CN113662229B - Blending uniformity control method - Google Patents
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- A24B—MANUFACTURE OR PREPARATION OF TOBACCO FOR SMOKING OR CHEWING; TOBACCO; SNUFF
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Abstract
The invention discloses a blending uniformity control method, which is designed for solving the problems of large instantaneous flow fluctuation and poor instantaneous flow precision of a blending slave scale of the conventional blending system. The invention ensures the blending uniformity and reduces the fluctuation of the instantaneous precision of the system by accurately controlling the blending system at the material head, the material middle and the material tail in stages, thereby reducing the error of the whole system and avoiding the phenomenon of uneven batch.
Description
Technical Field
The invention relates to the field of cigarette processing and manufacturing, in particular to a blending uniformity control method.
Background
In the tobacco manufacturing process, the blending link uniformly blends the raw materials with different components, so that the rolling quality of the product is ensured to be stable, and the method is an important link for producing the cut tobacco. The blending system generally consists of a blending main scale and a blending auxiliary scale. And tracking the instantaneous flow of the blending main scale by each blending slave scale, and calculating the blending flow according to the set blending proportion for blending. The calculation is as follows: blending slave scale set flow = blending master scale instantaneous flow × blending ratio.
Each blending slave scale performs blending control according to the calculated set flow, the set flow of each blending slave scale needs to be adjusted at any time according to the actual flow of the main scale, the system belongs to a tracking and regulating system, and if the instantaneous flow fluctuates greatly, for example, the head and tail of a material which are not easy to control, a large flow error can be generated. The prior art typically uses cumulative error compensation for correction, and although the total amount can be done, the uniformity in the production process is still poor. Meanwhile, in the production process, the stability of the material flow of the slave scale system is the basis for ensuring the blending accuracy, the material cut-off caused by the system fault can also cause that part of the material is not blended, and the error compensation can be larger after the recovery, so that the blending of the whole batch is more uneven, and the sucking taste of the product is finally influenced.
Disclosure of Invention
In view of the above, the present invention is directed to provide a blending uniformity control method, so as to solve the problems of low blending control precision and poor uniformity in the prior art.
The technical scheme adopted by the invention is as follows:
a blending uniformity control method, comprising:
dividing each batch of blending process into a material head stage, a material middle stage and a material tail stage according to the running state and the accumulated flow of the blending main scale in advance, and controlling the metering operation of the blending auxiliary scale in each stage according to the following modes:
in the stub bar stage, calculating the target set flow of the blending slave scale according to a preset blending proportion;
in the material feeding stage, calculating the target set flow of the blending slave scale according to a preset blending proportion, a short-time blending error and an accumulated blending error generated actually;
and in the material tail stage, calculating the target set flow of the blending slave scale according to the preset blending proportion, the short-time blending error and the predicted blending error based on the residual flow.
In at least one possible implementation, in the head stage, the target set flow rate of the dosing slave scale = the instantaneous flow rate of the dosing master scale × the dosing ratio.
In at least one possible implementation manner, in the material charging stage, the target set flow rate of the blending slave scale = a first set flow rate + a second set flow rate + a third set flow rate;
the first set flow = blending main scale instantaneous flow x blending proportion;
the second set flow = the cumulative error from the previous period of the scale divided by the duration of the previous period;
and the third set flow rate = the total accumulated error of the blending slave scale ÷ blending time, wherein the total accumulated error of the blending slave scale = the accumulated flow rate of the blending slave scale-the accumulated flow rate of the blending master scale multiplied by the blending proportion, and the blending time = the accumulated flow rate of the blending master scale ÷ the preset flow rate of the blending master scale.
In at least one possible implementation manner, in the material tail stage, the target set flow rate of the blending slave scale = fourth set flow rate + fifth set flow rate + sixth set flow rate;
the fourth set flow = blending main scale instantaneous flow x blending proportion;
the fifth set flow = doping the accumulated error from the previous period of the scale ÷ duration of the previous period;
the sixth set flow rate = the total accumulated error of the blending slave scale ÷ the blending remaining time, wherein the total accumulated error of the blending slave scale = the accumulated flow rate of the blending slave scale-the accumulated flow rate of the blending master scale × the blending proportion, and the blending remaining time = (the preset accumulated total flow rate of the master scale per batch-the accumulated flow rate of the blending master scale) ÷ the preset flow rate speed of the blending master scale.
