CN114532582B - Big data application analysis platform system and method based on ZJ17 type cigarette weight control system - Google Patents
Big data application analysis platform system and method based on ZJ17 type cigarette weight control system Download PDFInfo
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- CN114532582B CN114532582B CN202210239372.4A CN202210239372A CN114532582B CN 114532582 B CN114532582 B CN 114532582B CN 202210239372 A CN202210239372 A CN 202210239372A CN 114532582 B CN114532582 B CN 114532582B
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
- A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
- A24C5/32—Separating, ordering, counting or examining cigarettes; Regulating the feeding of tobacco according to rod or cigarette condition
- A24C5/34—Examining cigarettes or the rod, e.g. for regulating the feeding of tobacco; Removing defective cigarettes
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- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24C—MACHINES FOR MAKING CIGARS OR CIGARETTES
- A24C5/00—Making cigarettes; Making tipping materials for, or attaching filters or mouthpieces to, cigars or cigarettes
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- G—PHYSICS
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- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
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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
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention discloses a big data application analysis platform system and a big data application analysis platform method based on a ZJ17 type cigarette weight control system, and relates to finished product cigarette weight stability control and random sampling SD value qualification rate improvement. The implementation of the invention can realize the optimized configuration of brand parameters in the later period and the self-tuning and adjusting functions on the whole and the details, and lays a foundation for exploring an intelligent factory in a workshop.
Description
Technical Field
The invention relates to the technical field of cigarette production equipment, in particular to a big data application analysis platform system and a big data application analysis platform method based on a ZJ17 type cigarette weight control system.
Background
The cigarette enterprises in China began to introduce foreign advanced production equipment in the early 80 s of the 20 th century, and the fully automatic import production line (equipment) is against the huge gap between the automation level and the international advanced level of cigarette making machines out of China. By continuously adopting a new automatic control technology, the integrated control system is developed to the existing industrial field bus control technology and control integrated control system from relay logic control, PLC control and centralized monitoring, and meanwhile, the industrial process control technology gradually realizes networking and intellectualization along with the application of information technologies such as a network technology, a communication technology, a big data application technology and the like.
The widely used ZJ17 cigarette making and jointing machine set in domestic cigarette factory introduced PROTOS70 series cigarette making and jointing equipment developed and produced in 80 th century from German company, most of steep angle silk-drawing machines and pin roll motors in the VE part of silk-drawing machine still adopt direct current speed regulating system, on the basis of super high speed cigarette making and jointing technology, the frequency conversion speed regulating technology is adopted for general speed regulation in the transmission system, and on the basis of transmission with strict requirement for speed synchronization, the alternating current servo driving technology is adopted. In the existing domestic part of cigarette factories, an alternating current servo system is reformed on a steep-angle lifting belt and a direct current motor of a needle roller of a VE part of a tobacco shred feeder; however, most of the methods are limited to the transformation of a motor and a servo controller, and for the control mode, the speed tracking still adopts the original motor signal, so that the advantage of accurate control is not fully exerted.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides a big data application analysis platform system and a big data application analysis platform method based on a ZJ17 type cigarette weight control system, aiming at the defects of the existing cigarette in the weight control system and the cut tobacco blanking (a VE part of a tobacco feeder), the invention can further improve the weight control effect of the ZJ17 cigarette making and tipping unit, improve the weight stability of finished cigarettes and randomly sample the SD value qualification rate, implement the related electrical machinery transformation and establish the application analysis platform of a monitoring operation evaluation system, analyze the influence of the related electrical parameters of the cigarette making and tipping unit on the weight control effect, realize the brand parameter optimization configuration in the later period, realize the integral and detail self-setting regulation function, and lay a foundation for exploring an intelligent factory in a workshop.
