PLC can also send a signal to the slave station PLC, the slave station PLC controls the first roasting machine to start automatic operation, the number 1 roasting machine is controlled automatically by the slave station PLC, and the slave station PLC adopts a polling algorithm to realize accurate control; the temperature acquisition modules of the data acquisition control system are uniformly arranged on the outer wall of the roasting machine, the output resistance value is converted into a voltage signal through transmission and is input into the analog input module, the control of the biomass fuel feeding amount from the biomass fuel feeding port through the feeding auger is realized through PID temperature control, so that the accurate automatic control of the internal temperature of the roasting machine is realized, and the real-time detection of the internal temperature of the roasting machine is realized through observing the change curve of the temperature on the touch screen;
when the time of the positive rotation of the polishing machine reaches the set time, the polishing machine starts to rotate reversely, the tea leaves after being fried and dried enter the polishing machine through a corresponding feeding hole of the polishing machine to start to work, the polishing machine rotates forwards, meanwhile, when the time of the positive rotation of the polishing machine reaches the set time, the polishing machine starts to rotate reversely, the PLC of the slave station PLC controls an electric cabinet panel to monitor the working time of the positive rotation and the reverse rotation of the drying machine and the polishing machine in real time through a nixie tube display screen, meanwhile, the time of the positive rotation of the drying machine, the reverse rotation of the drying machine, the positive rotation of the polishing machine and the reverse rotation of the polishing machine is set in the slave station PLC, and after the reverse rotation time is over, the tea leaves after being polished are transported to a finished product area through a power transmission mechanism at the bottom to carry out subsequent treatment of the tea leaves.
The beneficial technical effects which can be realized by the invention at least comprise: the green tea stir-frying distributed control system designed by the invention consists of a weighing module and a stir-frying module, the whole stir-frying distributed control system is operated automatically, parameters such as key links, weighing weight, stir-frying temperature, working time of a stir-frying machine and the like are accurately controlled, the PLC is used for performing accurate polling control, faults occurring in the stir-frying process are timely checked and solved, the water content of tea after stir-frying is ensured to be within a certain range, manual intervention is reduced, the quality of tea is improved, the loss of various manpower and material resources is reduced through full-automatic operation, the production cost is reduced while the working efficiency is improved, the economic benefit is greatly improved, and the system has remarkable practicability and creativity.
Drawings
Fig. 1 is a schematic general diagram of a mechanical apparatus of a green tea parching distributed control system according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of the mechanical equipment of a green tea sauteing unit provided in an embodiment of the invention.
Fig. 3 is a schematic diagram of a mechanical apparatus of a green tea weighing cell provided in an embodiment of the present invention.
Fig. 4 is a block diagram of a PLC distributed control system according to an embodiment of the present invention.
Fig. 5 is a general diagram of a control system flow design provided in an embodiment of the present invention.
Fig. 6 is a flow chart of a parching unit provided in an embodiment of the present invention.
Fig. 7 is a touch screen simulation interface provided in an embodiment of the present invention.