In at least one possible implementation manner, the dividing the blending process of each batch into a material head stage, a material middle stage and a material tail stage includes:
taking the blending process of starting the blending system to operate within the preset time as a stub bar stage;
taking a blending process after a preset time and before the accumulated flow of a blending main scale reaches a preset threshold value as a material middle stage;
and taking the blending process after the accumulated flow of the blending main scale reaches a preset threshold value as a material tail stage.
In at least one possible implementation manner, the method further includes:
in the blending process, monitoring the material conveying state of the blending slave scale in real time according to a preset timing mechanism;
when the material conveying state of the blending slave scale is abnormal, the blending system is triggered to stop.
In at least one possible implementation, the triggering the blending system to shut down includes: and respectively controlling the blending master scale and the blending slave scale to stop running and outputting warning signals.
In at least one possible implementation manner, the monitoring, in real time, the material conveying state of the blending slave scale according to the preset timing mechanism includes:
and if the situation that the material-free state of the blending slave scale continues for the preset first timing duration is monitored, judging that the material conveying state of the blending slave scale is abnormal.
In at least one possible implementation manner, the monitoring, in real time, the material conveying state of the blending slave scale according to the preset timing mechanism includes:
and if the material on the feeding belt of the blending slave scale is monitored, and the low-position material-free state of the metering pipe behind the feeding belt is monitored for a second preset time duration, judging that the material conveying state of the blending slave scale is abnormal.
In at least one possible implementation manner, the monitoring, in real time, the material conveying state of the blending slave scale according to the preset timing mechanism includes:
and if the high-position material existence state of the metering pipe behind the feeding belt of the blending slave scale is monitored to be continuously long for a preset third timing time, judging that the material conveying state of the blending slave scale is abnormal.
The design concept of the invention is that aiming at the problems of large instantaneous flow fluctuation and poor instantaneous flow precision of the mixing and distributing system mixing and distributing slave scale in the prior art, the metering mode of the mixing and distributing slave scale of the mixing and distributing system is divided into three independent stages based on the running state of the mixing and distributing master scale for differential setting, and the instantaneous precision error and the accumulative precision error are utilized for control, in particular, the short-time error control and the accumulative error compensation are added, so that the control precision of the instantaneous mixing and distributing proportion is improved, and the mixing and distributing uniformity is effectively improved. The invention ensures the blending uniformity and reduces the fluctuation of the instantaneous precision of the system by accurately controlling the blending system at the material head, the material middle and the material tail in stages, thereby reducing the error of the whole system and avoiding the phenomenon of uneven batch.
Furthermore, the invention also adds an abnormity monitoring mechanism, utilizes multipoint feeding state monitoring to carry out combined judgment, and can stop blending operation in time once the blending system is found to be abnormal, thereby avoiding generating larger blending error.
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In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described with reference to the accompanying drawings, in which:
fig. 1 is a flowchart of a blending uniformity control method according to an embodiment of the present invention.
Detailed Description
Reference will now be made in detail to the embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention and are not to be construed as limiting the present invention.
The invention provides an embodiment of a blending uniformity control method, which specifically includes, as shown in fig. 1:
step S1, dividing each batch of blending process into a material head stage, a material middle stage and a material tail stage according to the running state and the accumulated flow of a blending main scale in advance, and controlling the metering operation of a blending auxiliary scale in each stage according to the following modes:
step S10, in the stub bar stage, calculating the target set flow of the blending slave scale according to a preset blending proportion;
s20, in the material mixing stage, calculating the target set flow of the mixing slave scale according to a preset mixing proportion, a short-time mixing error and an accumulated mixing error generated actually;
and S30, in the material tail stage, calculating the target set flow of the blending slave scale according to the preset blending proportion, the short-time blending error and the predicted blending error based on the residual flow.
In actual operation, the target set flow rate of the blending slave scale in the head stage = the instantaneous flow rate of the blending master scale × the blending ratio.
In actual operation, the target set flow rate of the mixing slave scale in the material feeding stage = a first set flow rate + a second set flow rate + a third set flow rate;
the first set flow = blending main scale instantaneous flow x blending proportion;
the second set flow = the cumulative error from the previous period of the scale divided by the duration of the previous period;
the third set flow rate = total cumulative error of the blending slave scale ÷ blending time, wherein the total cumulative error of the blending slave scale = cumulative flow rate of the blending slave scale-cumulative flow rate of the blending master scale × blending proportion, and the blending time = cumulative flow rate of the blending master scale ÷ predetermined flow rate speed of the blending master scale.
