CN113341867B - Full-automatic green tea stir-frying and distributing control system and method based on PLC - Google Patents
Full-automatic green tea stir-frying and distributing control system and method based on PLC Download PDFInfo
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- CN113341867B CN113341867B CN202110664332.XA CN202110664332A CN113341867B CN 113341867 B CN113341867 B CN 113341867B CN 202110664332 A CN202110664332 A CN 202110664332A CN 113341867 B CN113341867 B CN 113341867B
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/054—Input/output
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention discloses a full-automatic green tea stir-frying and distributing control system and method based on a PLC (programmable logic controller), wherein the system comprises an information management stage, a user monitoring stage, a system control stage and a field device stage; the information management level comprises an industrial control computer and a printer; the user monitoring level comprises a touch screen, a camera and a nixie tube display screen; the system control stage comprises a weighing system and a stir-frying system; the field control stage comprises a feeding mechanism, a lifting mechanism, a material conveying mechanism, a weighing mechanism, a stir-frying mechanism, a polishing mechanism, an executing mechanism, a power transmission mechanism, a PLC (programmable logic controller) and a data acquisition system; the system control stage realizes automatic control through the Ethernet communication of the master station PLC and the slave station PLC, the user monitoring stage can effectively monitor the operation of the whole system, when a fault occurs, the monitoring picture can directly jump to a fault page, the industrial control computer monitors and feeds back in real time, and the fault is timely arranged and treated. The distributed control system can accurately control the temperature, the leaf throwing amount, the 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 PLC.
Background
Green tea is unfermented, has the highest Chinese yield and is widely drunk, the green tea contains tea polyphenol and has the antioxidation effect, and caffeine in the green tea can promote the excitation of the central nervous system of a human body, strengthen the excitation process of cerebral cortex and play a role in refreshing, benefiting the mind and clearing the heart. In the green tea production process, the green tea is required to be deactivated, kneaded, dried and fried. The tea is dried by the stir-frying process of the green tea, wherein the process mainly comprises the step of removing the moisture of the tea, the step is also a key step related to the color, the smell and the taste of the finally formed tea, and meanwhile, the stir-frying temperature is well controlled, and if the temperature is too high, the moisture of the tea is lost too much, so that the tea is dried; if the temperature is too low, the water content of the tea is too high, which is unfavorable for subsequent storage and the quality of the tea is reduced. However, in China, tea leaf stir-frying machines are at the semi-mechanized and semi-manual level, intelligent full-automatic production is not formed, and most of the tea leaf stir-frying machines judge the stir-frying time and temperature manually by means of feel and experience, so that the quality of tea leaves cannot be ensured. The existing tea leaf stir-frying machine cannot accurately set feeding quantity, the stir-frying time is unreasonable to be distributed, and the temperature cannot be accurately controlled. The tea production cost is high, the tea factory benefit is low, and based on the problem, the full-automatic green tea stir-frying distributed control system based on the PLC is provided, full-automatic intelligent control can be realized, accurate matching of the feeding quantity of the tea stir-frying and each link of temperature and time is guaranteed, the distributed control system reduces manual intervention, production cost is reduced, and tea quality is guaranteed.
Disclosure of Invention
The technical problem that this patent solved adopts following technical scheme to realize: a full-automatic green tea stir-frying and distributing control system and method based on PLC (programmable logic controller) are provided, the whole stir-frying and distributing control system is automatically operated, parameters such as key links, weighing weight, stir-frying temperature, working time of a stir-frying machine and the like are accurately controlled, faults in the stir-frying process are timely eliminated and solved, the water content of the fried tea leaves is ensured to be within a certain range, manual intervention is reduced, and the quality of the tea leaves is improved.