In the figure: 1. a parching unit; 2. a lifting mechanism; 3. a weighing unit; 11. a smoke outlet; number 12.4 material conveying belt; 13.3 material conveying belt; 14. a biomass fuel feed inlet; no. 15.2 material conveying belt; number 16.1 material conveying belt; 17. a material conveying conveyor belt main bracket; 18. a roasting machine engine; 19. frying the dried tea leaves; 110. a polishing machine engine; 111. a feeding hole of the polishing machine; 112. a landing; 31. an upper weighing conveyer belt; 32. a lower weighing conveyer belt; 33. and a weighing sensor.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
A full-automatic green tea stir-frying distributed control system based on a PLC comprises an information management level, a user monitoring level, a system control level and a field device level, wherein the information management level is connected with the user monitoring level, the system control level and the field device level in a management mode, the user monitoring level is connected with the system control level and the field device level in a monitoring mode, and the system control level is connected with the field device level in a control mode;
the information management stage comprises an industrial personal computer and a printer; the user monitoring stage comprises a touch screen, a camera and a digital tube display screen; the system control level comprises a stir-drying system and a weighing system; the field device level comprises a drying mechanism, a feeding mechanism, a stir-frying unit 1, a lifting mechanism 2, a weighing unit 3, a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an execution mechanism, a PLC (programmable logic controller), a PLC control electrical cabinet and a data acquisition system;
the feeding mechanism is connected with the drying mechanism and the weighing unit 3, the lifting mechanism 2 is connected with the frying unit 1 and the weighing unit 3, and the conveying mechanism is integrally arranged on the rear side of the frying unit 1; the polishing mechanism is arranged at the front lower part of the frying unit 1; the power transmission mechanisms are respectively arranged at the bottoms of the feeding mechanism, the material conveying mechanism, the frying unit 1, the lifting mechanism 2 and the polishing mechanism, and the rotating speed is adjusted through a frequency converter; the PLC is divided into a master station PLC and a slave station PLC, the master station PLC is arranged in a PLC control electric cabinet of the master station, the slave station PLC is arranged in a PLC control electric cabinet of the slave station, communication is realized through Ethernet connection, and an execution mechanism is connected with a drying mechanism, a feeding mechanism, a stir-frying unit 1, a lifting mechanism 2, a weighing unit 3, a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an execution mechanism, the PLC and a data acquisition system; the data acquisition system comprises a temperature detection module, an analog input module and an analog output module.
As shown in fig. 1: the mechanical equipment part of the green tea stir-frying distributed control system mainly comprises a stir-frying unit 1, a lifting mechanism 2 and a weighing unit 3, tea leaves enter the weighing unit 3 through the lifting mechanism 2 after being dried, the tea leaves are transported on the weighing unit 3 at two sections of speeds, after the set weight is reached, the tea leaves are transported into a stir-frying machine through the lifting mechanism 2, after the stir-frying is finished, the tea leaves enter a polishing machine through a blanking port, and the tea leaves are further polished and shaped, so that the quality of the tea leaves is improved.
As shown in fig. 2: the mechanical equipment of the green tea frying and drying unit mainly comprises a polishing machine, a polishing machine engine 10, a polishing machine feeding port 11, a ladder 12, a smoke outlet 11, a No. 4 material conveying belt 12, a No. 3 material conveying belt 13, a feeding auger, a biomass fuel feeding port 14, a No. 2 material conveying belt 15, a No. 1 material conveying belt 16, a material conveying belt total support 17, a frying machine engine 18 and a fried and dried tea residue port 19; wherein, outlet flue 11 is installed in the roasting machine top layer, and 4 numbers fortune material conveyer belt 12, 3 numbers fortune material conveyer belt 13, 2 numbers fortune material conveyer belt 15, 1 numbers fortune material conveyer belt 16 are installed on fortune material conveyer belt main support 17, give 1 numbers, 2 numbers, 3 numbers, 4 numbers roasting machine material loading respectively through controlling 4 numbers fortune material conveyer belt 12, 3 numbers fortune material conveyer belt 13, 2 numbers fortune material conveyer belt 15, 1 numbers fortune material conveyer belt 16 just reversing, realize automatic control. The biomass fuel feeding port 14 provides energy for the operation of the roasting machine through the feeding auger, and the control system realizes accurate control of temperature through PID fuzzy control. The positive rotation of the engine can control the roasting machine to roast dry and the negative rotation of the engine can control the blanking of the roasting machine.