In actual operation, the target set flow = the fourth set flow + the fifth set flow + the sixth set flow of the material tail stage blending slave scale;
the fourth set flow = blending main scale instantaneous flow x blending proportion;
the fifth set flow = doping the accumulated error from the previous period of the scale ÷ duration of the previous period;
the sixth set flow rate = total accumulated error of the blending slave scale ÷ blending remaining time, wherein the total accumulated error of the blending slave scale = cumulative flow rate of the blending slave scale-cumulative flow rate of the blending master scale × blending proportion, and the blending remaining time = (preset total accumulated flow rate of the master scale per batch-cumulative flow rate of the blending master scale) ÷ blending master scale preset flow rate speed.
Further, the aforesaid dividing the blending process of each batch into a head stage, a middle stage and a tail stage can refer to the following steps: taking the blending process of starting the blending system to operate within the preset time as a stub bar stage; taking a blending process after a preset time and before the accumulated flow of a blending main scale reaches a preset threshold value as a material middle stage; and taking the blending process after the accumulated flow of the blending main scale reaches a preset threshold value as a material tail stage.
Further, the method may further include:
in the blending process, monitoring the material conveying state of the blending slave scale in real time according to a preset timing mechanism; when the material conveying state of the blending slave scale is abnormal, the blending system is triggered to stop. The triggering of the blending system shutdown can refer to respectively controlling the blending master scale and the blending slave scale to stop running and outputting a warning signal in actual operation.
Further, the real-time monitoring of the material conveying state of the blending slave scale according to the preset timing mechanism may include the following three conditions:
firstly, if the material-free state of the blending slave scale is monitored to last for a preset first timing duration, the material conveying state of the blending slave scale is judged to be abnormal.
And secondly, if the material on the feeding belt of the blending slave scale is monitored, and the low-position material-free state of the metering pipe behind the feeding belt is monitored for a second preset timing duration, judging that the material conveying state of the blending slave scale is abnormal.
And thirdly, if the high-position material existence state of the metering pipe behind the feeding belt of the blending slave scale is monitored to be continuously long for a preset third timing time, judging that the material conveying state of the blending slave scale is abnormal.
To facilitate an understanding of the above embodiments and their preferred versions, the following illustrative examples are provided herein for purposes of illustration:
in the main concept of the invention, the blending control is divided into three independent stages of a material head, a material middle stage and a material tail for targeted control:
(1) The stage of the blending system (mainly including the master scale system and the slave scale system) from the beginning to the preset time (for example, within 1 minute) can be regarded as the material head stage. Specifically, the flow rate of the blending main scale after starting to operate can be determined according to the flow rate statistics. At this stage, the target set flow rate of the blending slave scale = the instantaneous flow rate of the blending master scale × the blending ratio, which is the set flow rate calculated according to the blending ratio required by the process, that is, at the head stage, the established blending ratio control is adopted, and the blending slave scale is used for ensuring the blending tracking by utilizing the rising trend.
(2) The blending system may be considered to be in a normal operation phase (also referred to as a mid-batch phase) after a predetermined time (e.g., 1 minute later, which may also be based on blending master scale data) from the beginning of operation of the blending system. At this stage, the target set flow rate of the blending slave scale is formed by adding the following three parts, so that the instantaneous flow rate of the blending master scale can be accurately tracked.
A first part: the first set flow n1 of the blending slave scale = the instantaneous flow of the blending master scale × the blending ratio, which is also the set flow calculated according to the blending ratio required by the process.
A second part: the second set flow rate n2 of the dosing slave scale = cumulative error of the dosing slave scale from the previous period (e.g. previous 1 minute) ÷ duration of the previous period (1 minute), giving the dosing static error generated in the previous period (within the previous 1 minute), which is added as a disturbance to the dosing slave scale control to modify the first calculated set flow rate to allow the dosing slave scale system to more accurately track the master scale flow rate.
And a third part: the third set flow rate n3 of the dosing slave scale = total cumulative error of the dosing slave scale (total error from the start of dosing to the current time) ÷ dosing time (time interval from the start of dosing to the current time), wherein total cumulative error of the dosing slave scale = cumulative flow rate of the dosing slave scale-cumulative flow rate of the dosing master scale × dosing proportion, and dosing time = cumulative flow rate of the dosing master scale ÷ dosing master scale set flow rate speed (e.g., 5000 kg/hr).
That is, in the material portion, n2 is combined to correct the system static difference, and the system compensation is performed through n3, so that stable blending precision can be obtained.