In order to achieve the purpose, the invention adopts the technical scheme that:
a big data application analysis platform system based on a ZJ17 type cigarette weight control system comprises a central data processing module, a data monitoring module, an electromechanical equipment module, a human-computer interaction module and a data communication system among the modules; the central data processing module uploads various data collected by the data monitoring module to the terminal through a communication protocol in a unified way, and the data are identified, judged and processed to realize real-time monitoring and process control; the method is characterized in that:
the data monitoring module is used for detecting the density of cigarettes according to different production process flows of ZJ17 cigarettes and comprises a microwave density detector, an automatic adjusting negative pressure valve, a pressure sensor, a laser ranging sensor, a temperature sensor and a cut tobacco quantity online detection sensor which are arranged on corresponding equipment; the microwave density detection instrument has the functions of calculating the cigarette weight and identifying unqualified cigarettes, and transmits detection data to the main control unit for judgment and identification to adjust the cigarette weight, the sampling of the cigarettes and waste removal control; the pressure sensor is matched with the automatic adjusting negative pressure valve for use and used for adjusting the negative pressure value of the VE part of the tobacco shred feeder in real time, so that the separation of tobacco stems and tobacco shreds is kept in a dynamic balance, the monitoring of the negative pressure of the VE part of the tobacco shred feeder is realized, and the centralized pressure supply device is always kept in a dynamic stability; the automatic adjusting negative pressure valve is additionally arranged on the tobacco suction channel, the pressure sensor realizes real-time monitoring of the negative pressure of the VE part of the tobacco feeder, and the establishment of the corresponding relation of the tobacco shred structures with different brands and the matching negative pressure is undertaken; the laser ranging sensor is used for detecting the stability and the order of the cut tobacco flow in the leveling disc in real time, the problems that the cut tobacco channel is blocked and the breakage rate of the cut tobacco is increased due to large cut tobacco return quantity and the increase of the blank, air leakage and cut tobacco quantity at the end part due to insufficient cut tobacco at the compaction section of the cut tobacco flow caused by small cut tobacco return quantity are solved, and the cigarette weight control effect is effectively improved finally; in order to accurately measure the tobacco shred density, the temperature sensor needs to consider the influence of the tobacco shred temperature on the measurement, the tobacco shred temperature sensor is used for measuring the temperature of the tobacco shreds in the conveying process from a conveying belt of a hopper conveyor to a suction groove through a material piling groove and is used for accurately measuring the tobacco shred density, the influence on the weight fluctuation after the cigarettes are only formed is further reduced, and the measuring groove temperature sensor is used for detecting the tobacco shred temperature; the on-line detecting sensor for the shred return amount is used for detecting the quantity of the tobacco shreds in the front and back shred sucking belts of the flattening disc, and simultaneously performing secondary shred return amount test by combining the tobacco shreds with different brands so as to establish the correlation between the detection result of the sensor and the set value of the actual shred return amount; the dynamic measurement of the yarn returning amount is carried out by combining different settings of the rotating speed of the needle roller of the VE part of the yarn feeder, the association between the rotating speed of the needle roller and the yarn returning amount is established, and finally the association among the on-line detecting sensor of the yarn returning amount, the rotating speed of the needle roller and the yarn returning amount is established; the electromechanical equipment module is improved aiming at a steep angle lifting belt and a needle roller motor of a VE part of a wire supply machine of a ZJ17 type cigarette making and tipping machine set, an advanced alternating current servo control technology is introduced, multi-stage and variable frequency speed regulation control is adopted, speed and position positioning control is realized, a servo controller integrated with a self-contained encoder is additionally arranged, the servo controller comprises a speed ring, a position ring and a current ring, arithmetic operation feedback is carried out on the servo controller, and the functions of quick speed regulation, accurate positioning and effective output torque regulation can be realized; the servo controller is connected or connected with the main control unit into a whole in a communication mode, the rotating speeds of the steep angle lifting belt and the needle roller motor are converted into digital signals through the servo controller and sent to the central data processing module, and closed-loop accurate control is carried out on the basis of frequency conversion speed regulation, so that a more ideal process control effect is achieved.
Furthermore, the data monitoring module comprises an STM32103 series ARM processor serving as a main CPU and necessary matching parts including a crystal oscillator circuit, an RTC reset circuit and a power supply circuit, so that data receiving and data processing are guaranteed, and a control instruction is sent to realize closed-loop regulation.