As shown in fig. 3: the green tea parching and weighing unit mechanical equipment respectively comprises an upper layer weighing conveyor belt 31, a lower layer weighing conveyor belt 32 and a weighing sensor 33. Install blanking funnel directly over one side between upper weighing conveyer belt 31 and the lower floor's weighing conveyer belt 32, tealeaves passes through blanking funnel device blanking to upper weighing conveyer belt 31 or lower floor's weighing conveyer belt 32 after drying. Install the fender in blanking funnel inboard and turn over the board, keep off the material and turn over the board and pass through the photoelectric sensor response, can realize respectively keeping off the material and turn over board up-and-down motion, when keeping off the material and turn over the board upwards, tealeaves blanking to upper weighing conveyer belt 31, turn over the board when downwards, tealeaves blanking to lower floor weighing conveyer belt 32. Weighing sensor 33 is installed respectively to upper weighing conveyer belt 31 and lower floor's weighing conveyer belt 32 below, can read the weight of tealeaves on this moment the conveyer belt in real time, realizes throwing the accurate control of leaf volume.
Fig. 4 is a block diagram of a PLC distributed control system, which includes four parts, i.e., an information management stage, a user monitoring stage, a system control stage, and a field device stage. The information management stage mainly comprises two industrial control computers, one industrial control computer monitors the operation condition of the system, and the other industrial control computer processes the faults of the system in real time. The printer can print out the change conditions of the data such as temperature, time and the like when the system runs at any time. The user monitoring stage comprises a touch screen, a monitoring camera and a digital tube display screen. The touch screen can preset important parameters of the whole distributed control system and can observe the running state of the system in real time. The system control stage comprises two parts, namely a weighing link and a roasting unit, and realizes automatic control through communication between the PLCs. The field device level comprises a drying mechanism, a feeding mechanism, a stir-frying unit 1, a lifting mechanism 2, a weighing unit 3, a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an executing mechanism, a PLC (programmable logic controller), a PLC control electrical cabinet and a data acquisition system.
Fig. 5 shows a general flow design diagram of the whole distributed control system, tea leaves are dried and prepared to be discharged through a funnel, a photoelectric sensor receives signals to control a turning plate to move upwards and discharge the tea leaves to an upper-layer conveyor belt, and at the moment, a frequency converter controls the conveyor belt to firstly realize slow operation, and the operation lasts for 8s and stops for 2s every time. Upper weighing sensor reads weight data, converts voltage signal into through the analog quantity module through the changer and gets into slave station PLC, shows on upper weight charactron display screen through the MODBUS agreement, can read the data of weight in real time. After the tealeaves weight of the conveyer belt of weighing on the upper strata reached the default, the quick operation of upper conveyer belt is controlled to the converter, transports quantitative tealeaves to No. N roasting machine through promoting the conveyer belt and transporting the material conveyer belt and begins to fry futilely and the work of polishing. Meanwhile, once the weight of the upper-layer conveyor belt reaches a set value, the photoelectric sensor controls the turning plate to move downwards, tea leaves are discharged to the lower-layer conveyor belt, the frequency converter sets two sections of low speed and high speed respectively, the low speed is 8s for each operation and is stopped for 2s, and after a certain time, the lower-layer conveyor belt conveys the tea leaves to the No. N +1 roasting machine through the lifting conveyor belt after the tea leaves reach the set weight. So reciprocal, through slave station PLC and main website PLC program realization whole tealeaves fry dry collecting and distributing control system's accurate intelligent control.
Fig. 6 shows a flow design diagram of a stir-drying link of the whole distributed control system, as shown in the figure, firstly, a feeding auger engine at the rear of a stir-drying machine is started, the stir-drying machine starts to rotate forwards to preheat the stir-drying machine, a station PLC controls a material conveying conveyor belt No. 1 to rotate forwards, tea leaves enter the stir-drying machine No. 1, when the work of the stir-drying machine reaches a set time, the tea leaves start to rotate backwards, the stir-dried tea leaves enter a polishing machine through a feeding hole of the polishing machine to start to work, at the moment, the polishing machine rotates forwards, meanwhile, when the time of the forward rotation of the polishing machine reaches the set time, the polishing machine starts to rotate backwards, and after the time of the reverse rotation is over, the polished tea leaves are conveyed to a finished product area through the conveying conveyor belt at the bottom to perform subsequent treatment on the tea leaves.