The invention solves the technical problems by the following scheme:
a full-automatic green tea stir-frying and distributing control system based on PLC comprises an information management stage, a user monitoring stage, a system control stage and a field device stage, wherein the information management stage is connected with the user monitoring stage, the system control stage and the field device stage in a management mode, the user monitoring stage is connected with the system control stage and the field device stage in a monitoring mode, and the system control stage is connected with the field device stage in a control mode; the information management level comprises an industrial control computer and a printer; the user monitoring level comprises a touch screen, a camera and a nixie tube display screen; the system control stage comprises a stir-frying 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 control 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 stir-frying unit and the weighing unit, and the material conveying mechanism is integrally arranged at the rear side of the stir-frying unit; the polishing mechanism is arranged right below the stir-frying unit, the power transmission mechanism is respectively arranged below the feeding mechanism, below the material conveying mechanism, below the rear side of the stir-frying unit, below the lifting mechanism and below the rear side of the polishing mechanism, and the rotating speed is regulated through the frequency converter; the PLC programmable logic controller is divided into a master station PLC and a slave station PLC, the master station PLC is arranged in a PLC control electrical cabinet of the master station, the slave station PLC is arranged in a PLC control electrical cabinet of the slave station, communication is realized through Ethernet connection, and the slave station PLC 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 executing mechanism, a PLC programmable logic controller, a PLC control electrical cabinet and a data acquisition system through an executing mechanism; 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 monitoring and controlling the automatic operation field equipment level, checking historical operation data in real time and performing fault checking and alarm processing; the other industrial control computer is connected with the camera through Bluetooth and is used for monitoring the picture of the field device level operation, if the field device level fails, the industrial control computer jumps to the failure picture in real time and eliminates the failure in time.
Preferably, the touch screen and the nixie tube display screen are respectively and independently arranged on a panel of the PLC control electric cabinet, and the nixie tube display screen is used for displaying weighing weight data, the number of the stir-frying unit, the working time of the stir-frying unit and the working time of the polishing mechanism; the touch screen is connected with the master station PLC through the Ethernet, and the programs on the touch screen comprise a user login interface, parameter setting, stir-frying process monitoring and change trend of analog input data.
Preferably, every two stir-frying units are controlled by a slave station PLC, and all slave station PLCs automatically operate by communication with a master station PLC.
The data acquisition system sends data to the slave station PLC, the slave station PLC program sends a command to control each device, each device runs automatically 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 fails, the device can conduct investigation and fault processing 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 frying tea residue port; the upper portion at the stir-fry machine is installed to the outlet, and biomass fuel feed inlet sets up in the middle part of stir-fry machine, is connected with the stir-fry machine through the feed auger, and the stir-fry machine engine sets up in the rear lower part of stir-fry machine, and the setting of stir-fry tealeaves clout mouth is in the front portion of stir-fry machine.
Preferably, the material conveying mechanism comprises a No. 4 material conveying conveyor belt, a No. 3 material conveying conveyor belt, a No. 2 material conveying conveyor belt, a No. 1 material conveying conveyor belt and a material conveying conveyor belt total bracket; the rear upper portion of the stir-fry drying unit is provided with a material conveying conveyer belt total support, and a No. 4 material conveying conveyer belt, a No. 3 material conveying conveyer belt, a No. 2 material conveying conveyer belt and a No. 1 material conveying conveyer belt are sequentially arranged on the material conveying conveyer belt total support from left to right.
Preferably, the polishing mechanism comprises a polishing machine, a polishing machine engine, a polishing machine feed inlet and a bench; 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 connected with the polishing machine in a power mode, a polishing machine feed inlet is arranged at the joint of the frying unit and the polishing mechanism, and a bench is arranged at the front part of the polishing machine feed inlet.
Preferably, the weighing unit comprises an upper layer weighing conveyor belt, a lower layer weighing conveyor belt and a weight sensor; the weight sensor is fixed at the lower part of the upper layer weighing conveyor belt and the lower layer weighing conveyor belt; a blanking funnel is arranged right above one side between the upper layer weighing conveyor belt and the lower layer weighing conveyor belt, a material blocking turning plate is arranged on the inner side of the blanking funnel, and the material blocking turning plate is electrically connected with a photoelectric sensor, and the photoelectric sensor is electrically controlled to block the material turning plate.
Preferably, the weight sensor converts the acquired weight signal into a voltage signal in a transmitting way, and the voltage signal is input into the analog input module and output through the analog input module; the temperature detection module adopts PT100 resistance type temperature sensors which are uniformly arranged on the outer wall of the frying unit, and the output resistance signals are transmitted and converted into voltage signals which are 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 a MODBUS protocol, and data output by the analog input module are displayed in real time.
Further, weight data in the weight sensor can set a certain weight through the display screen, and the weight sensor and the transmitter are connected with the slave station PLC through a MODBUS communication protocol, so that the weight data on the conveyor belt can be displayed on the nixie tube display screen in real time, and observation is convenient.
Further, the frequency converter is connected with an analog output module EMAQ04 through a slave station PLC to output voltage signals to control the rotating speed of each engine.