Furthermore, the microwave density detector comprises a device for detecting the temperature, the moisture and the density value of the inside, the shell and the resonant cavity of the microwave density detector, and simultaneously acquiring the position of the leveling disc and the real-time deviation parameters of the weight control system, so as to realize the monitoring of the running process of the weight control system. The weight control effect can be effectively improved by accurately setting the cut tobacco return quantity, the setting of the cut tobacco return quantity has great influence on the shaping of cut tobacco flow in a leveling disc, the cut tobacco channel is blocked due to large cut tobacco return quantity, and the breakage rate of cut tobacco is increased; the tobacco shred returning amount is small, so that the tobacco shreds at the compacted section of the tobacco shred flow are insufficient, and the empty ends, the air leakage and the tobacco shred dropping amount at the end parts are increased; the sensor for detecting the cut tobacco return amount on line comprises a cut tobacco return amount calculated through the height difference of cut tobacco before and after the leveling disc, or a sensor for detecting the height of the cut tobacco is arranged above the auxiliary cut tobacco return conveyer belt, and the cut tobacco return amount is calculated through the height of the cut tobacco.
And furthermore, the man-machine interaction module is used for carrying out real-time data state display, data acquisition and analysis processing, displays the conditions of different production processes acquired by the processed sensors in the form of visual characters and graphs through data communication with the central data processing module, and realizes the summary display of the weight control effects of different units and the comparative analysis results of the relevant factors influencing the weight control to operators.
A control method of a big data application analysis platform system based on a ZJ17 type cigarette weight control system is characterized by comprising the following steps:
step S1: monitoring the operation process of the weight control system is realized by collecting the temperature, moisture and density measurement values of a CPU board, a shell and a resonant cavity in the microwave density detection instrument and collecting the position and real-time deviation parameters of a leveling disc of the weight control system, and the establishment of an evaluation model of the operation state of the weight control system is completed;
step S2: the alternating current servo control technology is improved aiming at an alternating current servo control system of a direct current motor of a steep angle lifting belt and a needle roller motor, the control precision of the alternating current servo control system needs to meet the operation of the steep angle lifting belt and the needle roller motor, and meanwhile, the corresponding relation between the parameters of the alternating current servo system and the control of the steep angle lifting belt and the needle roller motor of a ZJ17 unit needs to be fused;
and step S3: the on-line detection technology of the return cut amount is characterized in that a group of laser ranging sensors are additionally arranged on a cut tobacco suction forming part of a cut tobacco feeder VE part and used for detecting the heights of cut tobaccos in front and back cut tobacco suction belts of a leveling disc, the return cut amount is calculated from the height difference of the cut tobaccos in front and back of the leveling disc or is deduced by detecting the heights of the cut tobaccos in an auxiliary return cut conveyor belt, and meanwhile, manual test of the return cut amount is carried out by combining cut tobaccos of different brands so as to establish the correlation between the detection result of the sensors and the actual return cut amount;
and step S4: the time synchronism of detection values of all sensors, data acquisition of newly added detection points and the introduction of detection results of the comprehensive tester is realized, and objective data support is provided for the intelligent decision of later-stage big data analysis;
step S5: and (3) developing analysis software related to weight-related quality factors by relying on data generated by various sensors and detectors added in the project, and building a big data analysis platform system applied to a ZJ17 type cigarette weight control system.
The invention relates to a big data application analysis platform system and a method based on a ZJ17 type cigarette weight control system, which are used for carrying out analysis research aiming at two main factors influencing weight control, namely a procedure influencing the cigarette weight control in the production process and cut tobacco blanking (a VE part of a cut tobacco feeder); the weight control system comprises internal measurement of the microwave density detector, running state evaluation of the weight control system and a human-computer interaction system; the internal measurement of the microwave density detector is realized as follows: the method comprises the steps of collecting temperature, moisture and density measurement values of a CPU board, a shell, a resonant cavity and the like in the microwave density detector, and simultaneously collecting parameters such as the position of a leveling disc of a weight control system, real-time deviation and the like, monitoring the running process of the weight control system, drawing a running trend diagram of related parameters, and completing the establishment of an evaluation model of the running state of the weight control system.