Fig. 7 shows a touch screen simulation interface provided by the drying distributed control system, as shown in the figure, in order to improve the security of the system, two types of preset personnel are an engineer and an operator, only the engineer can enter a parameter setting page in the touch screen through inputting a user name and a password to preset and change parameters, the operator does not have permission to preset and change the parameters, and the operator can enter the parameter setting page again through inputting the user name and the password. On the page of parameter settings, the weight to be weighed can be set with an upper limit of 200 kg. Meanwhile, the time for feeding the weighed tea leaves into the roasting machine to be conveyed can also be set. After the roasting machine starts to work, a corresponding roasting link page can be entered, the specific work flow of roasting is observed, and a user can conveniently monitor whether the roasting machine works normally and the working time. 4 frying machine buttons are respectively arranged on a page for troubleshooting, and if the No. 2 frying machine fails, the corresponding frying machine button can be pressed down, and the frying machine is closed, so that the whole control system can directly skip the frying machine to continue sequential execution. Meanwhile, nixie tube display screens are respectively arranged on the weighing conveyer belts, so that the weight data on the weighing conveyer belts can be monitored in real time. A nixie tube display screen is also arranged on the panel of the electric cabinet of the roasting machine, so that the working time of the roasting machine can be displayed. The running time of the polishing machine is displayed through a nixie tube display screen arranged in front of the polishing machine, so that the data can be read in real time, and a user can observe the data conveniently.
Wherein, aiming at a specific PLC control part, the PLC of the main station mainly controls the operation of the upper weighing conveyer belt 31 and the lower weighing conveyer belt 32, the positive rotation and the negative rotation of the 4 conveying conveyer belts and the slave station PLC for controlling the two roasting machines. The specific mode is as follows: after the master station PLC receives the starting signal, the feed inlet turning plate is upward, the upper-layer conveyor belt is started to run at a low speed, the weight data of the upper-layer weighing sensor is read once every 8s by a polling algorithm, and the quick running of the upper-layer conveyor belt is started by controlling the frequency converter until the weight data of the upper-layer weighing conveyor belt reaches preset weight data. At the moment, the No. 1 material conveying conveyor belt is controlled to rotate forwards, and the No. 1 roasting machine is used for feeding materials. In case after the upper strata reached and set for weight, turned over the board downwards this moment, and slave station PLC can start the lower floor and weigh conveyer belt 32 and begin the operation at a slow speed, and in the same way, the charactron display screen can show real-time weight data, reaches the weight of setting for, and PLC can give the signal of No. 1 fortune material conveyer belt 16 reversal, and No. 2 fortune material conveyer belt 15 corotation gives the material loading of No. 2 fried dry machine. The operation is repeated in such a circulating way, when the No. 1 material conveying conveyor belt 16, the No. 2 material conveying conveyor belt 15 rotate forwards, and the No. 3 material conveying conveyor belt 13 rotates backwards, the No. 3 roasting machine is fed with materials; when the material conveying conveyor belt 16 of No. 1, the material conveying conveyor belt 15 of No. 2 corotate, the material conveying conveyor belt 13 of No. 3 corotates, and the material conveying conveyor belt 12 of No. 4 reverses, give the material loading of No. 4 roasting machine. And then, communication between the master station PLC and the slave station PLC is involved, when the number 1 roasting machine prepares for feeding, the slave station PLC feeds back signals to the master station PLC, and the master station PLC also sends signals to the slave station PLC to control the number 1 roasting machine to start automatic operation. The number 1 roasting machine is controlled by a slave station PLC under the automatic control. The method aims at a data acquisition control system, and mainly relates to accurate control of temperature, leaf throwing amount, operation time and other data. In the aspect of temperature, the temperature acquisition module adopts a PT100 resistance-type temperature sensor and is uniformly arranged on the outer wall of the roasting unit, and an output resistance value is converted into a voltage signal through a temperature transmitter and is input into the analog input module. The PID temperature control is used for controlling the feeding amount of the biomass fuel machine, so that the accurate and automatic control of the internal temperature of the roasting machine is realized. In the aspect of the leaf throwing amount, a weighing sensor is installed below a weighing conveyer belt in the weighing mechanism, collected weight signals are converted into voltage signals through a transmitter and input into an analog input module, a nixie tube display screen is communicated with a PLC through an MODBUS protocol, the current weight can be displayed in real time, and the PLC program is accurately controlled through a polling algorithm. In the aspect of running time, the working time of forward rotation and reverse rotation of the roasting machine and the polishing machine can be monitored in real time on the panel of the electrical control cabinet of the slave station through a nixie tube display screen. The nixie tube display screen is communicated with the PLC through an MODBUS protocol. Meanwhile, the PLC program can set the time for the forward rotation of the roasting machine, the reverse rotation of the roasting machine, the forward rotation of the polishing machine and the reverse rotation of the polishing machine.