(3) When the accumulated flow rate of the main scales reaches a preset threshold (for example, the accumulated total flow rate of a given main scale per batch can be set to 9800 kg, and then the preset threshold can be set to 9000 kg), the material tailing stage is considered. At this stage, the target set flow of the blending slave scale is formed by adding the following three parts, so that the instantaneous flow of the blending master scale can be accurately tracked.
A first part: the fourth set flow n4= the blending slave scale instantaneous flow x the blending ratio, which is also the set flow calculated according to the blending ratio of the process requirements.
A second part: the fifth set flow rate n5 of the blending slave scale = cumulative error of the previous period (for example, the previous 1 minute) of the blending slave scale divided by the duration (for 1 minute) of the previous period, the blending static difference generated in the previous period (for the previous 1 minute) is obtained, and the blending static difference is added into the blending slave scale control system as a disturbance quantity, and the set flow rate calculated by the first part is corrected, so that the blending slave scale system can track the flow rate of the blending master scale more accurately.
And a third part: the sixth set flow rate n6 of the blending slave scale = total accumulated error of the blending slave scale (total error from the beginning of blending to the current moment) ÷ blending remaining time (time interval from the current moment to the end of blending), wherein the total accumulated error of the blending slave scale = cumulative flow rate of the blending slave scale-cumulative flow rate of the blending master scale × blending ratio, and the blending remaining time = (preset cumulative total flow rate of the master scale 9800 kg-cumulative flow rate of the blending master scale) ÷ set flow rate speed of the blending master scale (5000 kg/h).
That is to say, in the tail stage of the material, the static difference of the system is corrected by combining n5, and the error of the residual flow is predicted through n6 along with the approaching of the blending ending time, so that the large-range compensation can be realized, the blending precision is ensured, and the correction is also performed when insufficient compensation or transitional compensation occurs in the middle stage of the material.
Finally, it can also be mentioned that, for monitoring the dosing error, for example, a photoelectric sensor or the like can be arranged above the feed belt of the dosing slave scale in order to detect the presence of material on the feed belt. If no material on the feed belt is monitored for 1 minute during the operation of the blending system, a blending system shutdown alarm may be triggered.
Furthermore, a metering tube can be arranged behind the feeding belt of the blending slave scale, and a photoelectric sensor device and the like can be arranged at the preset low position of the metering tube to detect the low material state of the metering tube. If the low-level material-free state lasts for 30 seconds under the premise that the feeding belt is charged, the feeding belt can be considered to be blocked, and the shutdown alarm of the blending system can also be triggered.
In addition, a photoelectric sensor or the like can be arranged at a preset high position of the metering pipe to detect the high material state of the metering pipe. If the high position of the metering pipe is monitored to be in a material state for 1 minute in the running process of the blending system, the metering pipe is considered to be blocked, and the shutdown alarm of the blending system can be triggered.
According to the design, when the blending slave scale system has a feeding abnormal state, the blending master scale system can be controlled to stop running so as to prevent the blending slave scale from failing to blend to cause the failure of the blending system, and meanwhile, the blending slave scale system also stops running so as to avoid the uneven blending of the whole.
In summary, the design concept of the invention is that, aiming at the problems of large instantaneous flow fluctuation and poor instantaneous flow precision of the mixing and dispensing slave scale of the existing mixing and dispensing system, the metering mode of the mixing and dispensing slave scale of the mixing and dispensing system is divided into three independent stages based on the running state of the mixing and dispensing master scale for differential setting, and the instantaneous precision error and the accumulative precision error are utilized for control, specifically, the short-time error control and the accumulative error compensation are added, so that the control precision of the instantaneous mixing and dispensing ratio is improved, and the mixing and dispensing uniformity is effectively improved. The invention accurately controls the blending system in the material head, the material middle and the material tail stage by stage, ensures the blending uniformity and reduces the fluctuation of the instantaneous precision of the system, thereby reducing the error of the whole system and avoiding the phenomenon of uneven batch.
In the embodiments of the present invention, "at least one" means one or more, "a plurality" means two or more. "and/or" describes the association relationship of the associated objects, and means that there may be three relationships, for example, a and/or B, and may mean that a exists alone, a and B exist simultaneously, and B exists alone. Wherein A and B can be singular or plural. The character "/" generally indicates that the former and latter associated objects are in an "or" relationship. "at least one of the following" and the like, refer to any combination of these items, including any combination of singular or plural items. For example, at least one of a, b, and c may represent: a, b, c, a and b, a and c, b and c or a and b and c, wherein a, b and c can be single or multiple.