The establishment of an evaluation model of the running state of the weight control system is the basis for realizing the running state evaluation of the weight control system, the acquisition of the internal measurement value data of the microwave density detector is read through a debugging interface according to a specified serial port communication protocol format, and the calculation output values of the weight control system, such as the position of a leveling disk, the real-time weight deviation and the like, are acquired through interception and unit IT80 communication, so that the analysis of a related communication protocol is required to be realized through a human-computer interaction system.
The big data application analysis platform system and method based on the ZJ17 type cigarette weight control system have the following beneficial technical effects: the operation evaluation of the weight control system is realized, the microwave detection real-time data is collected, the weight control system calculation data is comprehensively analyzed, the icon display is more visual, and the existing system cannot achieve the analysis function; the needle roller and the steep angle lifting belt motor are driven by alternating current servo control, the control mode is optimized, the control precision is improved, and the maintenance cost is reduced; the real-time numerical monitoring and the flow control of the negative pressure of the VE part of the filament supplier are realized; the monitoring of the wire returning amount is realized, and the real-time display of the wire returning amount is realized through a software algorithm; the intelligent analysis of relevant factors of weight control is realized, the optimized configuration of parameters is realized by using a big data analysis platform, and scientific basis and data support are provided for process guidance production.
Drawings
FIG. 1 is a process flow diagram of a big data application analysis platform system and method based on ZJ17 type cigarette weight control system according to the present invention;
fig. 2 is a system/control schematic of the present invention.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, 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 a part of the embodiments of the present invention, rather than all embodiments, and only the basic implementation flows and modes of the present invention are illustrated in a schematic manner. 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.
The present invention will be described in further detail with reference to the accompanying drawings.
As shown in fig. 1-2, a big data application analysis platform system based on a ZJ17 type cigarette weight control system comprises a central data processing module, a data monitoring module, an electromechanical equipment module, a human-computer interaction module and a data communication system among the modules; the central data processing module uploads various data collected by the data monitoring module to a terminal in a unified way through a communication protocol (such as CAN communication), and the data are identified, judged and processed, so that real-time monitoring and process control are realized; the method is characterized in that:
the data monitoring module is based on different production process flows of ZJ17 type cigarettes, and comprises a microwave density detector, an automatic adjusting negative pressure valve, a pressure sensor, a laser distance measuring sensor, a temperature sensor and a cut tobacco quantity online detection sensor which are arranged on corresponding equipment;
the microwave density detection instrument has the functions of calculating the cigarette weight and identifying unqualified cigarettes, and transmits detection data to the main control unit for judgment and identification to adjust the cigarette weight, the sampling of the cigarettes and waste removal control;
the pressure sensor is matched with the automatic adjusting negative pressure valve for adjusting the negative pressure value of the VE part of the tobacco shred feeder in real time, so that the separation of tobacco stems and tobacco shreds is in a dynamic balance, the monitoring of the negative pressure of the VE part of the tobacco shred feeder is realized, and the centralized pressure supply device is always in a dynamic stability; the automatic adjusting negative pressure valve is additionally arranged on the tobacco shred suction channel, the pressure sensor realizes real-time monitoring of the negative pressure of the VE part of the tobacco shred feeder and undertakes establishment of a corresponding relation of tobacco shred structures with different brands and matched negative pressure;
the laser ranging sensor is used for detecting the stability and the order of the cut tobacco flow in the leveling disc in real time, the problems that the cut tobacco channel is blocked and the breakage rate of the cut tobacco is increased due to large cut tobacco return quantity and the increase of the blank, air leakage and cut tobacco quantity at the end part due to insufficient cut tobacco at the compaction section of the cut tobacco flow caused by small cut tobacco return quantity are solved, and the cigarette weight control effect is effectively improved finally;