Aiming at the fault troubleshooting part, in the automatic operation process of the distributed control system, if any roasting machine in the roasting machine set has a fault, the system can timely troubleshoot and process the fault without influencing the normal operation of the distributed control system. The operation is as follows, when the roasting machine breaks down, the industrial personal computer can jump to the picture of the fault, and the roasting machine of the fault can be closed on the touch screen, so that the skipping of the fault roasting machine is realized in the PLC program, and the feeding of the next roasting machine is directly carried out. Meanwhile, the temperature inside the roasting machine can be detected in real time by observing the change curve of the temperature on the touch screen. The distributed control system realizes accurate intelligent control of a tea frying link, reduces manual intervention and improves the quality of tea.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (10)
1. A full-automatic green tea stir-frying distributed control system based on a PLC is characterized by comprising an information management level, a user monitoring level, a system control level and a field device level, wherein the information management level is connected with the user monitoring level, the system control level and the field device level in a management mode, the user monitoring level is connected with the system control level and the field device level in a monitoring mode, and the system control level is connected with the field device level in a control mode;
the information management stage comprises an industrial personal computer and a printer; the user monitoring stage comprises a touch screen, a camera and a digital tube display screen; the system control level comprises a stir-drying system and a weighing system; the field device level comprises a drying mechanism, a feeding mechanism, a stir-frying unit (1), a lifting mechanism (2), a weighing unit (3), a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an execution mechanism, a PLC (programmable logic controller), a PLC control electrical cabinet and a data acquisition system;
the feeding mechanism is connected with the drying mechanism and the weighing unit (3), the lifting mechanism (2) is connected with the frying unit (1) and the weighing unit (3), and the conveying mechanism is integrally arranged on the rear side of the frying unit (1); the polishing mechanism is arranged at the front lower part of the frying unit (1); the power transmission mechanism is respectively arranged at the bottoms of the feeding mechanism, the material conveying mechanism, the frying unit (1), the lifting mechanism (2) and the polishing mechanism, and the rotating speed is adjusted through a frequency converter; the PLC is divided into a master station PLC and a slave station PLC, the master station PLC is installed in a PLC control electric cabinet of the master station, the slave station PLC is installed in a PLC control electric cabinet of the slave station, communication is achieved through Ethernet connection, and an execution mechanism is used for connecting a drying mechanism, a feeding mechanism, a stir-frying unit (1), a lifting mechanism (2), a weighing unit (3), a material conveying mechanism, a polishing mechanism, a power transmission mechanism, an execution mechanism, the PLC control electric cabinet and a data acquisition system; the data acquisition system comprises a temperature detection module, an analog input module and an analog output module.