Further, the temperature sensor of the temperature detection module adopts PT100 as a temperature measuring element, is uniformly arranged on the wall and the bottom of the frying machine, and the output resistance value is converted into a voltage value through a temperature transmitter, and then is connected with an analog input module EMAE04 through a slave station PLC, and the temperature is regulated and controlled by fuzzy PID, so that the temperature is kept constant.
Further, the touch screen is a Weion touch screen, related parameters are set by programming an upper computer program, the change trend of temperature and weight data is monitored, and the operation of the distributed control system of the frying machine is performed in real time.
Further, the model of the master station PLC is Siemens PLC S7-200 smart CPU is ST60.
Further, the slave station PLC model is Siemens PLC S7-200 smart CPU is ST30.
Further, the model of the weight sensor is JLBU-1, and the weight is 200kg at the highest.
Further, the rated power of the engine is 0.55KW, and the frequency is 50Hz.
Further, the frequency converter is a Siemens frequency converter, and the model of the Siemens frequency converter is MM440.
A full-automatic green tea stir-frying and distributing control method based on PLC comprises the following steps:
1) Weighing: the 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 funnel, the photoelectric sensor receives signals to control the material blocking turning plate to upwards, the tea leaves are blanked to the upper layer weighing conveyor belt, at the moment, the frequency converter controls the upper layer weighing conveyor belt to firstly realize slow running, and each time of running for 8 seconds, the tea leaves are stopped for 2 seconds;
the weight sensor reads weight data of the upper layer weighing conveyor belt, converts the weight data into a voltage signal through transmission, enters a slave station PLC, is displayed on a nixie tube display screen through a MODBUS protocol, can read the weight data in real time, and when the weight of tea leaves of the upper layer weighing conveyor belt reaches a preset value, the frequency converter controls the upper layer weighing conveyor belt to rapidly operate, and quantitative tea leaves are conveyed to an N-number frying machine through a lifting mechanism and a conveying mechanism belt to start frying and polishing;
meanwhile, once the weight of the upper layer weighing conveyor belt reaches a set value, the photoelectric sensor controls the turning plate to downwards run, tea leaves are blanked to the lower layer weighing conveyor belt, the frequency converter sets two sections of speed to be slow and fast respectively, the speed is 8s each time the upper layer weighing conveyor belt runs, the lower layer weighing conveyor belt stops for 2s, after a certain time, when the weight of the tea leaves reaches the set value, the lower layer weighing conveyor belt conveys the tea leaves to an N+1 number frying machine through the lifting mechanism, and the lower layer weighing conveyor belt reciprocates in the same way;
2) Parching to dryness: firstly, starting a frying machine engine behind the frying machine, simultaneously starting a polishing machine engine, starting forward rotation of the frying machine, preheating the frying machine, controlling forward rotation of 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 by a slave station PLC, and enabling tea leaves to enter the No. 1, no. 2, no. 3 and No. 4 frying machines respectively;
when the No. 1 stir-frying machine is ready 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, so that the slave station PLC controls the No. 1 stir-frying machine to start to automatically operate, the No. 1 stir-frying machine is controlled by the slave station PLC, and the slave station PLC adopts a polling algorithm to realize accurate control; the temperature acquisition module of the data acquisition control system is uniformly arranged on the outer wall of the frying 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 feeding quantity of biomass fuel 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 frying machine is realized, and the temperature in the frying machine is detected in real time through the change curve of the observed temperature on the touch screen;
when the working time of the frying machine reaches the set time, the frying machine starts to rotate reversely, the fried tea leaves enter the polishing machine through the corresponding polishing machine feed inlet to start working, the polishing machine rotates positively at the moment, meanwhile, when the time of the forward rotation of the polishing machine reaches the set time, the polishing machine starts to rotate reversely, working time of the frying machine and the forward rotation and the reverse rotation of the polishing machine can be monitored in real time through a nixie tube display screen on a PLC control electrical cabinet panel of the slave station PLC, meanwhile, time of the forward rotation of the frying machine, the reverse rotation of the frying machine, the forward rotation of the polishing machine and the reverse rotation of the polishing machine are set in the slave station PLC, and after the reverse rotation time is finished, polished tea leaves 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 invention has the beneficial technical effects that at least comprises: the green tea stir-frying and distributing control system designed by the invention consists of two modules, namely weighing and stir-frying, the whole stir-frying and distributing control system runs automatically, the key links, weighing weight, stir-frying temperature, working time of a stir-frying machine and other parameters are precisely controlled, and the PLC is used for precisely polling control, so that faults in the stir-frying process are timely checked and solved, the water content of the fried tea leaves is ensured to be within a certain range, the manual intervention is reduced, the quality of the tea leaves is improved, the consumption of various manpower and material resources is reduced in the full-automatic operation, the production cost is reduced while the working efficiency is improved, the economic benefit is greatly improved, and the green tea stir-frying and distributing control system has remarkable practicability and creativity.