in order to accurately measure the tobacco shred density, the temperature sensor needs to consider the influence of the tobacco shred temperature on the measurement, the tobacco shred temperature sensor is used for measuring the temperature of the tobacco shreds in the conveying process from a conveying belt of a hopper conveyor to a suction groove through a material piling groove and is used for accurately measuring the tobacco shred density, the influence on the weight fluctuation after the cigarettes are only formed is further reduced, and the measuring groove temperature sensor is used for detecting the tobacco shred temperature;
the on-line detection sensor for the tobacco shred return amount is used for detecting the tobacco shred amount in the front and back tobacco shred sucking belts of the flattening disc, and meanwhile, the secondary tobacco shred return amount test is carried out by combining tobacco shreds with different brands so as to establish the correlation between the detection result of the sensor and the actual set value of the tobacco shred return amount; the dynamic measurement of the yarn returning amount is carried out by combining different settings of the rotating speed of the needle roller of the VE part of the yarn feeder, the association between the rotating speed of the needle roller and the yarn returning amount is established, and finally the association between the on-line detecting sensor of the yarn returning amount, the rotating speed of the needle roller and the yarn returning amount is established;
the electromechanical equipment module is improved aiming at a steep angle lifting belt and a needle roller motor of a VE part of a wire supply machine of a ZJ17 type cigarette making and tipping machine set, an advanced alternating current servo control technology is introduced, multi-stage and variable frequency speed regulation control is adopted, speed and position positioning control is realized, a servo controller integrated with a self-contained encoder is additionally arranged, the servo controller comprises a speed ring, a position ring and a current ring, arithmetic operation feedback is carried out on the servo controller, and the functions of quick speed regulation, accurate positioning and effective output torque regulation can be realized; the servo controller is connected or connected with the main control unit into a whole in a communication mode, the rotating speeds of the steep angle lifting belt and the needle roller motor are converted into digital signals through the servo controller and sent to the central data processing module, and closed-loop accurate control is carried out on the basis of frequency conversion speed regulation, so that a more ideal process control effect is achieved.
The data monitoring module comprises an STM32103 series ARM processor serving as a main CPU and necessary matched parts such as a crystal oscillator circuit, an RTC reset circuit, a power supply circuit and the like, so that data receiving and data processing are guaranteed, and a control instruction is sent to realize closed-loop regulation.
The microwave density detector detects the temperature, moisture and density values in the microwave density detector, such as a shell and a resonant cavity, and simultaneously acquires the position of a leveling disc of the weight control system, real-time deviation and other parameters to realize the monitoring of the running process of the weight control system. The weight control effect can be effectively improved by accurately setting the cut tobacco return quantity, the setting of the cut tobacco return quantity has great influence on the shaping of cut tobacco flow in a leveling disc, the cut tobacco channel is blocked due to large cut tobacco return quantity, and the breakage rate of cut tobacco is increased; the small amount of the returned tobacco shreds can cause insufficient tobacco shreds at the compacted section of the tobacco shred flow, and cause the increase of the empty head, the air leakage and the tobacco shred dropping amount at the end part.
The sensor for detecting the tobacco shred return amount on line comprises a sensor for calculating the tobacco shred return amount through the tobacco shred height difference before and after the leveling disc, or a sensor for detecting the tobacco shred height is arranged above the auxiliary tobacco shred return conveyer belt, and the tobacco shred return amount is calculated through the tobacco shred height.
The man-machine interaction module is used for carrying out data state real-time display, data acquisition, analysis processing and the like, displays the conditions of different production processes acquired by the processed sensors in the form of visual characters and graphs through data communication with the central data processing module, and realizes the summary display of the comparative analysis results of different unit weight control effects and relevant factors influencing weight control to operators.
The advanced alternating current servo control technology adopted by the invention can ensure that the needle roller motor can completely follow the speed of the main motor of the VE part of the yarn feeder, and the needle roller can also synchronously run along with the cigarette making and connecting unit in the stop and start states; the steep-angle shred lifting belt dragging system can completely follow the shred feeding speed specified by the control system, so that the material level in the shred metering tank is kept in a relatively good state. The method has the advantages of convenient operation, reduced equipment failure rate, reduced maintenance workload, and improved operation stability and reliability.