2. The PLC-based full-automatic green tea stir-frying centralized and distributed control system is characterized in that two industrial control computers are arranged, one industrial control computer is used for automatically operating field device level monitoring and control, checking historical operating data in real time, troubleshooting and alarming; and the other industrial control computer is connected with the camera through Bluetooth and is used for monitoring pictures of field equipment level operation.
3. The PLC-based full-automatic green tea stir-frying distributed control system according to claim 1, wherein the touch screen and the nixie tube display screen are respectively and independently installed on a panel of a PLC-controlled electrical cabinet, and the nixie tube display screen is used for displaying weighing weight data, the number of the stir-frying mechanism, the working time of the stir-frying mechanism and the working time of the polishing mechanism;
the touch screen is connected with the master station PLC through the Ethernet, and programs on the touch screen comprise a user login interface, parameter setting, stir-drying process monitoring and the change trend of analog input data.
4. The PLC-based full-automatic green tea stir-frying distributed control system according to claim 1, wherein the weighing sensor converts the collected weight signal into a voltage signal, inputs the voltage signal into the analog input module and outputs the voltage signal through the analog input module;
the temperature detection modules are uniformly arranged on the outer wall of the roasting mechanism, and output resistance signals are transmitted and converted into voltage signals, input into the analog quantity input module and output through the analog quantity input module;
the nixie tube display screen is communicated with the master station PLC and the slave station PLC through an MODBUS protocol, and displays data output by the analog input module in real time.
5. The full-automatic green tea roasting distributed control system based on the PLC of claim 1, wherein every two roasting mechanisms are controlled by a slave station PLC, and all the slave station PLCs automatically operate by communicating with the master station PLC.
6. The PLC-based full-automatic green tea stir-frying distributed control system is characterized in that the stir-frying unit (1) comprises a stir-frying machine, a smoke outlet (11), a feeding auger, a biomass fuel feeding port (14), a stir-frying machine engine (18) and a stir-frying tea residue port (19);
the smoke outlet (11) is arranged at the upper part of the roasting machine, the biomass fuel feed inlet (14) is arranged at the middle part of the roasting machine and is connected with the roasting machine through a feed auger, the engine (18) of the roasting machine is arranged at the lower part of the rear part of the roasting machine, and the tea leaf residue frying port (19) is arranged at the front part of the roasting machine.
7. The PLC-based full-automatic green tea stir-frying distributed control system according to claim 1, wherein the material conveying mechanism comprises a material conveying belt (12) No. 4, a material conveying belt (13) No. 3, a material conveying belt (15) No. 2, a material conveying belt (16) No. 1 and a material conveying belt general support (17);
the upper portion of the rear of the frying unit (1) is provided with a material conveying conveyor belt main support (17), and a material conveying conveyor belt (12) number 4, a material conveying conveyor belt (13) number 3, a material conveying conveyor belt (15) number 2 and a material conveying conveyor belt (16) number 1 are sequentially arranged on the material conveying conveyor belt main support (17) from left to right.
8. The PLC-based full-automatic green tea parching distributed control system according to claim 1, wherein the polishing mechanism comprises a polisher, a polisher motor (110), a polisher feed inlet (111) and a bench (112);
the polishing mechanism is arranged at the lower part of the frying unit (1), a polishing machine engine (110) is arranged at the rear part of the polishing machine, the polishing machine engine (110) is in power connection with the polishing machine, a polishing machine feeding port (111) is arranged at the joint of the frying unit (1) and the polishing mechanism, and a step (112) is arranged at the front part of the polishing machine feeding port (111).
9. The PLC-based full-automatic green tea parching distributed control system according to claim 1, wherein the weighing unit (3) comprises an upper weighing conveyer belt (31), a lower weighing conveyer belt (32) and a weight sensor (33);
the weight sensor (33) is fixed at the lower parts of the upper weighing conveyer belt (31) and the lower weighing conveyer belt (32);
a blanking funnel is installed right above one side between the upper weighing conveying belt (31) and the lower weighing conveying belt (32), a material blocking turning plate is installed on the inner side of the blanking funnel, the material blocking turning plate is electrically connected with a photoelectric sensor, and the photoelectric sensor is electrically controlled to block the material blocking turning plate.