Drawings
Fig. 1 is a schematic overall view of a mechanical device of a green tea stir-frying distributed control system provided in an embodiment of the invention.
Fig. 2 is a schematic diagram of a mechanical device of the green tea stir-frying unit provided in the embodiment of the invention.
Fig. 3 is a schematic view of a mechanical device of a green tea weighing unit 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 flow chart of a control system provided in an embodiment of the present invention.
Fig. 6 is a flow chart of a parching unit provided in the embodiment of the invention.
FIG. 7 is a diagram of a touch screen simulation interface provided in an embodiment of the present invention.
In the figure: 1. a stir-drying unit; 2. a lifting mechanism; 3. a weighing unit; 11. a smoke outlet; 12.4 a conveyor belt; 13.3 number of material conveying conveyor belts; 14. a biomass fuel feed inlet; 15.2 a material conveying belt; 16.1 number of material conveying conveyor belts; 17. a material conveying conveyor belt total bracket; 18. a frying machine engine; 19. parching the tea residue; 110. a polishing machine engine; 111. a feed inlet of the polishing machine; 112. a landing; 31. an upper layer weighing conveyor belt; 32. a lower layer weighing conveyor belt; 33. a weight sensor.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
A full-automatic green tea stir-frying and distributing control system based on PLC comprises an information management stage, a user monitoring stage, a system control stage and a field device stage, wherein the information management stage is connected with the user monitoring stage, the system control stage and the field device stage in a management mode, the user monitoring stage is connected with the system control stage and the field device stage in a monitoring mode, and the system control stage is connected with the field device stage in a control mode;
the information management level comprises an industrial control computer and a printer; the user monitoring level comprises a touch screen, a camera and a nixie tube display screen; the system control stage comprises a stir-frying 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 executing 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 stir-frying unit 1 and the weighing unit 3, and the material conveying mechanism is integrally arranged at the rear side of the stir-frying unit 1; the polishing mechanism is arranged right below the stir-frying unit 1, the power transmission mechanism is respectively arranged below the feeding mechanism, below the material conveying mechanism, below the rear side of the stir-frying unit 1, below the lifting mechanism 2 and below the rear side of the polishing mechanism, and the rotating speed is regulated through the frequency converter; the PLC programmable logic controller is divided into a master station PLC and a slave station PLC, wherein the master station PLC is arranged in a PLC control electrical cabinet of the master station, the slave station PLC is arranged in a PLC control electrical cabinet of the slave station, communication is realized through Ethernet connection, and the slave station PLC 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 executing mechanism, a PLC programmable logic controller, a PLC control electrical cabinet and a data acquisition system through an executing mechanism; 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 and distributing 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 at two sections on the weighing unit 3, after reaching a set weight, 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 further polishing and shaping are carried out on the tea leaves, so that the quality of the tea leaves is improved.
As shown in fig. 2: the mechanical equipment of the green tea stir-frying unit mainly comprises a polishing machine, a polishing machine engine 110, a polishing machine feed inlet 111, a bench 112, a smoke outlet 11, a No. 4 conveying conveyor belt 12, a No. 3 conveying conveyor belt 13, a feeding auger, a biomass fuel feed inlet 14, a No. 2 conveying conveyor belt 15, a No. 1 conveying conveyor belt 16, a conveying conveyor belt total support 17, a stir-frying machine engine 18 and a stir-frying tea residue opening 19; the smoke outlet 11 is arranged on the surface layer of the frying machine, the No. 4 conveying conveyor belt 12, the No. 3 conveying conveyor belt 13, the No. 2 conveying conveyor belt 15 and the No. 1 conveying conveyor belt 16 are arranged on the conveying conveyor belt total support 17, and the No. 1, the No. 2, the No. 3 and the No. 2 conveying conveyor belts 15 and the No. 1 conveying conveyor belt 16 are respectively fed to the No. 1, the No. 2, the No. 3 and the No. 4 frying machine by controlling the forward and backward rotation of the No. 4 conveying conveyor belt 12, the No. 3 conveying conveyor belt 13 and the No. 2 conveying conveyor belt 15, so that automatic control is realized. The biomass fuel feed inlet 14 supplies energy to the frying machine through the feeding auger, and the control system realizes accurate temperature control through PID fuzzy control. The positive rotation of the engine can control the frying machine to fry and the negative rotation controls the blanking of the frying machine.