The man-machine interaction module adopts a touch screen industrial personal computer capable of expanding the types of communication interfaces and the number of channels, so that the data acquisition and data processing functions of relevant detection point data such as the rotating speed of a needle roller, the rotating speed of a steep angle lifting belt, the VE partial negative pressure of a silk supply machine and the like are visually displayed in a chart mode, and the data and the chart can be exported according to the requirements of a user; the data acquisition platform can upload data in a wired network or wireless network mode.
A control method of a big data application analysis platform system based on a ZJ17 type cigarette weight control system comprises the following steps:
step S1: the method comprises the steps of monitoring the operation process of a weight control system by acquiring temperature, moisture and density measurement values of a CPU (central processing unit) board, a shell, a resonant cavity and the like in a microwave detection densitometer and acquiring parameters such as the position of a leveling disc of the weight control system and real-time deviation, and completing the establishment of an evaluation model of the operation state of the weight control system;
step S2: the alternating current servo control technology is improved aiming at an alternating current servo control system of a direct current motor of a steep angle lifting belt and a needle roller motor, the control precision of the alternating current servo control system needs to meet the operation of the steep angle lifting belt and the needle roller motor, and meanwhile, the corresponding relation between the parameters of the alternating current servo system and the control of the steep angle lifting belt and the needle roller motor of a ZJ17 unit needs to be fused;
and step S3: the online detection technology of the shred return amount is characterized in that a group of laser ranging sensors are additionally arranged on a shred suction forming part of a shred supply machine VE part and used for detecting the height of tobacco shreds in a shred suction belt before and after a leveling disc, the shred return amount is calculated out from the height difference of the tobacco shreds before and after the leveling disc or is calculated out by detecting the height of the tobacco shreds in an auxiliary shred return conveying belt, and meanwhile, manual test of the shred return amount is carried out by combining the tobacco shreds with different brands so as to establish the correlation between the detection result of the sensors and the actual shred return amount;
and step S4: the time synchronism of detection values of the sensors, data acquisition of newly added detection points and the import of detection results of the comprehensive tester is realized, and objective data support is provided for the analysis and intelligent decision of later-stage big data;
step S5: and developing analysis software related to weight-related quality factors by relying on data generated by various sensors and detectors added in the project, and building a big data analysis platform system applied to a ZJ17 type cigarette weight control system.
Through the steps, all the collected data are classified, counted, analyzed and displayed in data analysis software, the relevance of each factor and the cigarette weight data change is determined through the statistics of each factor data in a period of time and the comparison of the test data of the comprehensive tester, and the analysis result is displayed through a visual graph. Meanwhile, the data of the data acquisition terminals of all the units can be uploaded to a terminal management system in a unified way, and the data are summarized by arranging a wireless local area network; the terminal management system can realize the comparative analysis and the summary display of the control effects of different units and the related influence factors.
The invention relates to a big data application analysis platform system and a big data application analysis platform method based on a ZJ17 type cigarette weight control system, which are combined with an advanced alternating current servo control technology, collect parameter values of various factors influencing the cigarette weight in the production process through a multi-stage process sensor, monitor and adjust various parameters possibly causing weight deviation in real time, realize the monitoring of the running process of the weight control system, count, sort, judge, process and compare the summarized factor data, determine the relevance of the factor and the cigarette weight data change, and establish a big data application analysis platform system and a big data application analysis control method for controlling the weight of cigarettes in the whole production process. The intelligent analysis of relevant factors of weight control is realized, the optimized configuration of parameters is realized by using a big data analysis platform, and scientific basis and data support are provided for process guidance production in the future.
The above-described embodiments are illustrative of the present invention and not restrictive, it being understood that various changes, modifications, substitutions and alterations can be made herein without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.