10. A full-automatic green tea stir-frying distributed control method based on a PLC is characterized by comprising the following steps:
1) weighing: tea leaves are dried by the drying mechanism and then conveyed to the weighing unit (3) by the feeding mechanism for weighing, the tea leaves firstly enter the blanking hopper, the photoelectric sensor receives signals to control the material blocking turning plate to face upwards and blanking the tea leaves to the upper layer weighing conveyor belt (31), and at the moment, the frequency converter controls the upper layer weighing conveyor belt (31) to firstly realize slow running, and the operation lasts for 8s every time and stops for 2 s;
the weighing sensor (33) reads weight data of the upper weighing conveyor belt (31), the weight data are converted into voltage signals through transmission and enter the slave station PLC, the voltage signals are displayed on the nixie tube display screen through an MODBUS protocol, the weight data can be read in real time, when the weight of tea leaves on the upper weighing conveyor belt (31) reaches a preset value, the frequency converter controls the upper weighing conveyor belt (31) to run fast, and quantitative tea leaves are conveyed to the No. N roasting machine through the lifting mechanism (2) and the material conveying mechanism to be roasted and polished;
meanwhile, once the weight of the upper weighing conveyor belt (31) reaches a set value, the photoelectric sensor controls the turning plate to move downwards, tea leaves are discharged to the lower weighing conveyor belt (32), the frequency converter is provided with two sections of low speed and high speed, the low speed is 8s per operation and is stopped for 2s, after a certain time, after the tea leaves reach the set weight, the lower weighing conveyor belt (32) conveys the tea leaves to a No. N +1 roasting machine through the lifting mechanism (2), and the steps are repeated;
2) parching: firstly, a roasting machine engine (18) behind a roasting machine is started, a polishing machine engine (110) is started at the same time, the roasting machine starts to rotate forwards to preheat the roasting machine, a slave station PLC controls a No. 1 material conveying conveyor belt (16), a No. 2 material conveying conveyor belt (15), a No. 3 material conveying conveyor belt (13) and a No. 4 material conveying conveyor belt (12) to rotate forwards, and tea leaves enter the No. 1, the No. 2, the No. 3 and the No. 4 roasting machine respectively;
when the number 1 roasting machine is ready for feeding, a signal can be fed back to the master station PLC by the slave station PLC, the master station PLC can also send a signal to the slave station PLC, the slave station PLC controls the first roasting machine to start automatic operation, the number 1 roasting machine is controlled automatically by the slave station PLC, and the slave station PLC adopts a polling algorithm to realize accurate control; temperature acquisition modules of the data acquisition control system are uniformly arranged on the outer wall of the roasting machine, an output resistance value is converted into a voltage signal through transmission and is input into an analog input module, the control of the feeding amount of biomass fuel from a biomass fuel feeding port (14) through a feeding auger is realized through PID temperature control, so that the accurate automatic control of the internal temperature of the roasting machine is realized, and the real-time detection of the internal temperature of the roasting machine is realized through observing a temperature change curve on a touch screen;
when the work of the roasting machine reaches the set time, the rotation starts, the roasted tea leaves enter the polishing machine through the corresponding polishing machine feed inlet (111) to start working, the polishing machine rotates forwards, meanwhile, when the time of the rotation of the polishing machine reaches the set time, the polishing machine rotates backwards, the PLC of the slave station PLC controls the electric cabinet panel to monitor the work time of the rotation of the roasting machine and the polishing machine in real time through the nixie tube display screen, meanwhile, the rotation of the roasting machine, the rotation of the polishing machine and the rotation of the polishing machine are set in the slave station PLC, and after the rotation time is over, the polished tea leaves are transported to a finished product area through the power transmission mechanism at the bottom to carry out subsequent treatment on the tea leaves.
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