As shown in fig. 3: the green tea stir-drying weighing unit mechanical equipment comprises an upper layer weighing conveyor belt 31, a lower layer weighing conveyor belt 32 and a weight sensor 33. A blanking funnel is arranged right above one side between the upper layer weighing conveyor belt 31 and the lower layer weighing conveyor belt 32, and tea leaves are blanked onto the upper layer weighing conveyor belt 31 or the lower layer weighing conveyor belt 32 through a blanking funnel device after being dried. The material blocking turnover plate is arranged on the inner side of the blanking funnel, the material blocking turnover plate can respectively realize the up-and-down motion of the material blocking turnover plate through the induction of the photoelectric sensor, when the material blocking turnover plate is upward, tea is blanked to the upper layer weighing conveyor belt 31, and when the turnover plate is downward, tea is blanked to the lower layer weighing conveyor belt 32. The weight sensors 33 are respectively arranged below the upper layer weighing conveyor belt 31 and the lower layer weighing conveyor belt 32, so that the weight of tea leaves on the conveyor belt at the moment can be read in real time, and the accurate control of the leaf throwing amount is realized.
Fig. 4 is a block diagram of a PLC distributed control system, where the fry-dry distributed control system includes four parts, namely, an information management stage, a user monitoring stage, a system control stage, and a field device stage. The information management level mainly comprises two industrial control computers, one of which monitors the running condition of the system, and the other of which 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 operates at any time. The user monitoring level comprises a touch screen, a monitoring camera and a nixie 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 frying machine set, and realizes automatic control through communication between 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 then are ready to be blanked through a hopper, a photoelectric sensor receives signals to control a turning plate to be upward, and blanking is performed on an upper conveyor belt, at the moment, a frequency converter controls the conveyor belt to firstly realize slow running, and each time the conveyor belt runs for 8s, the conveyor belt stops for 2s. The upper weight sensor reads weight data, the weight data is converted into voltage signals through the transmitter through the analog quantity module and enters the slave station PLC, and the voltage signals are displayed on the upper weight nixie tube display screen through the MODBUS protocol, so that the weight data can be read in real time. When the weight of tea leaves on the upper layer weighing conveyor belt reaches a preset value, the frequency converter controls the upper layer conveyor belt to quickly run, and quantitative tea leaves are conveyed to the N-number frying machine through the lifting conveyor belt and the material conveying conveyor belt to start the frying and polishing work. 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 blanked to the lower layer conveyor belt, the frequency converter sets two sections of speeds to be slow and fast respectively, each section of speed is 8s in operation, 2s in operation is stopped, and after a certain time, when the weight of the tea leaves reaches the set value, the lower layer conveyor belt conveys the tea leaves to the N+1 stir-frying machine through the lifting conveyor belt. So reciprocating, through slave station PLC and the accurate intelligent control of main website PLC program realization whole tealeaves stir-fry distributed control system.
Fig. 6 shows a flow design diagram of a stir-frying link of the whole distributed control system, as shown in the drawing, a feeding auger engine behind a stir-frying machine is started, the stir-frying machine starts to rotate positively, a slave station PLC controls a No. 1 conveying belt to rotate positively, tea leaves enter the No. 1 stir-frying machine, after the stir-frying machine works for a set time, the tea leaves start to rotate reversely, after the stir-frying machine works, the tea leaves enter a polishing machine to start to work through a polishing machine feeding port, at the same time, after the time of forward rotation of the polishing machine reaches the set time, the polishing machine starts to rotate reversely, after the reverse rotation time is finished, the polished tea leaves are conveyed to a finished product area through a conveying belt at the bottom, and the tea leaves are subjected to subsequent treatment.