Claims (5)
1. A big data application analysis platform system based on a ZJ17 type cigarette weight control system comprises a central data processing module, a data monitoring module, an electromechanical equipment module, a human-computer interaction module and a data communication system among the modules; the central data processing module uploads various data collected by the data monitoring module to the terminal in a unified way through a communication protocol, and the data are identified, judged and processed, so that real-time monitoring and process control are realized; the method is characterized in that:
the data monitoring module is used for detecting the density of cigarettes according to different production process flows of ZJ17 cigarettes and comprises a microwave density detector, an automatic adjusting negative pressure valve, a pressure sensor, a laser ranging sensor, a temperature sensor and a cut tobacco quantity online detection sensor which are arranged on corresponding equipment; the microwave density detection instrument has the functions of calculating the cigarette weight and identifying unqualified cigarettes, and transmits detection data to the main control unit for judgment and identification to adjust the cigarette weight, the sampling of the cigarettes and waste removal control;
the pressure sensor is matched with the automatic adjusting negative pressure valve for adjusting the negative pressure value of the VE part of the tobacco shred feeder in real time, so that the separation of tobacco stems and tobacco shreds is in a dynamic balance, the monitoring of the negative pressure of the VE part of the tobacco shred feeder is realized, and the centralized pressure supply device is always in a dynamic stability; the automatic adjusting negative pressure valve is additionally arranged on the tobacco suction channel, the pressure sensor realizes real-time monitoring of the negative pressure of the VE part of the tobacco feeder, and the establishment of the corresponding relation of the tobacco shred structures with different brands and the matching negative pressure is undertaken;
the laser ranging sensor is used for detecting the stability and the order of the cut tobacco flow in the leveling disc in real time, the problems that the cut tobacco channel is blocked and the breakage rate of the cut tobacco is increased due to large cut tobacco return quantity and the increase of the blank, air leakage and cut tobacco quantity at the end part due to insufficient cut tobacco at the compaction section of the cut tobacco flow caused by small cut tobacco return quantity are solved, and the cigarette weight control effect is effectively improved finally;
in order to accurately measure the tobacco shred density, the temperature sensor needs to consider the influence of the tobacco shred temperature on the measurement, the tobacco shred temperature sensor is used for measuring the temperature of the tobacco shreds in the conveying process from a conveying belt of a hopper conveyor to a suction groove through a material piling groove and is used for accurately measuring the tobacco shred density, the influence on the weight fluctuation after the cigarettes are only formed is further reduced, and the measuring groove temperature sensor is used for detecting the tobacco shred temperature;
the on-line detecting sensor for the shred return amount is used for detecting the quantity of the tobacco shreds in the front and back shred sucking belts of the flattening disc, and simultaneously performing secondary shred return amount test by combining the tobacco shreds with different brands so as to establish the correlation between the detection result of the sensor and the set value of the actual shred return amount; the dynamic measurement of the yarn returning amount is carried out by combining different settings of the rotating speed of the needle roller of the VE part of the yarn feeder, the association between the rotating speed of the needle roller and the yarn returning amount is established, and finally the association between the on-line detecting sensor of the yarn returning amount, the rotating speed of the needle roller and the yarn returning amount is established;
the electromechanical equipment module is improved aiming at a steep angle lifting belt and a needle roller motor of a yarn feeder VE part of a ZJ17 type cigarette making and tipping unit, an advanced alternating current servo control technology is introduced, multistage and variable frequency speed regulation control is adopted, speed and position positioning control is realized, a servo controller integrated with a self-contained encoder is additionally arranged, the servo controller comprises a speed ring, a position ring and a current ring, algorithm operation feedback is carried out on the servo controller, and the functions of quick speed regulation, accurate positioning and effective output torque regulation can be realized; the servo controller is connected or connected with the main control unit into a whole in a communication mode, the rotating speeds of the steep angle lifting belt and the needle roller motor are converted into digital signals through the servo controller and are sent to the central data processing module, and closed-loop accurate control is carried out on the basis of frequency conversion and speed regulation, so that a more ideal process control effect is achieved.