The structure, features and effects of the present invention have been described in detail with reference to the embodiments shown in the drawings, but the above embodiments are merely preferred embodiments of the present invention, and it should be understood that technical features related to the above embodiments and preferred modes thereof can be reasonably combined and configured into various equivalent schemes by those skilled in the art without departing from and changing the design idea and technical effects of the present invention; therefore, the invention is not limited to the specific embodiments shown in the drawings, and all changes that can be made or modified to the equivalent embodiments without departing from the spirit and scope of the invention are intended to be covered by the specification and drawings.
Claims (8)
1. A blending uniformity control method, comprising:
dividing each batch of blending process into a material head stage, a material middle stage and a material tail stage according to the running state and the accumulated flow of the blending main scale in advance, and controlling the metering operation of the blending auxiliary scale in each stage as follows:
in the stub bar stage, calculating the target set flow of the blending slave scale according to a preset blending proportion;
in the material mixing stage, calculating a target set flow of the mixing slave scale according to a preset mixing proportion, a short-time mixing error and an accumulated mixing error generated actually, wherein the target set flow of the mixing slave scale comprises a material mixing stage, and the target set flow = a first set flow + a second set flow + a third set flow;
the first set flow = blending main scale instantaneous flow x blending proportion;
the second set flow = the accumulated error from the previous period of the scale divided by the duration of the previous period;
the third set flow rate = total accumulated error of the blending slave scale divided by blending time, wherein the total accumulated error of the blending slave scale = cumulative flow rate of the blending slave scale-cumulative flow rate of the blending master scale multiplied by blending proportion, and the blending time = cumulative flow rate of the blending master scale divided by preset flow rate speed of the blending master scale;
in the material tail stage, calculating the target set flow of the blending slave scale according to a preset blending proportion, a short-time blending error and a predicted blending error based on the residual flow, wherein the target set flow of the blending slave scale = a fourth set flow + a fifth set flow + a sixth set flow in the material tail stage;
the fourth set flow = the instantaneous flow of the blending main scale multiplied by the blending proportion;
the fifth set flow = the accumulated error from the previous period of the scale divided by the duration of the previous period;
the sixth set flow rate = the total accumulated error of the blending slave scale ÷ the blending remaining time, wherein the total accumulated error of the blending slave scale = the accumulated flow rate of the blending slave scale-the accumulated flow rate of the blending master scale × the blending proportion, and the blending remaining time = (the preset accumulated total flow rate of the master scale per batch-the accumulated flow rate of the blending master scale) ÷ the preset flow rate speed of the blending master scale.
2. The blending uniformity control method of claim 1, wherein in the head stage, the target set flow rate of the blending slave scale = the instantaneous flow rate of the blending master scale x the blending ratio.
3. The blending uniformity control method according to claim 1 or 2, wherein the dividing of each batch blending process into a head stage, a middle stage and a tail stage comprises:
taking the blending process of starting the blending system to operate within the preset time as a stub bar stage;
taking a blending process after a preset time and before the accumulated flow of a blending main scale reaches a preset threshold value as a material middle stage;
and taking the blending process after the accumulated flow of the blending main scale reaches a preset threshold value as a material tail stage.
4. The blending uniformity control method of claim 1 or 2, wherein the method further comprises:
in the blending process, monitoring the material conveying state of the blending slave scale in real time according to a preset timing mechanism;
when the material conveying state of the blending slave scale is abnormal, the blending system is triggered to stop.
5. The blending uniformity control method of claim 4, wherein the triggering a blending system shutdown comprises: and respectively controlling the blending main scale and the blending auxiliary scale to stop running and outputting warning signals.
6. The blending uniformity control method of claim 4, wherein the real-time monitoring of the material delivery state of the blending slave scale according to the preset timing mechanism comprises:
and if the situation that the material-free state of the blending slave scale continues for the preset first timing duration is monitored, judging that the material conveying state of the blending slave scale is abnormal.
7. The blending uniformity control method of claim 4, wherein the real-time monitoring of the material delivery state of the blending slave scale according to the preset timing mechanism comprises:
and if the material on the feeding belt of the blending slave scale is monitored, and the low-position material-free state of the metering pipe behind the feeding belt is monitored to continue for a preset second timing duration, judging that the material conveying state of the blending slave scale is abnormal.
8. The blending uniformity control method of claim 4, wherein the real-time monitoring of the material delivery state of the blending slave scale according to the preset timing mechanism comprises:
and if the high-position material existence state of the metering pipe behind the feeding belt of the blending slave scale is monitored to be continuously long for a preset third timing time, judging that the material conveying state of the blending slave scale is abnormal.
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