In fig. 7, in order to improve the security of the system, two preset types of personnel are respectively engineers and operators, only the engineers can enter a parameter setting page in the touch screen to preset and change parameters by inputting user names and passwords, the operators have no authority to preset and change, and the operators can enter the user names and passwords again if entering the parameter setting page again. On the parameter setting page, the weight of the balance weight can be set, and the upper limit is 200kg. Meanwhile, the time for feeding and conveying the weighed tea leaves into the frying machine can also be set. When the frying machine starts to work, a corresponding frying link page can be entered, the specific working flow of frying is observed, and a user can conveniently monitor whether the frying machine works normally or not and the working time. And 4 dryer buttons are respectively arranged on the fault investigation page, and if the No. 2 dryer fails, the corresponding dryer button can be pressed, and the dryer is closed, so that the whole control system can directly skip the dryer to continue to execute sequentially. Meanwhile, the nixie tube display screens are respectively arranged on the weighing conveyor belt, so that weight data on the weighing conveyor belt can be monitored in real time. The nixie tube display screen is also arranged on the panel of the electric cabinet of the frying machine, so that the working time of the frying 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 polishing machine can be read in real time, and a user can observe data conveniently.
Wherein, for specific PLC control part, the PLC of main website mainly controls the operation of upper strata weighing conveyer belt 31 and lower floor weighing conveyer belt 32, and the positive rotation and the reversal of 4 fortune material conveyer belts and the slave station PLC of two fry-drying machines of control. The specific mode is as follows: after receiving the starting signal, the main station PLC turns over the plate upwards at the feed inlet, starts the upper conveyor belt to run at a low speed, reads the weight data of the upper weight sensor every 8s through the polling algorithm, and starts the upper conveyor belt to run at a high speed through the control frequency converter after the weight data of the upper weighing conveyor belt reaches the preset weight data. At the moment, the No. 1 material conveying belt is controlled to rotate positively, and the No. 1 stir-frying machine is used for feeding. Once the upper layer reaches the set weight, the turning plate is turned downwards at the moment, the slave station PLC can start the lower layer weighing conveyor belt 32 to start to run slowly, and similarly, the nixie tube display screen can display real-time weight data, the set weight is reached, the PLC can reverse the No. 1 conveying conveyor belt 16, the No. 2 conveying conveyor belt 15 forwards rotates, and the No. 2 frying machine is fed. The method comprises the steps of circularly reciprocating, and feeding a No. 3 stir-frying machine when a No. 1 material conveying conveyor belt 16, a No. 2 material conveying conveyor belt 15 rotate positively and a No. 3 material conveying conveyor belt 13 rotates reversely; and when the No. 1 material conveying conveyor belt 16, the No. 2 material conveying conveyor belt 15 and the No. 3 material conveying conveyor belt 13 rotate positively and the No. 4 material conveying conveyor belt 12 rotates reversely, feeding the No. 4 stir-frying machine. And then, the communication of the master station PLC and the slave station PLC is related, when the No. 1 stir-frying machine is ready 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 so that the slave station PLC controls the No. 1 stir-frying machine to start to automatically operate. The automatic control of the No. 1 frying machine is controlled by a slave station PLC. The system mainly relates to accurate control of temperature, leaf throwing amount, running time and other data aiming at a data acquisition control system. In the aspect of temperature, a PT100 resistance type temperature sensor is adopted by the temperature acquisition module, the temperature acquisition module is uniformly arranged on the outer wall of the frying machine set, and the output resistance value is converted into a voltage signal through the temperature transmitter and is input into the analog input module. The control of the feeding quantity of the biomass fuel machine is realized through PID temperature control, so that the accurate automatic control of the internal temperature of the frying machine is realized. In the aspect of leaf throwing quantity, a weight sensor is arranged below a weighing conveyor belt in the weighing mechanism, an acquired weight signal is converted into a voltage signal through a transmitter and is input into an analog quantity input module, a nixie tube display screen is communicated with a PLC (programmable logic controller) through a MODBUS protocol, the current weight can be displayed in real time, and the PLC program is accurately controlled by a polled algorithm. In terms of running time, the working time of forward rotation and reverse rotation of the frying machine and the polishing machine can be monitored in real time through a nixie tube display screen on the panel of the electrical control cabinet of the secondary station. The nixie tube display screen is also communicated with the PLC through a MODBUS protocol. Meanwhile, the time for forward rotation of the frying machine, reverse rotation of the frying machine, forward rotation of the polishing machine and reverse rotation of the polishing machine can be set in the PLC program.