2. The big data application analysis platform system based on the ZJ17 type cigarette weight control system as claimed in claim 1, wherein the data monitoring module comprises an STM32103 series ARM processor as a main CPU, and necessary matching parts of a crystal oscillator circuit, an RTC reset circuit and a power supply circuit to ensure data receiving and data processing and send out a control instruction to realize closed-loop regulation.
3. The big data application and analysis platform system based on ZJ17 cigarette weight control system, as claimed in claim 2, wherein the microwave density detector comprises a device for detecting the temperature, moisture and density value inside the microwave density detector, the housing, and the resonant cavity, and simultaneously collecting the position and real-time deviation parameters of the leveling plate of the weight control system to monitor the operation process of the weight control system,
the weight control effect can be effectively improved by accurately setting the cut tobacco return quantity, the setting of the cut tobacco return quantity has great influence on the shaping of cut tobacco flow in a leveling disc, the cut tobacco channel is blocked due to large cut tobacco return quantity, and the breakage rate of cut tobacco is increased; the tobacco shred returning amount is small, so that the tobacco shreds at the compacted section of the tobacco shred flow are insufficient, and the empty ends, the air leakage and the tobacco shred dropping amount at the end parts are increased; the sensor for detecting the cut tobacco return amount on line comprises a cut tobacco return amount calculated through the height difference of cut tobacco before and after the leveling disc, or a sensor for detecting the height of the cut tobacco is arranged above the auxiliary cut tobacco return conveyer belt, and the cut tobacco return amount is calculated through the height of the cut tobacco.
4. The big data application analysis platform system based on the ZJ17 type cigarette weight control system, as claimed in claim 3, wherein the human-computer interaction module is used for real-time data state display, data acquisition and analysis processing, and displays the conditions of different production processes acquired by each processed sensor in the form of visual characters and graphics through data communication with the central data processing module, so as to realize the summary display of the comparative analysis results of different unit weight control effects and relevant factors influencing weight control to operators.
5. The control method of big data application analysis platform system based on ZJ17 cigarette weight control system according to claim 4, characterized in that it comprises the following steps:
step S1: monitoring the operation process of the weight control system is realized by collecting the temperature, moisture and density measurement values of a CPU board, a shell and a resonant cavity in the microwave density detection instrument and collecting the position and real-time deviation parameters of a leveling disc of the weight control system, and the establishment of an evaluation model of the operation state of the weight control system is completed;
step S2: the alternating current servo control technology is improved aiming at an alternating current servo control system of a direct current motor of a steep angle lifting belt and a needle roller motor, the control precision of the alternating current servo control system needs to meet the operation of the steep angle lifting belt and the needle roller motor, and meanwhile, the corresponding relation between the parameters of the alternating current servo system and the control of the steep angle lifting belt and the needle roller motor of a ZJ17 unit needs to be fused;
and step S3: the online detection technology of the shred return amount is characterized in that a group of laser ranging sensors are additionally arranged on a shred suction forming part of a shred supply machine VE part and used for detecting the height of tobacco shreds in a shred suction belt before and after a leveling disc, the shred return amount is calculated out from the height difference of the tobacco shreds before and after the leveling disc or is calculated out by detecting the height of the tobacco shreds in an auxiliary shred return conveying belt, and meanwhile, manual test of the shred return amount is carried out by combining the tobacco shreds with different brands so as to establish the correlation between the detection result of the sensors and the actual shred return amount;
and step S4: the time synchronism of detection values of the sensors, data acquisition of newly added detection points and the import of detection results of the comprehensive tester is realized, and objective data support is provided for the analysis and intelligent decision of later-stage big data;
step S5: and developing analysis software related to weight-related quality factors by relying on data generated by various sensors and detectors added in the project, and building a big data analysis platform system applied to a ZJ17 type cigarette weight control system.
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| CN1317940A (en) * | 1998-09-18 | 2001-10-17 | 菲利普莫里斯生产公司 | Cigarette mfg. machine and control system therefor |
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| DE102006017106A1 (en) * | 2006-04-10 | 2007-10-11 | Focke & Co.(Gmbh & Co. Kg) | Process for the production and / or packaging of cigarettes in a production and / or packaging plant |
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