In the process of automatically running the distributed control system, if any one of the frying machines in the frying machine set has faults, the system realizes timely fault detection and treatment without affecting the normal running of the distributed control system. The automatic control device specifically comprises an industrial computer, a touch screen, a PLC program, a control computer, a touch screen and a control computer. Meanwhile, the temperature inside the frying 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 the tea stir-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 understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made therein without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.
Claims (9)
1. The full-automatic green tea stir-frying and distributing control system based on the PLC is characterized by comprising an information management stage, a user monitoring stage, a system control stage and a field device stage, wherein the information management stage is in management connection with the user monitoring stage, the system control stage and the field device stage, the user monitoring stage is in monitoring connection with the system control stage and the field device stage, and the system control stage is in control connection with the field device stage;
the information management level comprises an industrial control computer and a printer; the user monitoring level comprises a touch screen, a camera and a nixie tube display screen; the system control stage comprises a stir-frying 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 executing 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 stir-frying unit (1) and the weighing unit (3), and the material conveying mechanism is integrally arranged at the rear side of the stir-frying unit (1); the polishing mechanism is arranged right below the stir-frying unit (1), and the power transmission mechanism is respectively arranged below the feeding mechanism, below the material conveying mechanism, below the rear side of the stir-frying unit (1), below the lifting mechanism (2) and below the rear side of the polishing mechanism, and the rotating speed is regulated through the frequency converter; the PLC programmable logic controller is divided into a master station PLC and a slave station PLC, the master station PLC is arranged in a PLC control electrical cabinet of the master station, the slave station PLC is arranged in a PLC control electrical cabinet of the slave station, communication is realized through Ethernet connection, and the slave station PLC 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 executing mechanism, a PLC programmable logic controller, a PLC control electrical cabinet and a data acquisition system through an executing mechanism; the data acquisition system comprises a temperature detection module, an analog input module and an analog output module;
the weighing unit (3) comprises an upper layer weighing conveyor belt (31), a lower layer weighing conveyor belt (32) and a weight sensor (33); the weight sensor (33) is fixed at the lower parts of the upper layer weighing conveyor belt (31) and the lower layer weighing conveyor belt (32); and a blanking funnel is arranged right above one side between the upper layer weighing conveyor belt (31) and the lower layer weighing conveyor belt (32), a material blocking turning plate is arranged on the inner side of the blanking funnel, and the material blocking turning plate is electrically connected with a photoelectric sensor, and the photoelectric sensor is electrically controlled to block the material turning plate.
2. The PLC-based full-automatic green tea stir-frying and distributing control system is characterized in that two industrial control computers are arranged, one industrial control computer is used for monitoring and controlling automatic operation field equipment levels, viewing historical operation data in real time and conducting fault investigation and alarm processing; the other industrial control computer is connected with the camera through Bluetooth and is used for monitoring the pictures of the field device level operation.
3. The full-automatic green tea stir-frying and distributing control system based on the PLC according to claim 1, wherein the touch screen and the nixie tube display screen are respectively and independently arranged on a panel of a PLC control electric cabinet, and the nixie tube display screen is used for displaying weighing weight data, the number of a stir-frying unit (1), the working time of the stir-frying unit (1) and the working time of a polishing mechanism;
the touch screen is connected with the master station PLC through the Ethernet, and the programs on the touch screen comprise a user login interface, parameter setting, stir-frying process monitoring and change trend of analog input data.
4. The PLC-based full automatic green tea fry-out and distribution control system of claim 1, wherein the weight sensor (33) converts the collected weight signal into a voltage signal, and inputs the voltage signal to the analog input module and outputs the voltage signal through the analog input module;
the temperature detection module is uniformly arranged on the outer wall of the frying unit (1), and an output resistance signal 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;
and the nixie tube display screen is communicated with the master station PLC and the slave station PLC through a MODBUS protocol, and data output by the analog input module are displayed in real time.
5. The full-automatic green tea stir-frying and distributing control system based on the PLC according to claim 1, wherein every two stir-frying units (1) are controlled by one slave station PLC, and all slave station PLCs automatically operate through communication with a master station PLC.
6. The full-automatic green tea stir-frying and distributing control system based on the PLC according to claim 1, wherein 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 tobacco outlet (11) is arranged on the upper part of the frying machine, the biomass fuel feeding port (14) is arranged in the middle of the frying machine and connected with the frying machine through the feeding auger, the engine (18) of the frying machine is arranged on the lower rear part of the frying machine, and the residual tea leaves (19) are arranged on the front part of the frying machine.
7. The full-automatic green tea stir-frying and distributing control system based on the PLC according to claim 1, wherein the material conveying mechanism comprises a No. 4 material conveying conveyor belt (12), a No. 3 material conveying conveyor belt (13), a No. 2 material conveying conveyor belt (15), a No. 1 material conveying conveyor belt (16) and a material conveying conveyor belt total support (17);
the rear upper portion of the stir-fry unit (1) is provided with a material conveying conveyer belt total support (17), and a No. 4 material conveying conveyer belt (12), a No. 3 material conveying conveyer belt (13), a No. 2 material conveying conveyer belt (15) and a No. 1 material conveying conveyer belt (16) are sequentially arranged on the material conveying conveyer belt total support (17) from left to right.
8. The PLC-based full automatic green tea roasting and distributing control system of claim 1, wherein the polishing mechanism comprises a polisher, a polisher engine (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 feed inlet (111) is arranged at the joint of the frying unit (1) and the polishing mechanism, and a ladder table (112) is arranged at the front part of the polishing machine feed inlet (111).
9. A full-automatic green tea stir-frying and distributing control method based on PLC is characterized by comprising the following steps:
1) Weighing: the 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 funnel, the photoelectric sensor receives signals to control the material blocking turning plate to be upward, the tea leaves are blanked to the upper layer weighing conveyor belt (31), at the moment, the frequency converter controls the upper layer weighing conveyor belt (31) to firstly realize slow running, and each time the tea leaves run for 8 seconds, the tea leaves are stopped for 2 seconds;
the weight sensor (33) reads weight data of the upper layer weighing conveyor belt (31), converts the weight data into voltage signals through transmission, enters the slave station PLC, is displayed on the nixie tube display screen through a MODBUS protocol, can read the weight data in real time, and when the weight of tea leaves of the upper layer weighing conveyor belt (31) reaches a preset value, the frequency converter controls the upper layer weighing conveyor belt (31) to rapidly operate, and quantitative tea leaves are conveyed to the N-number frying machine through the lifting mechanism (2) and the material conveying mechanism to start frying and polishing;
meanwhile, once the weight of the upper layer weighing conveyor belt (31) reaches a set value, the photoelectric sensor controls the turning plate to move downwards, tea leaves fall to the lower layer weighing conveyor belt (32), the frequency converter sets two sections of speed to be slow and fast respectively, the speed is 8s for each operation, the speed is 2s for stopping, after a certain time, when the weight of the tea leaves reaches the set value, the lower layer weighing conveyor belt (32) conveys the tea leaves to an N+1 frying machine through the lifting mechanism (2), and the process is repeated;
2) Parching to dryness: firstly, starting a frying machine engine (18) behind the frying machine, starting a polishing machine engine (110) at the same time, starting forward rotation of the frying machine, preheating the frying machine, and controlling 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 forward rotate by a slave station PLC (programmable logic controller), wherein tea leaves enter the No. 1, no. 2, no. 3 and No. 4 frying machines respectively;
when the No. 1 stir-frying machine is ready 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, so that the slave station PLC controls the No. 1 stir-frying machine to start to automatically operate, the No. 1 stir-frying machine is controlled by the slave station PLC, and the slave station PLC adopts a polling algorithm to realize accurate control; the temperature acquisition module of the data acquisition control system is uniformly arranged on the outer wall of the frying 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 feeding quantity of biomass fuel from the biomass fuel feeding port (14) through the feeding auger is realized through PID temperature control, so that the accurate automatic control of the internal temperature of the frying machine is realized, and the temperature in the frying machine is detected in real time through the change curve of the observed temperature on the touch screen;
when the working time of the frying machine reaches the set time, the frying machine starts to rotate reversely, the fried tea leaves enter the polishing machine through the corresponding polishing machine feed inlet (111) to start working, the polishing machine rotates positively at the same time, meanwhile, when the time of the polishing machine rotating positively reaches the set time, the polishing machine starts to rotate reversely, working time of the frying machine and the polishing machine rotating positively and reversely can be monitored in real time through a nixie tube display screen on a PLC control electrical cabinet panel of a slave station PLC, meanwhile, the working time of the frying machine rotating positively, the frying machine rotating reversely, the polishing machine rotating positively and the polishing machine rotating reversely is set in the slave station PLC, and after the rotating time is finished, the polished tea leaves are transported to a finished product area through a power transmission mechanism at the bottom to be subjected to subsequent processing of the tea leaves.
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